Patent Application
20240131550
The disclosure of the U.S. Provisional Patent Application No. 63/419,131, filed Oct. 25, 2022, is specifically incorporated by reference herein as if set forth in its entirety.
This disclosure relates generally to roofing shingles and to systems and methods for the manufacture of roofing shingles; and in particular, to systems and methods for the manufacture of roofing shingles including application of a fiberized adhesive to form roofing shingles.
Laminated roofing shingles can have an adhesive applied between a backer and an upper layer of shingle material for adhesively attaching the upper layer to the backer. It can be seen that needs exist for roofing shingles having an enhanced bond between the backer and upper layer of such roofing shingles without having to apply additional adhesive between the backer and upper layer, and for systems and methods of manufacturing such roofing shingles. The present disclosure addresses these and other related and unrelated issues.
Briefly described, according to aspects of the present disclosure, roofing shingles and systems and methods for manufacturing roofing shingles are provided. In embodiments, systems and methods for forming roofing shingles having an adhesive material applied between a first layer and a second layer thereof are provided. In some embodiments, the adhesive material can be applied as a fiberized adhesive.
In some embodiments, the system can comprise a conveying system along which a roofing substrate material is conveyed in a first direction through an adhesive station, which can include an adhesive applicator having a nozzle configured to apply an adhesive material along a surface of the roofing substrate material, for example, at areas corresponding to a common bond area between layers of the roofing substrate material forming the resultant roofing shingles. In some embodiments, the adhesive material can comprise a fiberized adhesive adapted to attach a first layer of the roofing substrate material to an additional, second layer of the roofing substrate material for forming the roofing shingles. In embodiments, the adhesive applicator further can include a drive system that is coupled to the nozzle and configured to move the nozzle in a second direction across the roofing substrate material as the roofing substrate material is moved in the first direction along a processing path and through the adhesive station. In embodiments, the nozzle is moved in the second direction back and forth across the roofing substrate material, which movement can be varied for selectively applying a selected pattern of the fiberized adhesive to a surface of the roofing substrate material.
In some embodiments, applying the fiberized adhesive can comprise moving the nozzle in an eccentric motion in the second direction across the substrate so as to apply the fiberized adhesive to the roofing substrate material in a substantially helical or circular pattern across the surface of the roofing substrate material. In embodiments, applying the fiberized adhesive can comprise applying a selected pattern of the fiberized adhesive, for example, a pattern having an increased width across the roofing substate material, and/or a flatter pattern of the fiberized adhesive, versus applying larger beads of adhesive to provide increased bonding of the layers. In some embodiments, the fiberized adhesive can be applied in lines, strips, dots, or beads, or combinations thereof, that, in embodiments, can have an elongated, flattened, straight, helical, curved or substantially curved configuration, or combinations thereof, and, in some embodiments, can have gaps defined therebetween; while in further embodiments, varying thicknesses or densities of the fiberized adhesive can be applied at selected locations along the surface of the roofing substrate material. In some embodiments, the fiberized adhesive can be formed in patterns having intermittent thickness and/or areas of fiberized adhesive with varying size gaps therebetween.
In embodiments, the drive system can comprise an eccentric bearing mechanism coupled to the nozzle and comprising a first drive gear, an eccentric bearing positioned in engagement with the first drive gear, a second drive gear coupled to the first drive gear by a drive belt, chain, or other coupling, and a motor connected to the second drive gear and configured to rotate the second drive gear. In embodiments, in operation of the drive system, the motor can be controlled to control rotation of the second drive gear, which rotation of the second drive gear is translated to the first drive gear by the drive belt, chain, or other coupling, causing the first drive gear to rotate, and in turn, causing rotation of the eccentric bearing. In some embodiments, as the eccentric bearing is rotated, the nozzle is moved across the roofing substrate material in an eccentric motion to apply a selected pattern, e.g., a substantially helical or circular pattern, of the fiberized adhesive to the surface of the roofing substrate material.
Alternatively, in embodiments, the drive system can comprise a crank driven by a motor and coupled to a support along which the nozzle is mounted; wherein as the crank rotates, the nozzle is moved across the roofing substrate material to apply the fiberized adhesive in the selected pattern. For example, in embodiments, the fiberized adhesive can be applied as a substantially continuous spray of adhesive material, and as the eccentric bearing or the crank rotate, the movement of the nozzle can be varied such that the fiberized adhesive can be applied in a selected pattern, including applying the fiberized adhesive intermittently to the surface of the roofing substrate material. In embodiments, the patterns of fiberized adhesive applied to the roofing material substrate further can be varied or adjusted by controlling the rate of rotation of the eccentric bearing or crank, so as to control a rate and extent of the movement of the nozzle across the roofing substate material, and/or by controlling a rate of movement of the roofing substrate material through the adhesive station.
According to aspects of the present disclosure, a method is disclosed, the method comprising: conveying a roofing substrate material along a processing path in a first direction; as the roofing substrate material is moved along the processing path, moving the roofing substrate material past an adhesive applicator; wherein, in embodiments, the adhesive applicator comprises a nozzle configured to apply an adhesive material to a surface of the roofing substrate material and a drive system linked to the nozzle and configured to move the nozzle in a second direction with respect to the processing path; moving the nozzle in the second direction across the roofing substrate material as the roofing substrate material is moved along the processing path in the first direction; and applying the adhesive material to the surface of the roofing substrate material with the adhesive applicator; wherein the adhesive is applied to the surface of the roofing substrate material in a substantially straight pattern, a substantially helical or circular pattern or a combination thereof.
In embodiments of the method, moving the nozzle in a second direction comprises rotating the nozzle of the adhesive applicator in an eccentric motion back and forth across the surface of the roofing substrate material.
In some embodiments, the drive system comprises an eccentric drive mechanism coupled to the nozzle, the eccentric drive mechanism comprising a first drive gear, an eccentric bearing positioned in engagement with the first drive gear, and a motor coupled to the first gear and configured to rotate the first drive gear; wherein rotation of the first drive gear causes rotation of the eccentric bearing; and wherein moving the nozzle in the second direction across the roofing substrate material comprises rotating the nozzle across the surface of the roofing substrate material in an eccentric motion in response to rotation of the eccentric bearing.
In some embodiments, moving the nozzle in the second direction across the roofing substrate material comprises moving the nozzle in the second direction across the surface of the roofing substrate material along an initial path of travel at a first rate, and moving the nozzle along a return path of travel back across the surface of the roofing substrate material at a second rate; wherein the second rate is different from the first rate.
In embodiments, the drive system can comprise an eccentric drive mechanism coupled to the nozzle, the eccentric drive mechanism comprising a first drive gear, an eccentric bearing positioned in engagement with the first drive gear, and a motor coupled to the eccentric bearing and configured to rotate the eccentric bearing; wherein as the eccentric bearing is rotated, the nozzle is moved in the second direction across the roofing substrate material as the roofing substrate material is moved in the first direction; and wherein applying the substantially straight pattern, substantially helical or circular pattern, or a combination thereof, of the adhesive material to the surface of the roofing substrate material further comprises rotating the nozzle in an eccentric motion as the nozzle is moved in the second direction.
In embodiments of the method, applying the substantially helical or circular pattern of the fiberized adhesive to the surface of the roofing substrate material further comprises applying varying thicknesses or densities of the adhesive material at selected locations along the surface of the roofing substrate material.
In embodiments of the method, applying the substantially helical or circular pattern of the adhesive material to the surface of the roofing substrate material further comprises dispersing a fiberized adhesive in an intermittent pattern of curved dashes or beads of the fiberized adhesive.
In embodiments of the method, applying the substantially straight pattern, substantially helical or circular pattern, or a combination thereof of the adhesive material to the surface of the roofing substrate material comprises intermittently spraying a fiberized adhesive to the surface of the roofing substrate material; and wherein the fiberized adhesive comprises a self-seal adhesive.
In some embodiments, intermittently spraying the fiberized adhesive to the surface of the roofing substrate material can comprise varying an amount of the fiberized adhesive supplied to the nozzle; applying at least a first thickness or density of the fiberized adhesive at a first position to the surface of the roofing substrate material, and applying a second thickness or density of the fiberized adhesive at a second position to the surface of the roofing substrate material.
In embodiments of the method, applying the pattern of the adhesive material to the surface of the roofing substrate material can comprise applying a substantially continuous fiberized spray of the adhesive material to the surface of the roofing substrate material with the nozzle as the nozzle is moved in the second direction across the roofing substrate material, and controlling movement of the roofing substrate material in the first direction to form an intermittent pattern of the fiberized adhesive on the surface of the roofing substrate material.
In embodiments, the adhesive material comprises an asphalt adhesive.
In addition, in some embodiments of the method, the drive system can comprise a support having a first end portion along which the nozzle is mounted and a second end portion linked to a crank, and a motor coupled to the crank and configured to drive rotation of the crank; wherein moving the nozzle across the processing path comprises controlling rotation of the crank so as to move the support in a substantially linear motion to cause move the nozzle back and forth across the surface of the roofing substrate material.
In embodiments, the roofing substrate material comprises a first layer and a second layer; and wherein applying the adhesive material to the surface of the roofing substrate material comprises applying a fiberized spray of a self-seal adhesive to a surface of at least one of the first and second layers along an area corresponding to a nail zone of a finished roofing shingle.
In embodiments of the method, applying the adhesive material to the surface of the roofing substrate material comprises depositing at least a first thickness or density of the adhesive material at a first position on the surface of the roofing substrate material and a second thickness or density of the adhesive material at a second position on the surface of the roofing substrate material along an area corresponding to a common bond area of a finished roofing shingle.
In some embodiments, the adhesive material comprises a self-seal fiberized adhesive adapted to substantially seal about a nail head of one or more fasteners received through a nail zone of a finished roofing shingle.
In other embodiments, applying the selected pattern of the fiberized adhesive to the surface of the roofing substrate material can comprise depositing a plurality of lines, strips, beads, dots, or combinations thereof, of the fiberized adhesive along a common bond area between first and second layers of a finished roofing shingle.
In some additional embodiments, applying the adhesive material to the surface of the roofing substrate material can comprise depositing a plurality of lines, strips, beads, dots, or combinations thereof, of a fiberized adhesive along an area opposite an exposure portion of a finished roofing shingle adjacent a forward edge thereof.
According to other aspects of the disclosure, an apparatus comprises a conveying system configured to move a roofing substrate material along a processing path in a first direction; and an adhesive applicator positioned along the processing path; the adhesive applicator comprising a nozzle configured to apply an adhesive material to a surface of the roofing substrate material; a drive system linked to the nozzle and configured to move the nozzle in a second direction as the roofing substrate material is moved the first direction; wherein movement of the nozzle in the second direction, movement of the roofing substrate material in the first direction, or a combination thereof, is controlled to apply a selected pattern of the adhesive material to the surface if the roofing substrate material; wherein the selected pattern of the adhesive material comprises at least one area having a first thickness or density of the adhesive material and at least one area having a second thickness or density of the adhesive material.
In embodiments, the drive system can comprise an eccentric bearing coupled to the nozzle in engagement with a drive gear, and a motor configured to rotate the drive gear, and wherein as the motor rotates the drive gear, the eccentric gear is rotated so as to cause the nozzle to move in an eccentric motion back and forth in the second direction across the surface of the roofing substrate material as the roofing substrate material is moved in the first direction.
In some embodiments, the drive system can comprise a support having a first end portion along which the nozzle is mounted and a second end portion linked to a crank; and a motor configured to drive rotation of the crank; wherein the crank is configured to move the support in a substantially linear motion so as to move the nozzle back and forth across the surface of the roofing substrate material.
In embodiments, the adhesive material comprises a self-seal adhesive applied as a fiberized spray.
In some embodiments, the adhesive material comprises an asphalt adhesive.
Another aspect of the disclosure includes, without limitation, a method comprising: conveying a roofing substrate material along a processing path in a first direction; applying a pattern of a fiberized adhesive to at least one surface of the roofing substrate material with an adhesive applicator; wherein, in embodiments, the adhesive applicator comprises a nozzle positioned along the processing path and configured to apply the pattern of fiberized adhesive to the roofing substrate material; and a drive system coupled to the nozzle and configured to move the nozzle in a second direction across the processing path; wherein applying the pattern of fiberized adhesive to the surface of the roofing substrate material comprises moving the nozzle in the second direction and depositing at least a first thickness or density of the fiberized adhesive at a first position on the surface of the roofing substrate material, and depositing a second thickness or density of the fiberized adhesive at a second position on the surface of the roofing substrate material.
In embodiments, applying the pattern of fiberized adhesive further comprises spraying a self-seal adhesive material on the surface of the roofing substrate material.
In embodiments, moving the nozzle in a second direction can further comprise rotating the nozzle in a helical or substantially circular motion; and wherein depositing at least the first thickness or density of the fiberized adhesive at the first position and depositing the second thickness or density of the fiberized adhesive at the second position can comprise intermittently spraying of the fiberized adhesive onto the surface of the roofing substrate material.
In embodiments, applying the pattern of the fiberized adhesive to the surface of the roofing substrate material can further comprise dispersing a substantially circular of helical pattern of the fiberized adhesive onto the surface of the roofing substrate material along a common bond area corresponding to a nail zone of a finished roofing shingle.
In addition, in embodiments, the fiberized adhesive can comprise a self-seal adhesive adapted to substantially seal about a nail head of one or more fasteners received through the nail zone of the finished roofing shingle.
According to still another aspect of the present disclosure, a roofing shingle is provided. In embodiments, the roofing shingle can comprise a first layer comprising a headlap portion; an exposure portion; and a nail zone defined between the headlap portion and the exposure portion; a second layer positioned beneath the first layer; and an adhesive material applied to at least one of the first layer and the second layer, wherein the adhesive material is applied in a pattern along a common bond area between the first and second layers, the adhesive material adapted to attach the first and second layers together along the common bond area; wherein the pattern includes at least a first thickness or density of the adhesive material at a first position along the common bond area, and a second thickness or density of the adhesive material at a second position along the common bond area.
In embodiments, the adhesive material can comprise a fiberized adhesive.
In embodiments, the common bond area is positioned substantially in alignment with the nail zone of a finished roofing shingle; and in some embodiments, the adhesive material can comprise a self-seal adhesive configured to adhere the second layer to the first layer and substantially seal about a fastener received through the nail zone.
According to another aspect, a roof structure comprises roof deck; and a plurality of roofing shingles positioned along the roof deck; wherein each of the roofing shingles comprises a roofing shingle, comprising: a first layer comprising a headlap portion; an exposure portion; and a nail zone defined between the headlap portion and the exposure portion; a second layer positioned beneath the first layer; and a fiberized adhesive applied between the first layer and the second layer; wherein the fiberized adhesive is applied along a common bond area and is applied in a pattern having at least a first thickness or density of the fiberized adhesive at a first position along the common bond area, and a second thickness or density of the fiberized adhesive at a second position along the common bond area; and wherein the fiberized adhesive is configured to adhere the second layer to the first layer.
In embodiments, the common bond area is positioned substantially in alignment with the nail zone of the roofing shingle; and wherein the fiberized adhesive comprises a self-seal adhesive adapted to substantially seal about a nail head or shank of a fastener received through the nail zone of the roofing shingle.
Accordingly, various aspects and embodiments of roofing shingles and systems and methods of forming roofing shingles are disclosed. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.
The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.
Embodiments of roofing shingles 100 having applications of adhesive materials, including application of a fiberized adhesive to a roofing substrate material 10 in selected patterns along a common bond area between layers of the roofing material substrate, and which, in embodiments, generally corresponds to a nail zone of a resultant formed roofing shingles, and systems and methods for forming roofing shingles, including the application of adhesive materials between the layers of roofing substrate materials for attachment of the layers together to form roofing shingles, according to principles of the present disclosure will now be described in more detail with reference to the attached drawing figures.
In embodiments, such as schematically illustrated in
In embodiments, the first and second layers 101/102 can be attached together by an adhesive material applied to at least one of the first and second layers in a selected pattern. By way of example and not limitation, in embodiments, the adhesive material can include self-seal adhesive material applied as a fiberized adhesive 103. In embodiments the fiberized adhesive 103 can be applied in an intermittent pattern that can be applied over an expanded or wider area across a surface of the roofing substrate material 10, such as indicated in
As used herein, the term “fiberized adhesive” can include a variety of adhesive materials that can be applied to attach layers of roofing substrate material in accordance with the principles of the present disclosure, including applications of one or more adhesive materials as a fiberized adhesive spray or similar application.
In some non-limiting embodiments, such as illustrated in
As indicated in
In embodiments, the second layer 102 is attached to at least a portion of the first layer 102 via application of the fiberized adhesive 103 to form each roofing shingle 100. In embodiments, the fiberized adhesive 103 can be applied as a spray of fiberized adhesive, and can form an adhesive strip configured to attach the first and second layers 101/102 together. For example, in some embodiments, the fiberized adhesive can be applied as a plurality of beads, dashes or dots of adhesive, with such adhesive strips, beads, dashes or dots forming with selected pattern, e.g. a swirl or a substantially helical, curved or circular pattern as shown in
As used herein, the term “common bond area” defines an area, indicated at 115 in
This common bond area further can be in registration with a “nail zone” 116 (
In embodiments, the common bond area can have a width of 0.25 inches to 3 inches wide, and in embodiments, a width of 0.25 inches to 2.75 inches wide; 0.25 inches to 2.5 inches wide; 0.25 inches to 2.25 inches wide; 0.25 inches to 2 inches wide; 0.25 inches to 1.75 inches wide; 0.25 inches to 1.5 inches wide; 0.25 inches to 1.25 inches wide; 0.25 inches to 1 inches wide; 0.25 inches to 0.875 inches wide; 0.25 inches to 0.75 inches wide; 0.25 inches to 0.5 inches wide; 0.25 inches to 0.375 inches wide; 0.375 inches to 3 inches wide; 0.375 inches to 2.75 inches wide; 0.375 inches to 2.5 inches wide; 0.375 inches to 2.25 inches wide; 0.375 inches to 2 inches wide; 0.375 inches to 1.75 inches wide; 0.375 inches to 1.5 inches wide; 0.375 inches to 1.25 inches wide; 0.375 inches to 1 inch wide; 0.375 inches to 0.875 inches wide; 0.375 inches to 0.75 inches wide; 0.375 inches to 0.5 inches wide; 0.5 inches to 3 inches wide; 0.5 inches to 2.75 inches wide; 0.5 inches to 2.5 inches wide; 0.5 inches to 2 inches wide; 0.5 inches to 1.75 inches wide; 0.5 inches to 1.5 inches wide; 0.5 inches to 1.25 inches wide; 0.5 inches to 1 inch wide, 0.5 inches to 0.875 inches wide; 0.5 inches to 0.75 inches wide; 0.75 inches to 3 inches wide; 0.75 inches to 2.75 inches wide; 0.75 inches to 2.5 inches wide; 0.75 inches to 2.25 inches wide; 0.75 inches to 2 inches wide; 0.75 inches to 1.75 inches wide; 0.75 inches to 1.5 inches wide; 0.75 inches to 1.25 inches wide; 0.75 inches to 1 inch wide; or 0.75 inches to 0.875 inches wide; 0.875 inches to 3 inches wide; 0.875 inches to 2.75 inches wide; 0.875 inches to 2.5 inches wide; 0.875 inches to 2.25 inches wide; 0.875 inches to 2 inches wide; 0.875 inches to 1.75 inches wide; 0.875 inches to 1.5 inches wide; 0.875 inches to 1.25 inches wide; 0.875 inches to 1 inch wide; 1 inch to 3 inches wide; 1 inch to 2.75 inches wide; 1 inch to 2.5 inches wide; 1 inch to 2.25 inches wide; 1 inch to 2 inches wide; 1 inch to 1.75 inches wide; 1 inch to 1.5 inches wide; 1 inch to 1.25 inches wide; 1.25 inches to 3 inches wide; 1.25 inches to 2.75 inches wide; 1.25 inches to 2.5 inches wide; 1.25 inches to 2.25 inches wide; 1.25 inches to 2 inches wide; 1.25 inches to 1.75 inches wide; 1.25 inches to 1.5 inches wide; 1.5 inches to 3 inches wide; 1.5 inches to 2.75 inches wide; 1.5 inches to 2.5 inches wide; 1.5 inches to 2.25 inches wide; 1.5 inches to 2 inches wide; 1.5 inches to 1.75 inches wide; 1.75 inches to 3 inches wide; 1.75 inches to 2.75 inches wide; 1.75 inches to 2.5 inches wide; 1.75 inches to 2.25 inches wide; 1.75 inches to 2 inches: 2 inches to 3 inches wide; 2 inches to 2.75 inches wide; 2 inches to 2.5 inches wide; 2 inches to 2.25 inches wide; 2.25 inches to 3 inches wide; 2.25 inches to 2.75 inches wide; 2.25 inches to 2.5 inches wide; 2.5 inches to 3 inches wide; 2.5 inches to 2.75 inches wide; and 2.75 inches to 3 inches wide. Other widths also can be provided.
In embodiments, the nail zone can have a width that substantially corresponds to a width of the common bond. In other embodiments, the nail zone can have a width that is less that the width of the common bond area, with the common bond area overlapping the nail zone on one or both of its upper and lower edges. For example, in embodiments, the nail zone can have a width of 0.10 inches to 3 inches; and in some embodiments, can have a width of 0.10 inches to 2.5 inches wide; 0.10 inches to 2.25 inches wide; 0.10 inches to 2 inches wide; 0.10 inches to 1.75 inches wide; 0.10 inches to 1.5 inches wide; 0.10 inches to 1.25 inches wide; 0.10 inches to 1 inches wide; 0.10 inches to 0.875 inches wide; 0.10 inches to 0.75 inches wide; 0.10 inches to 0.5 inches wide; 0.10 inches to 0.375 inches wide; 0.375 inches to 2.5 inches wide; 0.375 inches to 2.25 inches wide; 0.375 inches to 2 inches wide; 0.375 inches to 1.75 inches wide; 0.375 inches to 1.5 inches wide; 0.375 inches to 1.25 inches wide; 0.375 inches to 1 inch wide; 0.375 inches to 0.875 inches wide; 0.375 inches to 0.75 inches wide; 0.375 inches to 0.5 inches wide; 0.5 inches to 2.5 inches wide; 0.5 inches to 2 inches wide; 0.5 inches to 1.75 inches wide; 0.5 inches to 1.5 inches wide; 0.5 inches to 1.25 inches wide; 0.5 inches to 1 inch wide, 0.5 inches to 0.875 inches wide; 0.5 inches to 0.75 inches wide; 0.75 inches to 2.5 inches wide; 0.75 inches to 2.25 inches wide; 0.75 inches to 2 inches wide; 0.75 inches to 1.75 inches wide; 0.75 inches to 1.5 inches wide; 0.75 inches to 1.25 inches wide; 0.75 inches to 1 inch wide; or 0.75 inches to 0.875 inches wide; 0.875 inches to 2.5 inches wide; 0.875 inches to 2.25 inches wide; 0.875 inches to 2 inches wide; 0.875 inches to 1.75 inches wide; 0.875 inches to 1.5 inches wide; 0.875 inches to 1.25 inches wide; 0.875 inches to 1 inch wide; 1 inch to 2.5 inches wide; 1 inch to 2.25 inches wide; 1 inch to 2 inches wide; 1 inch to 1.75 inches wide; 1 inch to 1.5 inches wide; 1 inch to 1.25 inches wide; 1.25 inches to 2.5 inches wide; 1.25 inches to 2.25 inches wide; 1.25 inches to 2 inches wide; 1.25 inches to 1.75 inches wide; 1.25 inches to 1.5 inches wide; 1.5 inches to 2.5 inches wide; L5 inches to 2.25 inches wide; 1.5 inches to 2 inches wide; 1.5 inches to 1.75 inches wide; 1.75 inches to 3 inches wide; 1.75 inches to 2.5 inches wide; 1.75 inches to 2.25 inches wide; 1.75 inches to 2 inches; 2 inches to 2.5 inches wide; 2 inches to 2.25 inches wide. Other widths are also can be used. In addition, as indicated in
As illustrated in
In embodiments, the adhesive station 205 includes an adhesive applicator 206 (
In embodiments, the fiberized adhesive 103 can include various adhesive materials, for example, a contact adhesive, a pressure sensitive adhesive or other, similar self-seal adhesive that can be applied as a fiberized spray or application. For example, the fiberized adhesive can include asphalt adhesives, butyl adhesives, acrylic adhesives, epoxies, polyurethane adhesives, solvent-based adhesives, emulsion adhesives, and/or, other similar self-seal adhesive materials. In embodiments, the fiberized adhesive 103 can further comprise an adhesive material with re-sealing properties such that as fasteners (e.g., roofing nails, screws or other mechanical fasteners) are inserted along the nail zone of the roofing shingles, and through the first layer and second layer or backer thereof, the fiberized adhesive can be adopted to substantially self-reseal around the shank and/or head of the fastener.
As further indicated in
As indicated in
In some embodiments, other patterns, such as a flatter fiberized adhesive pattern, can be applied to the roofing substrate material 10, rather than a plurality of discrete dots or beads, and can be applied to the roofing substrate material along or across a wider area of the roofing substrate material, defining a common bond area 115 of increased width, while still enabling utilization of substantially the same amount of adhesive, or, in embodiments, less adhesive. Such a flatter wider fiberized adhesive pattern can be adjusted to create a stronger adhesive bond between the first and second layers by providing an increased or larger cross-section of adhesive along the common bond area of the roofing shingles, as opposed to a standard self-seal line or dot of adhesive. In some embodiments, the fiberized pattern also can comprise substantially flat layer of fiberized adhesive formed as a substantially rectangular strip, and, alternatively, or in addition, can comprise a plurality of dashes, lines, beads, dots, or combinations thereof, of fiberized adhesive applied across the surface of the roofing substrate material, with at least a portion of such dashes, lines, beads, dots, or combinations thereof. For example, in embodiments, such as indicated in
In embodiments, the selected patterns of the fiberized adhesive applied to the roofing substrate material will be configured help conserve or reduce an amount of adhesive material required to attach the first and second layers without reducing strength of the adhesive bond therebetween. For example, in some embodiments, the selected patterns can include depositing varying thicknesses or densities of the fiberized adhesive applied, and in embodiments, different thicknesses or densities of the fiberized adhesive can be applied at different locations, e.g., at least a first thickness or density can be applied to the roofing substrate material at a first position along the surface of the roofing substrate material, and a second thickness or density of the fiberized adhesive can be applied at a second position along the surface of the roofing substrate material. In addition, in embodiments, the selected patterns can included gaps or spaces, which also can help conserve or reduce an amount of adhesive material required to attach the first and second layers.
In addition, as the roofing shingles are attached to the roof deck by fasteners F, such as shown
In an embodiment, as indicated in
In the present embodiment, as shown in
As indicated in
In an embodiment, the motor 321 of the drive system can include a servo motor having an internal controller, or wherein can be linked to a control system, and can include programing for a cam motion configured to drive the rotation of the eccentric drive mechanism. For example, the motor can be operated at varying rates to vary the rotation of the eccentric bearing 310, and correspondingly vary movement of the nozzle in an eccentric motion in the second direction, e.g. for causing the nozzle to apply a substantially circular or helical pattern of the fiberized adhesive having different thicknesses or densities of the fiberized adhesive applied at different areas along the surface 204 of the roofing substrate material 10. For example, selected patterns 350 of swirls or arcs of the fiberized adhesive can be applied across the surface 204, including lines, dots, beads, strips, or combinations thereof, being spread apart at varying distances. In addition, such eccentric motion can cause the nozzle to move at different rates, which, in embodiments, can create an intermittent pattern of the fiberized adhesive as shown in
In other embodiments, operation of the adhesive applicator 206 can be controlled such that varying thicknesses or densities of the fiberized adhesive can be applied to the surface of the roofing substrate material at different points or locations. For example, the motor 321 can be controlled to control the movement of the nozzle across the surface of the roofing substrate material to change (e.g. speed up or slow down) such rotation so that the fiberized adhesive can be applied in a greater amount or with a greater thickness at areas adjacent the ends of the roofing shingles, e.g., at locations where the nozzle starts its movement in the second direction across the roofing substrate material, and when the nozzle reaches the end of its length of travel and is turned and begins its movement along a return path of travel back across the surface of the roofing substrate material in its eccentric motion as the roofing substrate material is passed therebelow.
In embodiments, such as indicated in
In embodiments, the offset between the eccentric bearing and the first drive gear can be selected to create gaps defined in the pattern of the fiberized adhesive applied to the surface of the roofing substrate material; for example, due to the return movement of the nozzle in an opposite direction across the surface of the roofing substrate material, such as indicated in
As a result, in embodiments, the systems and methods of the present disclosure may enable a reduction in amounts of the fiberized adhesive required to ensure a substantial bond between the first and second layers of the roofing shingles, e.g., a reduced amount of adhesive can be used without weakening the strength of the attachment between the layers of a laminated roofing shingle. In addition, in embodiments, the application of the fiberized adhesive can help substantially lock the fasteners inserted into the nail zone in place to help deter shifting of the roofing shingles after installation.
In embodiments, the nozzle can comprise a spray nozzle; and in some embodiments can include a bead applicator nozzle, while in other embodiments, a spray nozzle or other applicator can be used. In embodiments, the crank can be rotated by a motor, such as a servo motor or other similar drive mechanism, and as the crank is rotated, it can impart an eccentric motion to the support, and in response, the support can be caused to move in a substantially linear direction as indicated by arrows 210/210′, which in turn causes the movement of the nozzle back and forth in the second direction across the surface of the roofing substrate material, such as indicated in
In addition, in embodiments, due to the off-center connection of the first end of the support to the crank, the nozzle can be moved across the surface of the roofing substrate material at a first rate of movement, and as the nozzle is moved in a return motion back across the surface of the roofing substrate material, it can be moved at a second rate of movement, which can differ from the first rate of movement such that the nozzle can apply an intermittent pattern of adhesive. Further, in embodiments, the crank can be located at varying positions along a length of the support 406 to adjust a length of the travel of the nozzle across the roofing substrate material,
For example, as indicated in
As further indicated in
In further embodiments, the amount of fiberized adhesive material applied by the nozzle can be varied or controlled to form varying patterns or thicknesses of the fiberized adhesive material applied to the surface of the roofing substrate material. For example, the nozzle can be connected to a supply of the fiberized adhesive, which supply can be controlled so as to feed varying amounts of the fiberized adhesive to the nozzle as the nozzle is moved in the second direction is moved back and forth across the surface of the roofing substrate material moving therebelow to apply different thicknesses of the fiberized adhesive to the roofing substrate material.
In addition, in still other embodiments, the systems and methods of the present disclosure can be adapted to apply the selected pattern of the fiberized adhesive to the surface of the roofing substrate material can comprise depositing a plurality of lines, strips, beads, dots, or combinations thereof, of the fiberized adhesive along an area opposite an exposure portion of a finished roofing shingle adjacent a forward edge thereof. For example, in embodiments, the fiberized adhesive can include a sealant material adapted to attach and seal the bottom surface of each roofing shingle to a front surface of a roofing shingle of a lower course of roofing shingles along a roof deck; and can be applied by controlling movement of the nozzle across the roofing substrate material and a flow of the fiberized adhesive being applied by the nozzle to selectively apply dots, dashes, lines, strips, beads, or combinations thereof, of the fiberized adhesive at locations below the exposure portion of each roofing shingle, and adjacent the front edges thereof.
The present disclosure has been described herein in terms of examples that illustrate principles and aspects of the present disclosure. The skilled artisan will understand, however, that a wide gamut of additions, deletions, and modifications, both subtle and gross, may be made to the presented examples without departing from the spirit and scope of the present disclosure.
The present Patent application claims the benefit of U.S. Provisional Patent Application No. 63/419,131, filed Oct. 25, 2022.
| Number | Date | Country | |
|---|---|---|---|
| 63419131 | Oct 2022 | US |
