1111111111111111111111111119Q1111jI!!1111111111111111111111111
`
`US007666498B2
`
`(12) United States Patent (cid:9)
`(12) Ulllted States Patent
`Collins et al. (cid:9)
`Collins et al.
`
`(54) PRINT METHODOLOGY FOR APPLYING
`(54) PRINT METHODOLOGY FOR APPLYING
`POLYMER MATERIALS TO ROOFING
`POLYMER MATERIALS TO ROOFING
`MATERIALS TO FORM NAIL TABS OR
`MATERIALS TO FORM NAIL TABS OR
`REINFORCING STRIPS
`REINFORCING STRIPS
`
`_
`_
`_
`(76) Inventors: David Allan Collins, 11302 Memorial
`(76) Inventors: David Allan Collins, 11302 Memorial
`Dr., Houston, TX (US) 77024; George
`Dr., Houston, TX (US) 77024; George
`William Jackson, 3100 Walnut Bend,
`William Jackson’ 3100 Walnut BePd’
`#222, Houston, TX (US) 77042; Miguel
`#222, Houston, TX (Us) 77042; Mlgllel
`E. Madero O'Brien, Sierra Amatepec
`E- Madero 0’Br1en, slerra Amatepec
`371, Lomas de Chapultepec, Mexico,
`371, Lomas de Chapultepec, Mexico,
`D.F. (MX) 11000
`D'F' (MX) 11000
`
`( * ) Notice:
`( * ) 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 369 days.
`U.S.C. 154(b) by 369 days.
`
`_
`(21) Appl. No.: 11/475,455
`(21) Appl' NO" 11/475’455
`
`(22) Filed: (cid:9)
`
`Jun. 27, 2006
`
`(65) (cid:9)
`(65)
`
`Prior Publication Data
`Prior Publication Data
`Us 2006/0240230 A1
`Oct 26 2006
`US 2006/0240230 Al (cid:9)
`Oct. 26, 2006
`’
`Related U_s_ Application Data
`Related U.S. Application Data
`_
`_
`_
`_
`_
`(62) Division of application No. 10/855,264, filed on May
`(62) Dlvlslon of apphcanon NO‘ 10/855,264’ ?led on May
`27, 2004, now Pat. No. 7,201,946.
`27’ 2004’ HOW Pat' No' 7,201,946
`(60) Provisional application No. 60/474,194, ?led on May
`(60) Provisional application No. 60/474,194, filed on May
`29s 2003, provisional application NO_ 60/485’774s
`29, 2003, provisional application No. 60/485,774,
`?led on ]u1_ 9, 2003'
`filed on Jul. 9, 2003.
`
`(51) Int. Cl.
`(51) Int, Cl,
`(2006.01)
`B32B 7/12 (cid:9)
`(200601)
`B 323 7/12
`(52) U.S. Cl. (cid:9)
` 428/343; 428/98; 428/141;
`(52) us. Cl. ....................... .. 428/343; 428/98; 428/141;
`428/172; 428/195.1; 428/201; 428/213; 428/214;
`428/172; 428/195.1; 428/201; 428/213; 428/214;
`428/345; 428/346; 427/186; 427/187; 427/188;
`428/345; 428/346; 427/186; 427/187; 427/188;
`427/428.18; 427/428.19; 427/428.2; 52/746.11
`427/428.18; 427/428.19; 427/4282; 52/746.11
`
`120
`120
`
`(10) Patent N0.:
`(10) Patent No.: (cid:9)
`(45) Date of Patent: (cid:9)
`(45) Date of Patent:
`
`US 7,666,498 B2
`US 7,666,498 B2
`Feb. 23, 2010
`Feb. 23, 2010
`
`
`(58) Field of Classification Search (cid:9)
`52/746.11;
`(58) Field of Classi?cation Search ............ .. 52/746.11;
`427/186-188, 428.18-428.2; 428/141, 98,
`427/186*188, 4281844282; 428/141, 98,
`428/172, 195.1, 201, 213-214, 343, 345-346
`428/172, 195.1, 201, 2134214, 343, 3454346
`See application file for complete search history.
`See application ?le for complete search history.
`References Cited
`References Cited
`
`(56)
`(56)
`
`U.S. PATENT DOCUMENTS
`U-S- PATENT DOCUMENTS
`3,003,906 A * 10/1961 Fasold et al. (cid:9)
` 156/269
`3,003,906 A * 10/1961 Fasold et a1. .............. .. 156/269
`6,210,757 Bl * 4/2001 Taylor et al. (cid:9)
` 427/356
`6,210,757 B1 *
`4/2001 Taylor et a1. .... ..
`427/356
`2003/0044526 Al * 3/2003 Lassiter (cid:9)
` 427/186
`2003/0044526 A1* 3/2003 Lassiter ................. .. 427/186
`2003/0215594 Al * 11/2003 Hamdar et al. (cid:9)
` 428/40.1
`2003/0215594 A1* 11/2003 Hamdar et a1. ........... .. 428/401
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`W0
`WOW/29256
`* 8/1997
`WO (cid:9)
`W097/29256 (cid:9)
`* 8/1997
`* _
`_
`* cited by examiner
`“ted by examlner
`Primary Examiner (cid:9) David R Sample
`Primary ExamineriDavid R Sample
`Assistant ExamineriPrashant J Khatri
`Assistant Examiner (cid:9) Prashant J Khatri
`
`(57)
`
`ABSTRACT
`
`A method of making a composite roo?ng material and the
`A method of making a composite roofing material and the
`resulting material by depositing nail tabs made of a thermo-
`resulting material by depositing nail tabs made of a thermo
`plastic, thermosetting, adhesive or elastomer material, in a
`plastic, thermosetting, adhesive or elastomer material, in a
`liquid state, onto the base substrate of the composite roofing
`liquid state, onto the base substrate of the composite roo?ng
`material or onto the saturated or coated roofing material, or
`material or onto the saturated or coated roo?ng material, or
`onto a transfer surface to be pressed or laminated onto the
`onto a transfer surface to be pressed or laminated onto the
`roo?ng material. A preferred embodiment transfers the nail
`roofing material. A preferred embodiment transfers the nail
`tabs onto an engraved transfer impression roll and uses a
`tabs Onto an engraved transfer impression T011 and uses a
`pressurized applicator to inject the viscous tab material into
`pressurized applicator to inject the viscous tab material into
`engraved patterns depressed in raised areas of the impression
`engraved patterns depressed in raised areas of the impression
`roll., then deposits the material onto the roofing material. A
`roll., then deposits the material onto the roo?ng material. A
`preferred embodiment also includes the thermoplastic or
`preferred embodiment also includes the thermoplastic or
`thermosetting material in a liquid or viscous state hardened or
`thermosetting material in a liquid or viscous state hardened or
`cured by either its exposure to the air or by the use of ultra-
`Cured by either its exposure to the air Or by the use Of ultra
`violet or visible light.
`violet or visible light.
`
`7 Claims, 10 Drawing Sheets
`7 Claims, 10 Drawing Sheets
`
`122
`122
`
`Petitioner - Owens Corning
`Ex. 1018, p. 1 of 185
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 1 of 10 (cid:9)
`Sheet 1 0f 10
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`US 7,666,498 B2
`US 7,666,498 B2
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`106
`106
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`102
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`\'.---108
`Fig. 1
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`104
`104
`
`100
`‘100
`
`120
`120
`
`122
`122
`
`Fig. 1 B
`Fig. 1B
`
`Petitioner - Owens Corning
`Ex. 1018, p. 2 of 185
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010
`Feb. 23, 2010 (cid:9)
`
`Sheet 2 0f 10
`Sheet 2 of 10 (cid:9)
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`110
`
`1 1 1
`
`112
`
`Fig. 1A
`Fig. 1A
`
`Petitioner - Owens Corning
`Ex. 1018, p. 3 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 3 of 10 (cid:9)
`Sheet 3 0f 10
`
`US 7,666,498 B2
`US 7,666,498 B2
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`206
`
`204
`
`0
`
`y--202
`
`200
`
`Fig. 2
`Fig. 2
`
`Petitioner - Owens Corning
`Ex. 1018, p. 4 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010
`Feb. 23, 2010 (cid:9)
`
`Sheet 4 0f 10
`Sheet 4 of 10 (cid:9)
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`304
`
`J.-
`
`.... (cid:9)
`
`\
`
`•
`e •
`
`•
`•
`
`•
`•
`
`/ •
`1
`I
`,1
`
`300' `..
`
`vs. -- .....
`
`i
`
`II
`
`306"\
`306
`
`•
`
`1 (cid:9)
`
`r (cid:9)
`1
`I
`I (cid:9)
`r- --1_1 (cid:9)
`_
`1_1-1 - : (cid:9)
`L _ _ J (cid:9)
`
`r (cid:9)
`1 (cid:9)
`1 (cid:9)
`L (cid:9)
`
`i
`, r
`
`1 (cid:9)
`.')
`I. --
` J
`
`302
`
`r
`
`Fig. 3
`
`Petitioner - Owens Corning
`Ex. 1018, p. 5 of 185
`
`(cid:9)
`(cid:9)
`(cid:9)
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 5 of 10 (cid:9)
`Sheet 5 0f 10
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`402
`
`.\-400
`
`r (cid:9)
`
`1::
`
`Fig. 4
`Fig. 4
`
`Petitioner - Owens Corning
`Ex. 1018, p. 6 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 6 of 10 (cid:9)
`Sheet 6 6f 10
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`414
`
`/41O
`
`418
`
`Fig. 4A
`Fig. 4A
`
`Petitioner - Owens Corning
`Ex. 1018, p. 7 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010
`Feb. 23, 2010 (cid:9)
`
`Sheet 7 0f 10
`Sheet 7 of 10 (cid:9)
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`504
`
`502
`
`Co]
`
`Fig. 5
`Fig. 5
`
`Petitioner - Owens Corning
`Ex. 1018, p. 8 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 8 0f 10
`Sheet 8 of 10
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`602
`
`710
`
`712
`
`712% 0
`
`Fig. 7A
`Fig. 7A
`
`Petitioner - Owens Corning
`Ex. 1018, p. 9 of 185
`
`(cid:9)
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010
`Feb. 23, 2010 (cid:9)
`
`Sheet 9 0f 10
`Sheet 9 of 10 (cid:9)
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`704
`
`Fig. 8A
`
`810
`810
`
`Fig. 8B
`Fig. 8B
`
`Petitioner - Owens Corning
`Ex. 1018, p. 10 of 185
`
`

`

`U.S. Patent (cid:9)
`US. Patent
`
`Feb. 23, 2010 (cid:9)
`Feb. 23, 2010
`
`Sheet 10 of 10 (cid:9)
`Sheet 10 0f 10
`
`US 7,666,498 B2
`US 7,666,498 B2
`
`900
`900
`
`912
`
`L'—9’IO
`
`910
`
`Fig. 9
`Fig. 9
`
`Petitioner - Owens Corning
`Ex. 1018, p. 11 of 185
`
`

`

`US 7,666,498 B2
`US 7,666,498 B2
`
`1
`1
`PRINT METHODOLOGY FOR APPLYING
`PRINT METHODOLOGY FOR APPLYING
`POLYMER MATERIALS TO ROOFING
`POLYMER MATERIALS TO ROOFING
`MATERIALS TO FORM NAIL TABS OR
`MATERIALS TO FORM NAIL TABS OR
`REINFORCING STRIPS
`REINFORCING STRIPS
`
`CROSS REFERENCE TO RELATED
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`APPLICATIONS
`
`5
`
`This application is a divisional application from applica
`This application is a divisional application from applica-
`tion Ser. No. 10/855,264 filed May 27, 2004 now U.S. Pat. 10
`tion Ser. No. 10/855,264 ?led May 27, 2004 now US. Pat.
`No. 7,201,946 and is related to the following U.S. patent
`No. 7,201,946 and is related to the following US. patent
`applications:
`applications:
`provisional patent application No. 60/474, 1 94 titled Machine
`provisional patent application No. 60/474,194 titled Machine
`and Method for Applying Thermoplastics and Adhesives To
`and Method for Applying Thermoplastics and Adhesives To
`Roo?ng Materials With Nail Tabs ?led May 29, 2003 and
`Roofing Materials with Nail Tabs filed May 29, 2003 and
`provisional patent application No. 60/485,774 titled Machine
`provisional patent application No. 60/485,774 titled Machine
`and Method for Applying Thermoplastics and Adhesives To
`and Method for Applying Thermoplastics and Adhesives To
`Roo?ng Materials With Nail Tabs ?led Jul. 9, 2003, Which are
`Roofing Materials with Nail Tabs filed Jul. 9, 2003, which are
`hereby incorporated by reference as if fully set forth herein.
`hereby incorporated by reference as if fully set forth herein.
`
`15
`
`20
`20
`
`STATEMENT REGARDING FEDERALLY
`STATEMENT REGARDING FEDERALLY
`SPONSORED RESEARCH OR DEVELOPMENT
`SPONSORED RESEARCH OR DEVELOPMENT
`
`Not applicable (cid:9)
`Not applicable
`
`25
`25
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`35
`35
`
`The invention relates generally to roo?ng materials or
`The invention relates generally to roofing materials or
`other building materials normally employed as cover materi-
`other building materials normally employed as cover materi
`30
`30
`als over a wood roof deck or stud wall and more specifically
`als over a Wood roof deck or stud Wall and more speci?cally
`to such cover materials and methods for incorporating therein
`to such cover materials and methods for incorporating therein
`a plurality of integrally formed nail tabs or a continuous
`a plurality of integrally formed nail tabs or a continuous
`reinforcing strip.
`reinforcing strip.
`The Typical Roof Composition. (cid:9)
`The Typical Roof Composition.
`A roof installation generally comprises at least two distinc-
`A roof installation generally comprises at least tWo distinc
`tive layers applied over a roof deck With each layer being
`tive layers applied over a roof deck with each layer being
`comprised of a separate roofing material. The first layer is an
`comprised of a separate roo?ng material. The ?rst layer is an
`underlayment, usually a substantially asphalt saturated sub
`underlayment, usually a substantially asphalt saturated sub-
`strate material that attaches directly to the roof deck, often-
`strate material that attaches directly to the roof deck, often
`40
`40
`times a wood frame of wood studs and plywood sheets or
`times a Wood frame of Wood studs and plyWood sheets or
`board material. The second layer is made up of the shingles,
`board material. The second layer is made up of the shingles,
`rolled roofing, wood shakes, and metal or tile roof coverings
`rolled roo?ng, Wood shakes, and metal or tile roof coverings
`themselves. The shingles and rolled roo?ng are substantially
`themselves. The shingles and rolled roofing are substantially
`made from a fiberglass or other inorganic fibrous material 45
`made from a ?berglass or other inorganic ?brous material
`45
`coated With a substantially asphalt or asphalt-mix coating,
`coated with a substantially asphalt or asphalt-mix coating,
`stone granules and other materials. Speci?c materials, layers
`stone granules and other materials. Specific materials, layers
`of materials and actual application methods differ by manu-
`of materials and actual application methods differ by manu
`facturer and type of building application. Normally, the
`facturer and type of building application. Normally, the
`underlayment assists in making the roof resistant to water 50
`underlayment assists in making the roof resistant to Water
`50
`intrusion.
`intrusion.
`The Typical Underlayment Substrate.
`The Typical Underlayment Substrate.
`The underlayment is usually an asphalt saturated substrate.
`The underlayment is usually an asphalt saturated substrate.
`The starting material for the underlayment, or the substrate
`The starting material for the underlayment, or the substrate
`material itself, is a base composite material usually referred to 55
`material itself, is a base composite material usually referred to
`55
`as "dry felt" or "organic felt", but the substrate material could
`as “dry felt” or “organic felt”, but the substrate material could
`also be a fiberglass mat or other inorganic material mat or a
`also be a ?berglass mat or other inorganic material mat or a
`hybrid of both. Examples of types of dry felt starting material
`hybrid of both. Examples of types of dry felt starting material
`are rag, paper, wood sawdust and could include fiberglass or
`are rag, paper, Wood saWdust and could include ?berglass or
`other inorganic material, oftentimes in a fibrous state, 60
`other inorganic material, oftentimes in a ?brous state,
`60
`although other suitable starting base materials may be
`although other suitable starting base materials may be
`employed. The starting base material, in a preferred embodi
`employed. The starting base material, in a preferred embodi-
`ment, is a fibrous paper called dry felt made from treating
`ment, is a ?brous paper called dry felt made from treating
`recyclable cardboard, mixed recycled papers and wood saw-
`recyclable cardboard, mixed recycled papers and Wood saW
`dust or a fibrous mat made from inorganic materials chemi- 65
`dust or a ?brous mat made from inorganic materials chemi
`65
`cally or mechanically formed into a fibrous state; however,
`cally or mechanically formed into a ?brous state; hoWever,
`this invention is not limited thereto. The term "substrate" used
`this invention is not limited thereto. The term “substrate” used
`
`2
`2
`herein is used generically for all suitable starting base mate
`herein is used generically for all suitable starting base mate-
`rial including dry felt, ?berglass mat and polyester mat or any
`rial including dry felt, fiberglass mat and polyester mat or any
`other base material on which a composite roofing or building
`other base material on Which a composite roo?ng or building
`material is built upon. Dry felt, when saturated with an
`material is built upon. Dry felt, When saturated With an
`asphalt-based material, produces an underlayment roo?ng
`asphalt-based material, produces an underlayment roofing
`material known in the trade as "tar paper" or "saturated felt,"
`material knoWn in the trade as “tar paper” or “saturated felt,”
`Which is produced in various grades depending upon thick
`which is produced in various grades depending upon thick-
`ness and Weight. Fiberglass mat and polyester mat When
`ness and weight. Fiberglass mat and polyester mat when
`coated with an asphalt, rubber-asphalt or asphalt-mix mate-
`coated With an asphalt, rubber-asphalt or asphalt-mix mate
`rial produce the base substrate for shingles and other residen
`rial produce the base substrate for shingles and other residen-
`tial and commercial rolled roo?ng products.
`tial and commercial rolled roofing products.
`The Underlayment Installation.
`The Underlayment Installation.
`Regardless of the type of underlayment roo?ng 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 af?x each length to the roof deck or building
`material and affix each length to the roof deck or building
`sides support sheets or boards at a plurality of locations so that
`sides support sheets orboards at a plurality of locations so that
`it stays in place prior to the installation of the covering
`it stays in place prior to the installation of the covering
`shingles. The af?xing or fastening devices for this material
`shingles. The affixing or fastening devices for this material
`are generally staples and nails. Staples and nails are readily
`are generally staples and nails. Staples and nails are readily
`applied by power devices; however, both are notoriously sus-
`applied by poWer devices; hoWever, both are notoriously sus
`ceptible to either pulling out of the sheets or boards when
`ceptible to either pulling out of the sheets or boards When
`there is uplift on the underlayment or, when the staples or
`there is uplift on the underlayment or, When the staples or
`nails stay in place, tearing of the roo?ng material at the
`nails stay in place, tearing of the roofing material at the
`fastening locations. Even When shingling is to folloW imme
`fastening locations. Even when shingling is to follow imme-
`diately, the underlayment can still be exposed alone to Windy
`diately, the underlayment can still be exposed alone to windy
`and other adverse conditions, such as when the installers walk
`and other adverse conditions, such as When the installers Walk
`or crawl on the underlayment.
`or craWl on the underlayment.
`Moreover, it is desirable that the underlayment be securely
`Moreover, it is desirable that the underlayment be securely
`attached independently of the shingles, Wood shakes, metal
`attached independently of the shingles, wood shakes, metal
`tile or other roof covering not only in the pre-shingling or
`tile or other roof covering not only in the pre-shingling or
`pre-roof covering stage of installation, but also in the ?nal
`pre-roof covering stage of installation, but also in the final
`installation. This is because shingles or other roof coverings
`installation. This is because shingles or other roof coverings
`do get damaged, blown or ripped off the roof under adverse
`do get damaged, bloWn or ripped off the roof under adverse
`weather conditions and a secure independently installed
`Weather conditions and a secure independently installed
`underlayment Will provide some interim protection from the
`underlayment will provide some interim protection from the
`Weather elements prior to roof repair. When the underlayment
`weather elements prior to roof repair. When the underlayment
`is not securely fastened, then the underlayment may be blown
`is not securely fastened, then the underlayment may be bloWn
`aWay or ripped concurrently With shingle damage.
`away or ripped concurrently with shingle damage.
`Current Underlayment Installation Practice Using Wash
`Current Underlayment Installation Practice Using Wash-
`ers.
`ers.
`To securely install the underlayment and avoid the tearing
`To securely install the underlayment and avoid the tearing
`described above, it has long been a common practice to either
`described above, it has long been a common practice to either
`use roofing nails with large heads or to use an auxiliary large
`use roo?ng nails With large heads or to use an auxiliary large
`washer or tab that lies underneath the nail head. Such large
`Washer or tab that lies underneath the nail head. Such large
`washer or tab successfully resists being torn through as with
`Washer or tab successfully resists being torn through as With
`a smaller nail head of regular size. The use of such washer or
`a smaller nail head of regular siZe. The use of such Washer or
`tab has not been totally satisfactory, however, since such use
`tab has not been totally satisfactory, hoWever, since such use
`is time consuming, somewhat expensive, and can be some-
`is time consuming, someWhat expensive, and can be some
`what dangerous when the installation is on a fairly steeply
`What dangerous When the installation is on a fairly steeply
`pitched roof and/or the conditions are inclement. This is
`pitched roof and/ or the conditions are inclement. This is
`because it requires two hands to either slip the washer over the
`because it requires tWo hands to either slip the Washer over the
`nail or to hold a tab down while driving the nail through. If the
`nail or to hold a tab doWn While driving the nail through. If the
`installer has to reach while only supporting himself or herself
`installer has to reach While only supporting himself or herself
`on a toe board, it may be uncomfortable and/or unstable to be
`on a toe board, it may be uncomfortable and/ or unstable to be
`unable to use either hand for additional support when neces-
`unable to use either hand for additional support When neces
`sary. Moreover, nails with large, unconventional heads are not
`sary. 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. Ordinarily,
`they cannot be used in ordinary power equipment. Ordinarily,
`poWer equipment for driving nails can be loaded only With
`power equipment for driving nails can be loaded only with
`standard nail cartridges.
`standard nail cartridges.
`It is an advantage of the present invention to provide a
`It is an advantage of the present invention to provide a
`gravure printing or offset printing process for the application
`gravure printing or offset printing process for the application
`of polymer nail tabs or continuous strips to underlayment or
`of polymer nail tabs or continuous strips to underlayment or
`other roo?ng material.
`other roofing material.
`
`Petitioner - Owens Corning
`Ex. 1018, p. 12 of 185
`
`

`

`US 7,666,498 B2
`US 7,666,498 B2
`
`3
`3
`It is another advantage of the present invention to provide
`It is another advantage of the present invention to provide
`a lamination process for the deposition of polymer material to
`a lamination process for the deposition of polymer material to
`form nail tab or continuous strips on underlayment or other
`form nail tab or continuous strips on underlayment or other
`roo?ng material.
`roofing material.
`It is yet another advantage of the present invention to
`It is yet another advantage of the present invention to
`provide an underlayment or other roofing material with a
`provide an underlayment or other roo?ng material With a
`plurality of nail tabs or continuous reinforcement strips
`plurality of nail tabs or continuous reinforcement strips
`applied through a gravure or other printing process.
`applied through a gravure or other printing process.
`It is still yet another advantage of the present invention to
`It is still yet another advantage of the present invention to
`provide a method for applying polymer material through a
`provide a method for applying polymer material through a
`pressurized delivery system in a gravure or other printing
`pressurized delivery system in a gravure or other printing
`process.
`process.
`It is another advantage of the present invention to provide
`It is another advantage of the present invention to provide
`a system for depositing a plurality of generally rounded tabs
`a system for depositing a plurality of generally rounded tabs
`to underlayment or other roofing material using an etched
`to underlayment or other roo?ng material using an etched
`pattern or an open pattern, with no cell walls or other points of
`pattern or an open pattern, With no cell Walls or otherpoints of
`interruption Within the pattern.
`interruption within the pattern.
`It is another advantage of the present invention to provide
`It is another advantage of the present invention to provide
`a system for depositing a line of polymer material onto under-
`a system for depositing a line of polymer material onto under
`layment, or any other roo?ng material.
`layment, or any other roofing material.
`
`BRIEF SUMMARY OF THE INVENTION
`BRIEF SUMMARY OF THE INVENTION
`
`The invention is to the print method, a gravure, rotogravure
`The invention is to the print method, a gravure, rotogravure
`or gravure-like transfer printing (the “gravure process”) or
`or gravure-like transfer printing (the "gravure process") or
`offset printing, of an appropriately viscous and substantially
`offset printing, of an appropriately viscous and substantially
`polymeric material onto roofing material, or onto a continu-
`polymeric material onto roo?ng material, or onto a continu
`ous transfer material and then transferred, including utiliZing
`ous transfer material and then transferred, including utilizing
`a laminating process, onto the roofing material, in a continu-
`a laminating process, onto the roo?ng material, in a continu
`ous process. The gravure process employs a print cylinder
`ous process. The gravure process employs a print cylinder
`Which has etched or engraved cells of varying depth, Width
`which has etched or engraved cells of varying depth, width
`and shape and Which cells can be varied to apply differing
`and shape and which cells can be varied to apply differing
`amounts of tab material as a means of controlling the pattern
`amounts of tab material as a means of controlling the pattern
`and other attributes of the resultant nail tab.
`and other attributes of the resultant nail tab.
`A composite roofing material includes a final condition
`A composite roo?ng material includes a ?nal condition
`underlayment, roll roo?ng or shingle material having bonded
`underlayment, roll roofing or shingle material having bonded
`thereto appropriate rows of nail tabs or continuous reinforc-
`thereto appropriate roWs of nail tabs or continuous reinforc
`ing strips preferably made of, either in total or in part, a
`ing strips preferably made of, either in total or in part, a
`polymer material, including but not limited to an adhesive or
`polymer material, including but not limited to an adhesive or
`plastic-based material, including thermo-plastic, thermo-set
`plastic-based material, including thermo-plastic, thermo-set-
`ting, hot-melt adhesive, elastomer or ultra-violet light curing
`ting, hot-melt adhesive, elastomer or ultra-violet light curing
`materials, and can include materials of contrasting color to
`materials, and can include materials of contrasting color to
`the roofing material or any other materials which tailor the
`the roo?ng material or any other materials Which tailor the
`primary polymeric material’s properties.
`primary polymeric material's properties.
`The material used or applied in the print methodologies
`The material used or applied in the print methodologies
`described herein, to form nail tabs or continuous reinforcing
`described herein, to form nail tabs or continuous reinforcing
`strips on the roo?ng materials, are substantially polymer
`strips on the roofing materials, are substantially polymer
`materials (the term "tab material" is used herein to describe
`materials (the term “tab material” is used herein to describe
`these materials). The polymer materials speci?cally include,
`these materials). The polymer materials specifically include,
`but are not limited to, thermoplastics, thermosets, adhesive,
`but are not limited to, thermoplastics, thermosets, adhesive,
`including light curable adhesives, and elastomers and include
`including light curable adhesives, and elastomers and include
`any additives Which tailor the polymer material’s properties.
`any additives which tailor the polymer material's properties.
`Speci?cally, for example, the tab material may be reinforced
`Specifically, for example, the tab material may be reinforced
`with fibers, metal, flakes or other similar particles or my be
`With ?bers, metal, ?akes or other similar particles or my be
`diluted with fillers or simply air.
`diluted With ?llers or simply air.
`A gravure or other print process is used to apply substantial
`A gravure or other print process is used to apply substantial
`polymer tab or continuous strip material to an engraved cyl-
`polymer tab or continuous strip material to an engraved cyl
`inder, and then Wipe the tab material from the cylinder’s
`inder, and then wipe the tab material from the cylinder's
`surface with a doctor blade, leaving the tab material only in
`surface With a doctor blade, leaving the tab material only in
`the engraved image areas on the cylinder. Each engraved
`the engraved image areas on the cylinder. Each engraved
`image area etched into the cylinder, commonly called the
`image area etched into the cylinder, commonly called the
`print cylinder, creates a depression, the design of which con-
`print cylinder, creates a depression, the design of Which con
`trols the shape, width and thickness of the formed nail tabs.
`trols the shape, Width and thickness of the formed nail tabs.
`The process to make the nail tabs or the continuous rein-
`The process to make the nail tabs or the continuous rein
`forcing strip is to convey the substrate material and/or the
`forcing strip is to convey the substrate material and/or the
`saturated underlayment, roll roofing or shingle material in a
`saturated underlayment, roll roo?ng or shingle material in a
`continuous process and into contact with an etched cylinder
`continuous process and into contact With an etched cylinder
`
`5
`
`25
`5 2
`
`3 5
`35
`
`4
`4
`and with sufficient pressure so that the roofing material picks
`and With suf?cient pressure so that the roo?ng material picks
`up the tab material left in the depressions on the cylinder
`up the tab material left in the depressions on the cylinder
`while the tab material is in a liquid state and to form tabs of
`While the tab material is in a liquid state and to form tabs of
`appropriate siZe and appropriately patterned across the roof
`appropriate size and appropriately patterned across the roof-
`ing material’s surface.
`ing material's surface.
`In an alternative, a continuous transfer material is in con-
`In an alternative, a continuous transfer material is in con
`tact With the etched gravure print cylinder and With the roof
`tact with the etched gravure print cylinder and with the roof-
`ing material with sufficient pressure so that the continuous
`ing material With suf?cient pressure so that the continuous
`transfer material both picks up the tab material left in the
`1° transfer material both picks up the tab material left in the
`depressions on the print cylinder and transfers the tab material
`depressions on the print cylinder and transfers the tab material
`onto the roo?ng material While the tab material is in a liquid
`onto the roofing material while the tab material is in a liquid
`or semi-liquid state and to form tabs or continuous reinforc-
`or semi-liquid state and to form tabs or continuous reinforc
`ing strips of appropriate siZe and appropriately patterned
`5 ing strips of appropriate size and appropriately patterned
`across both the continuous transfer material and the under-
`across both the continuous transfer material and the under
`layment, roll roo?ng or shingle material.
`layment, roll roofing or shingle material.
`In accordance with a preferred embodiment of the inven-
`In accordance With a preferred embodiment of the inven
`2o tion, there is disclosed a method of making a roofing material,
`tion, there is disclosed a method of making a roo?ng material,
`20
`Which comprises treating an extended length of substrate
`which comprises treating an extended length of substrate
`roo?ng material or composite roo?ng material having the
`roofing material or composite roofing material having the
`steps of depositing tab material substantially in a liquid state
`steps of depositing tab material substantially in a liquid state
`onto the surface of the roofing material at a plurality of loca-
`onto the surface of the roo?ng material at a plurality of loca
`tions, the tab material solidifying and bonding to the surfac