(12) United States Patent
`(12) United States Patent
`Lassiter
`Lassiter
`
`11111111111111111111111111111°!1,1111111,!9[1111111111111111111111111111
`US006451409B1
`US 6,451,409 B1
`US 6,451,409 B1
`*Sep. 17, 2002
`*Sep. 17, 2002
`
`(to) Patent No.: (cid:9)
`(io) Patent No.:
`(45) Date of Patent: (cid:9)
`(45) Date of Patent:
`
`US006451409B1
`
`(cid:9) (cid:9)
`
`ROOFING MATERIAL WITH INTEGRALLY
`(54)
`(54) ROOFING MATERIAL WITH INTEGRALLY
`FORMED NAIL TABS
`FORMED NAIL TABS
`
`(76)
`(76)
`
`Inventor: (cid:9) Robert F. Lassiter, 141 S. Barton La.,
`Inventor: Robert F. Lassiter, 141 S. Barton La.,
`Levelland, TX (US) 79336
`Levelland, TX (US) 79336
`
`Notice: (cid:9)
`( * )
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`U.S.C. 154(b) by 0 days.
`
`This patent is subject to a terminal dis-
`This patent is subject to a terminal dis
`claimer.
`claimer.
`
`(21) Appl. No.: 08/561,816
`(21) Appl. No.: 08/561,816
`
`(22) Filed: (cid:9)
`(22) Filed:
`
`Nov. 22, 1995
`Nov. 22, 1995
`
`Related U.S. Application Data
`Related U.S. Application Data
`
`(63) Continuation-in-part of application No. 08/544,300, filed on
`(63) Continuation-in-part of application No. 08/544,300, filed on
`Oct. 17, 1995, now abandoned.
`Oct. 17, 1995, now abandoned.
`
` E04B 7/00
`Int. C1.7 (cid:9)
`(51)
`E04B 7/00
`Int. C I.
`(51)
` 428/147; 428/195; 428/198;
`(52) U.S. Cl.
`428/147; 428/195; 428/198;
`(52) U.S. CI(cid:9)
`428/196; 428/197; 428/200; 428/206; 428/207;
`428/196; 428/197; 428/200; 428/206; 428/207;
`52/408; 52/410; 52/411; 52/413; 52/376;
`52/408; 52/410; 52/411; 52/413; 52/376;
`52/364; 52/366
`52/364; 52/366
` 428/147, 195,
`(58) Field of Search (cid:9)
`428/147, 195,
`(58) Field of Search (cid:9)
`428/198, 196, 197, 200, 206, 207; 52/408,
`428/198, 196, 197, 200, 206, 207; 52/408,
`410, 411, 413, 376, 364, 366
`410, 411, 413, 376, 364, 366
`
`(56)
`(56)
`
`References Cited
`References Cited
`
`U.S. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
`
`9/1975 Maier (cid:9)
`
`3,904,032 A
`9/1975 Maier (cid:9) (cid:9)
`3,904,032 A
`7/1977 Butler (cid:9)
`
`4,033,499 A
`7/1977 Butler
`(cid:9) (cid:9)
`4,033,499 A
`4,554,196 A (cid:9)
`* 11/1985 Meeker (cid:9)
`
`4,554,196 A * 11/1985 Meeker
`4,624,721 A
`11/1986 Sadler et al. (cid:9)
`
`11/1986 Sadler et al (cid:9)
`4,624,721 A
`4,627,207 A
`12/1986
`Young et al. (cid:9)
`
`12/1986 Young et al (cid:9) (cid:9)
`4,627,207 A
`4,641,472 A
`2/1987
`Young et al. (cid:9)
`
`2/1987 Young et al (cid:9)
`4,641,472 A
`4,788,807 A
`12/1988
`Whitman (cid:9)
`
`12/1988 Whitman (cid:9)
`4,788,807 A
`5,130,178 A (cid:9)
`*
`7/1992
`Zerfass et al. (cid:9)
`
`5,130,178 A *
`7/1992 Zerfass et al (cid:9)
`5,309,685 A (cid:9)
`* 5/1994 Rathgeber et al. (cid:9)
`
`5,309,685 A *
`5/1994 Rathgeber et al (cid:9)
`5,365,709 A
`11/1994 Lassiter (cid:9)
`
`5,365,709 A
`11/1994 Lassiter
`5,407,313 A
`4/1995 Bruins et al. (cid:9)
`
`5,407,313 A
`4/1995 Bruins et al (cid:9)
`5,415,511 A
`5/1995 Damron (cid:9)
`
`5,415,511 A
`5/1995 Damron (cid:9)
`5,469,671 A (cid:9)
`* 11/1995 Rathgeber et al. (cid:9)
`
`5,469,671 A * 11/1995 Rathgeber et al.
`
`206/347
`206/347
`227/120
`227/120
`428/67
`428/67
`156/92
`156/92
`52/361
`52/361
`52/361
`52/361
`52/410
`52/410
`428/198
`428/198
`52/58
`52/58
`52/408
`52/408
`411/544
`411/544
`411/480
`411/480
`52/58
`52/58
`
`* cited by examiner
`* cited by examiner
`
`Primary Examiner—William P. Watkins, III
`Primary Examiner—William P. Watkins, III
`
`(57) (cid:9)
`(57)
`
`ABSTRACT
`ABSTRACT
`
`A composite roofing material includes a final condition
`A composite roofing material
`includes a final condition
`underlayment material having bonded thereto appropriate
`underlayment material having bonded thereto appropriate
`rows of nail tabs preferably made of thermoplastic-based
`rows of nail tabs preferably made of thermoplastic-based
`material, such as low density polyethylene material, and of
`material, such as low density polyethylene material, and of
`a contrasting color to the underlayment material. A process
`a contrasting color to the underlayment material. A process
`is used to make the nail tabs by conveying the saturated
`is used to make the nail tabs by conveying the saturated
`underlayment material in a continuous process past appro-
`underlayment material in a continuous process past appro
`priate sets of nozzles that are coordinated with the speed of
`priate sets of nozzles that are coordinated with the speed of
`conveyance to deposit the tabs while in a liquid state and to
`conveyance to deposit the tabs while in a liquid state and to
`form tabs of appropriate size and appropriately patterned
`form tabs of appropriate size and appropriately patterned
`across the underlayment surface. Each nozzle can include
`across the underlayment surface. Each nozzle can include
`multiple orifices to control the width and thickness of the
`multiple orifices to control the width and thickness of the
`formed tabs. A similar process is disclosed for making other
`formed tabs. A similar process is disclosed for making other
`building cover materials having rows of nail tabs coinciding
`building cover materials having rows of nail tabs coinciding
`with standard stud spacing.
`with standard stud spacing.
`
`3,779,373 A (cid:9)
`3,779,373 A
`3,841,474 A (cid:9)
`3,841,474 A
`
`12/1973 Maier (cid:9)
`12/1973 Maier (cid:9)
`10/1974 Maier (cid:9)
`10/1974 Maier (cid:9)
`
` 206/56 DF
`206/56 DF
` 206/346
`206/346
`
`8 Claims, 2 Drawing Sheets
`8 Claims, 2 Drawing Sheets
`
`28
`28 S~
`
`TANK
`TANK
`
`PUMP
`PUMP
`
`r,30
`
`MICRO—
`MICRO
`PROCESSOR
`PROCESSOR
`
`MICRO—
`MICRO
`PROCESSOR
`PROCESSOR
`29
`
`12
`
`/26
`29a (cid:9)
`Yr---/
`
`22a
`
`24
`
`\--17
`
`29x
`
`
`29b
`
`18
`
`0
`
`34
`
`Petitioner - Owens Corning
`Ex. 1003, p. 1 of 7
`
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`

`
`Waled *S11
`
`& 9
`
`d
`
`!Z5
`
`Os
`
`Z Jo 1 lamIS
`
`oM
`
`s
`K<
`
`!Z5
`sr
`re
`re
`
`29x
`1-21
`,c
`22x
`22x
`
`3
`
`es es es
`
`34
`
`HI 60e-13'17'9 Sfl
`
`dc
`
`r
`
`ON
`
`in
`
`oN
`
`O W
`
`r130
`,30
`
`MICRO-
`MICRO
`PROCESSOR
`PROCESSOR
`
`-
`
`TANK
`TANK
`
`& P
`
`PUMP
`UMP
`
`28
`28
`
`MICRO-
`MICRO
`PROCESSOR
`PROCESSOR
`29
`29
`
`29b
`29b
`
`/26
`-26
`29a (cid:9)
`29a
`~
`
`Yr
`
`22a
`22a
`
`V17
`\-17
`
`/
`24
`24-
`
`12
`
`(cid:9)1nnnn1 r—
`UUUULU
`
`-)L16
`
`14
`
`10
`
`FIG. I
`I
`FIG.
`
`Petitioner - Owens Corning
`Ex. 1003, p. 2 of 7
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Sep. 17, 2002
`Sep. 17, 2002
`
`Sheet 2 of 2
`Sheet 2 of 2 (cid:9)
`
`US 6,451,409 B1
`US 6,451,409 B1
`
`MICROPROCESSORS
`MICROPROCESSORS
`a-
`
`10.TO ROLLER 27a
`TO ROLLER 27a
`
`17
`
`26c
`26c
`
`126b
`[26b
`
`126a
`
`hoiwi (cid:9)
`Fir 9a (cid:9)
`2
`29a
`
`he*
`J-29b
`29b
`
`TANK
`
`PUMP
`
`728
`
`FIG, 2
`FIG. 2
`
`40
`42
`44
`46
`26a
`
`48
`
`FIG. 3
`FIG. 3
`
`29a
`/-29a
`
`52" —
`
`50"
`
`FIG. 4
`FIG. 4
`
`Petitioner - Owens Corning
`Ex. 1003, p. 3 of 7
`
`(cid:9)
`

`
`US 6,451,409 B1
`US 6,451,409 B1
`
`1
`ROOFING MATERIAL WITH INTEGRALLY
`ROOFING MATERIAL WITH INTEGRALLY
`FORMED NAIL TABS
`FORMED NAIL TABS
`
`This application is a continuation-in-part of application
`This application is a continuation-in-part of application
`Ser. No. 08/544,300, filed Oct. 17, 1995, now abandoned, 5
`Ser. No. 08/544,300, filed Oct. 17, 1995, now abandoned,
`5
`entitled "Roofing Material With Integrally Formed Nail
`entitled "Roofing Material With Integrally Formed Nail
`Tabs" by the same inventor.
`Tabs" by the same inventor.
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`
`10
`This invention pertains to roofing materials or other 10
`This invention pertains to roofing materials or other
`building materials normally employed as cover materials
`building materials normally employed as cover materials
`prior to the installation of roofing shingles or external
`prior to the installation of roofing shingles or external
`building finish siding and more specifically to such cover
`building finish siding and more specifically to such cover
`materials incorporating therein a plurality of integrally
`materials incorporating therein a plurality of
`integrally
`formed nail tabs.
`formed nail tabs.
`
`15
`15
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`2
`auxiliary large washer or tab that lies underneath the nail
`auxiliary large washer or tab that lies underneath the nail
`head. Such large washer or tab successfully resists being
`head. Such large washer or tab successfully resists being
`torn through as with a smaller nail head of regular size. The
`torn through as with a smaller nail head of regular size. The
`use of such washer or tab has not been totally satisfactory,
`use of such washer or tab has not been totally satisfactory,
`however, since such use is time consuming, somewhat
`however, since such use is time consuming, somewhat
`expensive, and can be somewhat dangerous when the instal-
`expensive, and can be somewhat dangerous when the instal
`lation is on a fairly steeply pitched roof and/or the conditions
`lation is on a fairly steeply pitched roof and/or the conditions
`are inclement. This is because it requires two hands to either
`are inclement. This is because it requires two hands to either
`slip the washer over the nail or to hold a tab down while
`slip the washer over the nail or to hold a tab down while
`driving the nail through. If the installer is having to reach
`driving the nail through. If the installer is having to reach
`while only supporting himself or herself on a toeboard, it
`while only supporting himself or herself on a toeboard, it
`may be uncomfortable and/or unstable to be unable to use
`may be uncomfortable and/or unstable to be unable to use
`either hand for additional support when necessary.
`either hand for additional support when necessary.
`Moreover, nails with large, unconventional heads are not
`Moreover, nails with large, unconventional heads are not
`recommended both because they are expensive and because
`recommended both because they are expensive and because
`they cannot be used in ordinary power equipment.
`they cannot be used in ordinary power equipment,
`ordinarily, power equipment for driving nails can be loaded
`ordinarily, power equipment for driving nails can be loaded
`only with standard nail cartridges.
`only with standard nail cartridges.
`U.S. Pat. No. 5,365,709, commonly owned herewith,
`U.S. Pat. No. 5,365,709, commonly owned herewith,
`describes an improved underlayment roofing material that
`describes an improved underlayment roofing material that
`includes a plurality of suitable nail tabs attached to a felt
`includes a plurality of suitable nail tabs attached to a felt
`base. The concept therein described was to produce a roll of
`base. The concept therein described was to produce a roll of
`underlayment that had the tabs in place so that the installer
`underlayment that had the tabs in place so that the installer
`would not have to separately handle a washer or a separated
`would not have to separately handle a washer or a separated
`tab and nail. With the tabs in place, the installer would
`tab and nail. With the tabs in place,
`the installer would
`merely target the tabs one by one with a conventional power
`merely target the tabs one by one with a conventional power
`driven nail gun. Such installation would be many times
`driven nail gun. Such installation would be many times
`faster than installations previously described and would be
`faster than installations previously described and would be
`less cumbersome to the installer since the nailing process
`less cumbersome to the installer since the nailing process
`would not require both hands when a nail gun is used.
`would not require both hands when a nail gun is used.
`However, the underlayment therein described has not been
`However, the underlayment therein described has not been
`used commercially. To make a dry felt material with glued-
`used commercially. To make a dry felt material with glued-
`on tabs, as described in the '709 patent, into saturated felt
`on tabs, as described in the '709 patent, into saturated felt
`material requires the adhesive and the tab material to not
`material requires the adhesive and the tab material to not
`materially degrade during the asphalt saturation process.
`materially degrade during the asphalt saturation process.
`The high temperature of this process and the rollers used
`The high temperature of this process and the rollers used
`tend to either melt the adhesive glue, melt the tab material
`tend to either melt the adhesive glue, melt the tab material
`itself, scrape off the tabs, or a combination of all three, any
`itself, scrape off the tabs, or a combination of all three, any
`of which renders the resulting saturated felt material
`of which renders the resulting saturated felt material
`unreliable, if not unsuited, for commercial use.
`unreliable, if not unsuited, for commercial use.
`It has been discovered, as hereinafter described, that tabs
`It has been discovered, as hereinafter described, that tabs
`can be permanently and reliably affixed or bonded to satu-
`can be permanently and reliably affixed or bonded to satu
`rated felt material avoiding many of the problems attendant
`rated felt material avoiding many of the problems attendant
`to affixing tabs to the dry felt base material as described in
`to affixing tabs to the dry felt base material as described in
`the '709 patent. Moreover, it has been discovered that the
`the '709 patent. Moreover, it has been discovered that the
`process of producing suitable tabs onto saturated felt mate-
`process of producing suitable tabs onto saturated felt mate
`rial can be automated using liquid thermoplastic tab material
`rial can be automated using liquid thermoplastic tab material
`that quickly solidifies and adheres or bonds to the surface of
`that quickly solidifies and adheres or bonds to the surface of
`the saturated felt material.
`the saturated felt material.
`Also, importantly, it has been discovered that the produc-
`Also, importantly, it has been discovered that the produc
`tion of tabs onto the saturated felt material can be done
`tion of tabs onto the saturated felt material can be done
`immediately following the step of dipping or spraying the
`immediately following the step of dipping or spraying the
`dry felt material with a suitable hot asphalt mix to make
`dry felt material with a suitable hot asphalt mix to make
`saturated felt material. Thus, the conversion of dry felt to
`saturated felt material. Thus, the conversion of dry felt to
`saturated felt can be combined in an automated process with
`saturated felt can be combined in an automated process with
`the subsequent production of the tabs.
`the subsequent production of the tabs.
`In addition to saturated felt material used in a roofing
`In addition to saturated felt material used in a roofing
`application, suitable tabs can also be similarly installed
`application, suitable tabs can also be similarly installed
`using liquid thermoplastic tab material to other base sheeting
`using liquid thermoplastic tab material to other base sheeting
`materials, such as siding materials used for wrapping the
`materials, such as siding materials used for wrapping the
`side of a framed house or other structure prior to securing the
`side of a framed house or other structure prior to securing the
`finish siding.
`finish siding.
`Therefore, it is a feature of the present invention to
`Therefore,
`it is a feature of the present
`invention to
`provide an improved sheeting material having nail tabs
`provide an improved sheeting material having nail
`tabs
`produced directly onto at least one of its surfaces.
`produced directly onto at least one of its surfaces.
`It is another feature of the present invention to provide an
`It is another feature of the present invention to provide an
`improved underlayment roofing material incorporating nail
`improved underlayment roofing material incorporating nail
`
`20
`
`25
`25
`
`30
`30
`
`35
`
`40
`40
`
`45
`45
`
`A shingle roof installation generally comprises at least
`A shingle roof installation generally comprises at
`least
`two distinctive layers. The first layer is an underlayment,
`two distinctive layers. The first layer is an underlayment,
`usually a saturated asphalt material that attaches directly to
`usually a saturated asphalt material that attaches directly to
`the plywood sheets or board material that supports the
`the plywood sheets or board material
`that supports the
`shingles. The second layer is made up of the shingles
`shingles. The second layer is made up of the shingles
`themselves. Normally, the underlayment assists in making
`themselves. Normally, the underlayment assists in making
`the roof resistant to water intrusion. The starting material for
`the roof resistant to water intrusion. The starting material for
`the underlayment is a base material usually referred to as
`the underlayment is a base material usually referred to as
`"dry felt". Examples of types of dry felt starting material are
`"dry felt". Examples of types of dry felt starting material are
`rag, paper and fiberglass, which is not exhaustive of possible
`rag, paper and fiberglass, which is not exhaustive of possible
`starting base materials. The starting base material that has
`starting base materials. The starting base material that has
`actually been subject to experimentation is a fibrous paper
`actually been subject to experimentation is a fibrous paper
`made from treating recyclable cardboard; however, this
`made from treating recyclable cardboard; however,
`this
`invention is not limited thereto. The term "dry felt" used
`invention is not limited thereto. The term "dry felt" used
`herein is used generically for all suitable starting base
`herein is used generically for all suitable starting base
`material. Dry felt material when saturated with an asphalt
`material. Dry felt material when saturated with an asphalt
`material produces an underlayment roofing material known
`material produces an underlayment roofing material known
`in the trade as "tar paper" or "saturated felt", which is
`in the trade as "tar paper" or "saturated felt", which is
`produced in various grades depending on thickness and
`produced in various grades depending on thickness and
`weight.
`weight.
`Regardless of the type of underlayment roofing material
`Regardless of the type of underlayment roofing material
`that has been employed, common practice in the installation
`that has been employed, common practice in the installation
`industry has been to unroll a length of the underlayment
`industry has been to unroll a length of the underlayment
`material and affix each length to the support sheets or boards
`material and affix each length to the support sheets or boards
`at a plurality of locations so that it stays in place prior to the
`at a plurality of locations so that it stays in place prior to the
`installation of the covering shingles. The affixing or fasten-
`installation of the covering shingles. The affixing or fasten
`ing devices for this material are generally staples and nails.
`ing devices for this material are generally staples and nails.
`Staples and regular nails are readily applied by power
`Staples and regular nails are readily applied by power
`devices; however, both are notoriously susceptible to either
`devices; however, both are notoriously susceptible to either
`pulling out of the sheets or boards when there is an uplift on
`pulling out of the sheets or boards when there is an uplift on
`the underlayment or, when the staples or nails stay in place,
`the underlayment or, when the staples or nails stay in place,
`tearing of the roofing material at the fastening locations.
`tearing of the roofing material at
`the fastening locations.
`Even when shingling is to follow immediately, the under-
`Even when shingling is to follow immediately, the under
`layment can still be exposed alone to windy and other
`layment can still be exposed alone to windy and other
`adverse conditions, such as when the installers walk or crawl
`adverse conditions, such as when the installers walk or crawl
`on the underlayment.
`on the underlayment.
`Moreover, it is desirable that the underlayment be
`Moreover,
`it
`is desirable that
`the underlayment be
`securely attached independently of the shingles not only in
`securely attached independently of the shingles not only in
`the pre-shingling stage of installation, but also in the final
`the pre-shingling stage of installation, but also in the final
`installation. This is because shingles do get blown or ripped
`installation. This is because shingles do get blown or ripped
`off under adverse weather conditions and a securely inde-
`off under adverse weather conditions and a securely inde
`pendently installed underlayment will provide some interim
`pendently installed underlayment will provide some interim
`protection from the weather elements prior to roof repair.
`protection from the weather elements prior to roof repair.
`When the underlayment is not securely fastened, then the
`When the underlayment is not securely fastened, then the
`underlayment may be blown away or ripped concurrently
`underlayment may be blown away or ripped concurrently
`with shingle damage.
`with shingle damage.
`To securely install the underlayment and avoid the tearing 65
`To securely install the underlayment and avoid the tearing
`65
`described above, it has long been a common practice to
`described above,
`it has long been a common practice to
`either use roofing nails with large heads or to use an
`either use roofing nails with large heads or to use an
`
`50
`50
`
`55
`55
`
`60
`60
`
`Petitioner - Owens Corning
`Ex. 1003, p. 4 of 7
`
`

`
`US 6,451,409 B1
`US 6,451,409 B1
`
`4
`3
`tabs therein that are tough and compliant that are produced
`Each "nozzle" used for making the deposits is preferably
`tabs therein that are tough and compliant that are produced
`Each "nozzle" used for making the deposits is preferably
`directly on saturated felt material.
`either a plurality of closely spaced orifices in a common
`directly on saturated felt material.
`either a plurality of closely spaced orifices in a common
`manifold housing or an elongated slit opening so as to cover
`manifold housing or an elongated slit opening so as to cover
`It is yet another feature of the present invention to provide
`It is yet another feature of the present invention to provide
`a wide enough area for making tabs of the preferred width
`a wide enough area for making tabs of the preferred width
`such an underlayment roofing material incorporating nail
`such an underlayment roofing material
`incorporating nail
`5 dimension without forming a tab that is too thick. When a
`dimension without forming a tab that is too thick. When a
`tabs therein that are of a material that is reliable when used
`tabs therein that are of a material that is reliable when used 5
`plurality of orifices are employed, the liquid material flow-
`plurality of orifices are employed, the liquid material flow
`in the extremes of ambient temperature conditions encoun-
`in the extremes of ambient temperature conditions encoun
`ing from the individual orifices blends together, cools and
`ing from the individual orifices blends together, cools and
`tered in typical installations.
`tered in typical installations.
`hardens to form the individual tabs.
`hardens to form the individual tabs.
`It is still another feature of the present invention to
`It
`is still another
`feature of the present
`invention to
`provide an improved underlayment roofing material utiliz-
`provide an improved underlayment roofing material utiliz
`ing an automated process for applying a liquid thermoplastic
`ing an automated process for applying a liquid thermoplastic
`material at appropriate tab positions using nozzles that are
`material at appropriate tab positions using nozzles that are
`readily programmably controlled.
`readily programmably controlled.
`It is yet another feature of the present invention to provide
`It is yet another feature of the present invention to provide
`an improved underlayment material, wherein the overall
`an improved underlayment material, wherein the overall 15
`15
`process is continuous and automated to include the satura-
`process is continuous and automated to include the satura
`tion of dry felt material to make saturated felt material
`tion of dry felt material
`to make saturated felt material
`followed by the production of suitable nail tabs from pres-
`followed by the production of suitable nail tabs from pres
`surized liquid thermoplastic-based or other material that
`surized liquid thermoplastic-based or other material
`that
`subsequently hardens and securely bonds to the surface of
`subsequently hardens and securely bonds to the surface of 20
`20
`the saturated felt material.
`the saturated felt material.
`
`10
`10
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`So that the manner in which the above recited features,
`So that the manner in which the above recited features,
`advantages and objects of the invention, as well as others
`advantages and objects of the invention, as well as others
`which will become apparent, are attained and can be under-
`which will become apparent, are attained and can be under
`stood in detail, more particular description of the invention
`stood in detail, more particular description of the invention
`briefly summarized above may be had by reference to the
`briefly summarized above may be had by reference to the
`embodiment thereof which is illustrated in the appended
`embodiment thereof which is illustrated in the appended
`drawings, which drawings form a part of this specification.
`drawings, which drawings form a part of this specification.
`It is to be noted, however, that the drawings illustrate only
`It is to be noted, however, that the drawings illustrate only
`a preferred embodiment of the invention and is therefore not
`a preferred embodiment of the invention and is therefore not
`to be considered limiting of its scope as the invention may
`to be considered limiting of its scope as the invention may
`admit to other equally effective embodiments.
`admit to other equally effective embodiments.
`In the drawings:
`In the drawings:
`FIG. 1 is a schematic side view of an automated process
`FIG. 1 is a schematic side view of an automated process
`of manufacturing a composite roofing material of the inven-
`of manufacturing a composite roofing material of the inven
`tion in accordance with a preferred procedure.
`tion in accordance with a preferred procedure.
`FIG. 2 is a schematic top view of the nail tab production
`FIG. 2 is a schematic top view of the nail tab production
`area of the automated process shown in FIG. 1.
`area of the automated process shown in FIG. 1.
`FIG. 3 is a schematic representation of a nozzle with a
`FIG. 3 is a schematic representation of a nozzle with a
`manifold housing having a plurality of orifices used in the
`manifold housing having a plurality of orifices used in the
`process of manufacturing the composite roofing material as
`process of manufacturing the composite roofing material as
`shown in FIG. 2.
`shown in FIG. 2.
`FIG. 4 is a schematic representation of a nozzle having an
`FIG. 4 is a schematic representation of a nozzle having an
`elongated slit used in the process of manufacturing the
`elongated slit used in the process of manufacturing the
`composite roofing material as shown in FIG. 2.
`composite roofing material as shown in FIG. 2.
`
`DESCRIPTION OF THE PREFERRED
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`EMBODIMENTS
`
`The making of the composite roofing material preferably
`The making of the composite roofing material preferably
`employs a machine manufactured by Nordson Corp. of
`employs a machine manufactured by Nordson Corp. of
`Westlake, Ohio that uses one or more nozzle sets for
`Westlake, Ohio that uses one or more nozzle sets for
`dispensing multiple beads of viscous liquid, as set forth in
`dispensing multiple beads of viscous liquid, as set forth in
`U.S. Pat. No. 5,335,825, which is incorporated herein for all
`U.S. Pat. No. 5,335,825, which is incorporated herein for all
`purposes. This machine has been utilized in the past, for
`purposes. This machine has been utilized in the past, for
`example, in laying down small beads of glue onto stock
`example,
`in laying down small beads of glue onto stock
`cardboard, which when subsequently cut and folded pro-
`cardboard, which when subsequently cut and folded pro
`duces boxes. Other suitable equipment can be used, if
`duces boxes. Other suitable equipment can be used,
`if
`desired.
`desired.
`The process illustrated in FIG. 1 is generally a roller
`The process illustrated in FIG. 1 is generally a roller
`driven system that moves from left to right in the drawing.
`driven system that moves from left to right in the drawing.
`The end of a roll 10 of appropriate dry felt material to be
`The end of a roll 10 of appropriate dry felt material to be
`saturated is conveyed using a drive roller 12 to a treatment
`saturated is conveyed using a drive roller 12 to a treatment
`area 14 for asphalt saturating the dry felt in conventional
`area 14 for asphalt saturating the dry felt in conventional
`fashion. This saturating treatment stage is illustrated as a
`fashion. This saturating treatment stage is illustrated as a
`series of turns of the unrolled felt material since that fairly
`series of turns of the unrolled felt material since that fairly
`represents how the material is fed through the hot asphalt
`represents how the material is fed through the hot asphalt
`bath or pit to saturate the dry felt material. The temperature
`bath or pit to saturate the dry felt material. The temperature
`of the asphalt that is applied is typically in excess of 400° F.
`of the asphalt that is applied is typically in excess of 400° F.
`As the saturated felt material exits the saturating treatment
`As the saturated felt material exits the saturating treatment
`stage, it may be cooled by use of a water cooled chill roll 16.
`stage, it may be cooled by use of a water cooled chill roll 16.
`Other means of cooling the saturated felt may be used, if
`Other means of cooling the saturated felt may be used, if
`desired. For example, conveying the material through a long
`desired. For example, conveying the material through a long
`distance in a cool ambient environment would produce the
`distance in a cool ambient environment would produce the
`same cooling result.
`same cooling result.
`It has been discovered, however, the subsequent produc-
`It has been discovered, however, the subsequent produc
`tion of the nail tabs can be produced without detriment onto
`tion of the nail tabs can be produced without detriment onto
`
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`
`A composite roofing material is made starting with a roll
`A composite roofing material is made starting with a roll
`of dry felt material. In the preferred method of producing the
`of dry felt material. In the preferred method of producing the 25
`25
`underlayment roofing material in accordance with this
`underlayment
`roofing material
`in accordance with this
`invention, the dry felt material is introduced to the beginning
`invention, the dry felt material is introduced to the beginning
`of a continuous and automated process having a system of
`of a continuous and automated process having a system of
`driven rollers for transporting the roofing material through
`driven rollers for transporting the roofing material through
`the process. First, the dry felt material undergoes treatment
`the process. First, the dry felt material undergoes treatment 30
`30
`in conventional fashion to produce asphalt saturated felt
`in conventional
`fashion to produce asphalt saturated felt
`material from the dry felt material. Then, a suitable liquid
`material from the dry felt material. Then, a suitable liquid
`thermoplastic-based or other material is deposited on the
`thermoplastic-based or other material
`is deposited on the
`rapidly moving saturated felt using appropriately positioned
`rapidly moving saturated felt using appropriately positioned
`nozzles or nozzle sets. The on/off operation of the nozzles or
`nozzles or nozzle sets. The on/off operation of the nozzles or 35
`35
`nozzle sets and the movement of the saturated felt material
`nozzle sets and the movement of the saturated felt material
`are respectively controlled and coordinated by one or more
`are respectively controlled and coordinated by one or more
`suitable programmable microprocessors. The thermoplastic-
`suitable programmable microprocessors. The thermoplastic-
`based material may include an appropriate adhesive to
`based material may include an appropriate adhesive to
`ensure that it bonds to the surface of the saturated felt
`ensure that
`it bonds to the surface of the saturated felt 40
`40
`material as it rapidly cools and hardens to form the desired
`material as it rapidly cools and hardens to form the desired
`nail pads or tabs. The thermoplastic-based material may be
`nail pads or tabs. The thermoplastic-based material may b