I 11111 11111111 III 11111 11111 111!),I1110111J1121,111111111111111110111111
`
`US007201946B2
`
`(12) United States Patent (cid:9)
`(12) United States Patent
`Collins et al. (cid:9)
`Collins et al.
`
`(54)
`(54) 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
`
`(76)
`(76) Inventors: David Allan Collins, 11302 Memorial
`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 Bend
`#222, Houston, TX (US) 77042; Miguel
`#222, Houston, TX (US) 77042; Miguel
`E. Madero O'Brien, Sierra Amatepec
`E. Madero O’Brien, Sierra Amatepec
`371, Lomas de Chapultepec, Mexico
`371, Lomas de Chapultepec, Mexico
`City, D.F. (MX) 11000
`City, 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 239 days.
`U.S.C. 154(b) by 239 days.
`
`(21)
`Appl. N0.: 10/855,264
`(21) Appl. No.: 10/855,264
`
`Filed:
`(22)
`(22) Filed: (cid:9)
`
`May 27, 2004
`May 27, 2004
`
`(65)
`(65) (cid:9)
`
`Prior Publication Data
`Prior Publication Data
`
`US 2004/0237462 Al (cid:9)
`US 2004/0237462 A1
`
`Dec. 2, 2004
`Dec. 2, 2004
`
`Related U.S. Application Data
`Related US. Application Data
`
`(60)
`(60) Provisional application No. 60/485,774, filed on Jul.
`Provisional application No. 60/485,774, ?led on Jul.
`9, 2003, provisional application No. 60/474,194, ?led
`9, 2003, provisional application No. 60/474,194, filed
`on May 29, 2003.
`on May 29, 2003.
`
`(51) Int. Cl.
`(51)
`Int. Cl.
`(2006.01)
`(2006.01)
`B05D 1/28 (cid:9)
`B05D 1/28
`(2006.01)
`(2006.01)
`B05D 3/06 (cid:9)
`B05D 3/06
` 427/428.06; 427/508; 427/428.18;
`(52) U.S. Cl. (cid:9)
`(52)
`427/428.06; 427/508; 427/428.18;
`US. Cl. .......... ..
`427/428.2
`427/428.2
` 427/508,
`(58) Field of Classification Search (cid:9)
`(58)
`Field of Classi?cation Search .............. .. 427/508,
`427/186, 188, 256, 428.06, 428.18, 428.2;
`427/186, 188, 256, 428.06, 428.18, 428.2;
`52/746.11
`52/746.11
`See application ?le for complete search history.
`See application file for complete search history.
`
`(10) Patent No.: (cid:9)
`(10) Patent N0.:
`(45) Date of Patent: (cid:9)
`(45) Date of Patent:
`
`US 7,201,946 B2
`US 7,201,946 B2
`Apr. 10, 2007
`Apr. 10, 2007
`
`(56)
`(56)
`
`References Cited
`References Cited
`
`U.S. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
`
`4,554,196 A * 11/1985 Meeker (cid:9)
`
`428/67
`4,554,196 A * 11/1985 Meeker ..................... .. 428/67
`5,365,709 A * 11/1994 Lassiter (cid:9)
`
`52/408
`5,365,709 A * 11/1994 Lassiter
`52/408
`6,451,409 Bl* 9/2002 Lassiter (cid:9)
`
`428/147
`6,451,409 B1* 9/2002 Lassiter ................. .. 428/147
`2003/0215594 Al* 11/2003 Hamdar et al. (cid:9)
`
`428/40.1
`2003/0215594 A1* 11/2003 Hamdar et a1. .......... .. 428/40.1
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`
`EP (cid:9)
`EP
`WO (cid:9)
`W0
`
`023609 A2 * 12/1986
`023609 A2 * 12/1986
`WO 97/29256 Al * 8/1997
`WO 97/29256 A1 * 8/1997
`
`* cited by examiner
`* cited by examiner
`
`Primary ExamineriWilliam Phillip Fletcher, 111
`Primary Examiner (cid:9) William Phillip Fletcher, III
`
`(57)
`(57) (cid:9)
`
`ABSTRACT
`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 ther
`resulting material by depositing nail tabs made of a ther-
`moplastic, thermosetting, adhesive or elastomer material, in
`moplastic, thermosetting, adhesive or elastomer material, in
`a liquid state, onto the base substrate of the composite
`a liquid state, onto the base substrate of the composite
`roofing material or onto the saturated or coated roofing
`roo?ng material or onto the saturated or coated roo?ng
`material, or onto a transfer surface to be pressed or lami-
`material, or onto a transfer surface to be pressed or lami
`nated onto the roo?ng material. A preferred embodiment
`nated onto the roofing material. A preferred embodiment
`transfers the nail tabs onto an engraved transfer impression
`transfers the nail tabs onto an engraved transfer impression
`roll and uses a pressurized applicator to inject the viscous tab
`roll and uses a pressurized applicator to inject the viscous tab
`material into engraved patterns depressed in raised areas of
`material into engraved patterns depressed in raised areas of
`the impression roll., then deposits the material onto the
`the impression roll., then deposits the material onto the
`roo?ng material. A preferred embodiment also includes the
`roofing material. A preferred embodiment also includes the
`thermoplastic or thermosetting material in a liquid or vis-
`thermoplastic or thermosetting material in a liquid or vis
`cous state hardened or cured by either its exposure to the air
`cous state hardened or cured by either its exposure to the air
`or by the use of ultra-violet or visible light.
`or by the use of ultra-violet or visible light.
`
`8 Claims, 10 Drawing Sheets
`8 Claims, 10 Drawing Sheets
`
`Petitioner - Owens Corning
`Ex. 1019, p. 1 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 1 of 10 (cid:9)
`Sheet 1 0f 10
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`106
`106
`
`102
`
`-108
`
`Fig. I
`
`104
`104
`
`100
`100
`
`120
`120
`
`122
`122
`
`Fig. 1B
`Fig. 1B
`
`Petitioner - Owens Corning
`Ex. 1019, p. 2 of 165
`
`(cid:9)
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 2 0f 10
`Sheet 2 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`1 1 0
`
`1 1 1
`
`1 1 2
`
`Fig. 1A
`Fig. I A
`
`Petitioner - Owens Corning
`Ex. 1019, p. 3 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 3 0f 10
`Sheet 3 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`206
`
`202
`
`200
`
`CD
`
`Fig. 2
`
`Petitioner - Owens Corning
`Ex. 1019, p. 4 of 165
`
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 4 0f 10
`Sheet 4 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`304
`
`306
`
`300'
`
`r-_
`- =
`I (cid:9)
`L _ _ J
`
`L (cid:9)
`
`1
`r
`C')
`I.-
` J
`
`If
`
`302
`
`W
`
`Fig. 3
`Fig. 3
`
`Petitioner - Owens Corning
`Ex. 1019, p. 5 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 5 of 10 (cid:9)
`Sheet 5 0f 10
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`r (cid:9)
`
`Fig. 4
`
`Petitioner - Owens Corning
`Ex. 1019, p. 6 of 165
`
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 6 of 10 (cid:9)
`Sheet 6 0f 10
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`414
`
`Fig. 4A
`Fig. 4A
`
`Petitioner - Owens Corning
`Ex. 1019, p. 7 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 7 0f 10
`Sheet 7 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`/ t o (cid:9)
`,I (cid:9)
`
`ITT/ L
`11 , ,
`
`
`/ t o , (cid:9),
`
`1iflt ‘i
`t (cid:9)
`
`i
`l% (cid:9)
`P
`I'l
`1
`I : 1 t 1 % I i
`,
`
`502
`
`[0]
`
`Fig. 5
`Fig. 5
`
`Petitioner - Owens Corning
`Ex. 1019, p. 8 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007 (cid:9)
`
`Sheet 8 0f 10
`Sheet 8 of 10
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`606
`
`602
`602
`
`soo-1 (cid:9)
`
`Fig. 6
`
`710
`
`712
`712
`
`Fig. 7A
`Fig. 7A
`
`Petitioner - Owens Corning
`Ex. 1019, p. 9 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 9 0f 10
`Sheet 9 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`704
`
`Fig. 8A
`
`810
`810
`
`Petitioner - Owens Corning
`Ex. 1019, p. 10 of 165
`
`(cid:9)
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Apr. 10, 2007
`Apr. 10, 2007
`
`Sheet 10 0f 10
`Sheet 10 of 10 (cid:9)
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`900---A
`900
`
`..
`
`-912
`
`\———91O
`
`--...---910
`
`Fig. 9
`Fig. 9
`
`Petitioner - Owens Corning
`Ex. 1019, p. 11 of 165
`
`(cid:9)
`

`
`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
`
`The present application is related to the following US.
`The present application is related to the following U.S.
`patent application: provisional patent application No.
`patent application: provisional patent application No.
`60/474,194 titled Machine and Method for Applying Ther
`60/474,194 titled Machine and Method for Applying Ther-
`moplastics and Adhesives To Roo?ng Materials With Nail
`moplastics and Adhesives To Roofing Materials with Nail
`Tabs ?led May 29, 2003 and provisional patent application
`Tabs filed May 29, 2003 and provisional patent application
`No. 60/485,774 titled Machine and Method for Applying
`No. 60/485,774 titled Machine and Method for Applying
`Thermoplastics and Adhesives To Roo?ng Materials With
`Thermoplastics and Adhesives To Roofing Materials with
`Nail Tabs ?led Jul. 9, 2003, Which are hereby incorporated
`Nail Tabs filed Jul. 9, 2003, which are hereby incorporated
`by reference as if fully set forth herein.
`by reference as if fully set forth herein.
`
`STATEMENT REGARDING FEDERALLY
`STATEMENT REGARDING FEDERALLY
`SPONSORED RESEARCH OR DEVELOPMENT
`SPONSORED RESEARCH OR DEVELOPMENT
`
`Not applicable
`Not applicable
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`The invention relates generally to roo?ng materials or
`The invention relates generally to roofing materials or
`other building materials normally employed as cover mate-
`other building materials normally employed as cover mate
`rials over a wood roof deck or stud wall and more specifi-
`rials over a Wood roof deck or stud Wall and more speci?
`cally to such cover materials and methods for incorporating
`cally to such cover materials and methods for incorporating
`therein a plurality of integrally formed nail tabs or a con-
`therein a plurality of integrally formed nail tabs or a con
`tinuous reinforcing strip.
`tinuous reinforcing strip.
`The Typical Roof Composition.
`The Typical Roof Composition.
`A roof installation generally comprises at least two dis-
`A roof installation generally comprises at least tWo dis
`tinctive layers applied over a roof deck With each layer being
`tinctive 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
`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
`made from a ?berglass or other inorganic ?brous material
`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
`underlayment assists in making the roof resistant to Water
`intrusion.
`intrusion.
`The Typical Underlayment Substrate.
`The Typical Underlayment Substrate.
`The underlayment is usually an asphalt saturated sub
`The underlayment is usually an asphalt saturated sub-
`strate. The starting material for the underlayment, or the
`strate. The starting material for the underlayment, or the
`substrate material itself, is a base composite material usually
`substrate material itself, is a base composite material usually
`referred to as "dry felt" or "organic felt", but the substrate
`referred to as “dry felt” or “organic felt”, but the substrate
`material could also be a fiberglass mat or other inorganic
`material could also be a ?berglass mat or other inorganic
`material mat or a hybrid of both. Examples of types of dry
`material mat or a hybrid of both. Examples of types of dry
`felt starting material are rag, paper, wood sawdust and could
`felt starting material are rag, paper, Wood saWdust and could
`include fiberglass or other inorganic material, oftentimes in
`include ?berglass or other inorganic material, oftentimes in
`a fibrous state, although other suitable starting base mate-
`a ?brous state, although other suitable starting base mate
`rials may be employed. The starting base material, in a
`rials may be employed. The starting base material, in a
`preferred embodiment, is a fibrous paper called dry felt
`preferred embodiment, is a ?brous paper called dry felt
`made from treating recyclable cardboard, mixed recycled
`made from treating recyclable cardboard, mixed recycled
`papers and wood sawdust or a fibrous mat made from
`papers and Wood saWdust or a ?brous mat made from
`inorganic materials chemically or mechanically formed into
`inorganic materials chemically or mechanically formed into
`a fibrous state; however, this invention is not limited thereto.
`a ?brous state; hoWever, this invention is not limited thereto.
`The term "substrate" used herein is used generically for all
`The term “substrate” used herein is used generically for all
`suitable starting base material including dry felt, ?berglass
`suitable starting base material including dry felt, fiberglass
`mat and polyester mat or any other base material on which
`mat and polyester mat or any other base material on which
`
`US 7,201,946 B2
`US 7,201,946 B2
`
`10
`10
`
`2
`2
`a composite roo?ng or building material is built upon. Dry
`a composite roofing or building material is built upon. Dry
`felt, when saturated with an asphalt-based material, pro-
`felt, When saturated With an asphalt-based material, pro
`duces an underlayment roo?ng material knoWn in the trade
`duces an underlayment roofing material known in the trade
`as "tar paper" or "saturated felt," which is produced in
`as “tar paper” or “saturated felt,” Which is produced in
`various grades depending upon thickness and Weight. Fiber
`5 various grades depending upon thickness and weight. Fiber-
`glass mat and polyester mat When coated With an asphalt,
`glass mat and polyester mat when coated with an asphalt,
`rubber-asphalt or asphalt-mix material produce the base
`rubber-asphalt or asphalt-mix material produce the base
`substrate for shingles and other residential and commercial
`substrate for shingles and other residential and commercial
`rolled roo?ng products.
`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
`15 material and affix each length to the roof deck or building
`material and af?x each length to the roof deck or building
`sides support sheets or boards at a plurality of locations so
`sides support sheets or boards at a plurality of locations so
`that it stays in place prior to the installation of the covering
`that 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
`20 applied by power devices; however, both are notoriously
`20
`susceptible to either pulling out of the sheets or boards when
`susceptible 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
`25 diately, the underlayment can still be exposed alone to windy
`25
`and other adverse conditions, such as when the installers
`and other adverse conditions, such as When the installers
`walk or crawl on the underlayment.
`Walk or craWl 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, Wood
`securely attached independently of the shingles, wood
`30
`30 shakes, metal tile or other roof covering not only in the
`shakes, metal tile or other roof covering not only in the
`pre-shingling or pre-roof covering stage of installation, but
`pre-shingling or pre-roof covering stage of installation, but
`also in the final installation. This is because shingles or other
`also in the ?nal installation. This is because shingles or other
`roof coverings do get damaged, bloWn or ripped off the roof
`roof coverings do get damaged, blown or ripped off the roof
`under adverse weather conditions and a secure indepen-
`under adverse Weather conditions and a secure indepen
`35 dently installed underlayment will provide some interim
`35
`dently 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.
`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
`described above, it has long been a common practice to
`45 either use roofing nails with large heads or to use an
`either use roo?ng nails With large heads or to use an
`45
`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,
`50 however, since such use is time consuming, somewhat
`hoWever, since such use is time consuming, someWhat
`50
`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 has to reach While
`55 driving the nail through. If the installer has to reach while
`55
`only supporting himself or herself on a toe board, it may be
`only supporting himself or herself on a toe board, it may be
`uncomfortable and/or unstable to be unable to use either
`uncomfortable and/or unstable to be unable to use either
`hand for additional support when necessary. Moreover, nails
`hand for additional support When necessary. Moreover, nails
`with large, unconventional heads are not recommended both
`With large, unconventional heads are not recommended both
`because they are expensive and because they cannot be used
`60 because they are expensive and because they cannot be used
`60
`in ordinary poWer equipment. Ordinarily, poWer equipment
`in ordinary power equipment. Ordinarily, power equipment
`for driving nails can be loaded only with standard nail
`for driving nails can be loaded only With standard nail
`cartridges.
`cartridges.
`It is an advantage of the present invention to provide a
`It is an advantage of the present invention to provide a
`65 gravure printing or offset printing process for the application
`gravure printing or offset printing process for the application
`65
`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.
`
`4
`40
`
`Petitioner - Owens Corning
`Ex. 1019, p. 12 of 165
`
`

`
`US 7,201,946 B2
`US 7,201,946 B2
`
`5
`
`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
`a lamination process for the deposition of polymer material
`to form nail tab or continuous strips on underlayment or
`to form nail tab or continuous strips on underlayment or
`other roo?ng material.
`other 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 10
`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 15
`to underlayment or other roo?ng material using an etched
`pattern or an open pattern, with no cell walls or other points
`pattern or an open pattern, With no cell Walls or other points
`of interruption Within the pattern.
`of 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
`a system for depositing a line of polymer material onto
`underlayment, or any other roo?ng material.
`underlayment, or any other roofing material. (cid:9)
`
`20
`20
`
`BRIEF SUMMARY OF THE INVENTION
`BRIEF SUMMARY OF THE INVENTION
`
`4
`4
`the saturated underlayment, roll roo?ng or shingle material
`the saturated underlayment, roll roofing or shingle material
`in a continuous process and into contact with an etched
`in a continuous process and into contact With an etched
`cylinder and With suf?cient pressure so that the roo?ng
`cylinder and with sufficient pressure so that the roofing
`material picks up the tab material left in the depressions on
`material picks up the tab material left in the depressions on
`the cylinder while the tab material is in a liquid state and to
`the cylinder While the tab material is in a liquid state and to
`form tabs of appropriate siZe and appropriately patterned
`form tabs of appropriate size and appropriately patterned
`across the roofing material's surface.
`across the roo?ng material’s surface.
`In an alternative, a continuous transfer material is in
`In an alternative, a continuous transfer material is in
`contact With the etched gravure print cylinder and With the
`contact with the etched gravure print cylinder and with the
`roofing material with sufficient pressure so that the continu-
`roo?ng material With su?icient pressure so that the continu
`ous transfer material both picks up the tab material left in the
`ous transfer material both picks up the tab material left in the
`depressions on the print cylinder and transfers the tab
`depressions on the print cylinder and transfers the tab
`material onto the roo?ng material While the tab material is
`material onto the roofing material while the tab material is
`in a liquid or semi-liquid state and to form tabs or continuous
`in a liquid or semi-liquid state and to form tabs or continuous
`reinforcing strips of appropriate siZe and appropriately pat
`reinforcing strips of appropriate size and appropriately pat-
`terned across both the continuous transfer material and the
`terned across both the continuous transfer material and the
`underlayment, roll roo?ng or shingle material.
`underlayment, roll roofing or shingle material.
`In accordance with a preferred embodiment of the inven-
`In accordance With a preferred embodiment of the inven
`tion, there is disclosed a method of making a roofing
`tion, there is disclosed a method of making a roo?ng
`material, Which comprises treating an extended length of
`material, which comprises treating an extended length of
`substrate roo?ng material or composite roo?ng material
`substrate roofing material or composite roofing material
`having the steps of depositing tab material substantially in a
`having the steps of depositing tab material substantially in a
`liquid state onto the surface of the roofing material at a
`liquid state onto the surface of the roo?ng material at a
`plurality of locations, the tab material solidifying and bond
`plurality of locations, the tab material solidifying and bond-
`ing to the surface of the roo?ng material Wherein the tab
`ing to the surface of the roofing material wherein the tab
`material is deposited on the roo?ng material by an engraved
`material is deposited on the roofing material by an engraved
`pattern print roll.
`pattern print roll.
`In accordance With another preferred embodiment of the
`In accordance with another preferred embodiment of the
`invention, there is disclosed a method of making a roofing
`invention, there is disclosed a method of making a roo?ng
`material comprising the steps of depositing tab material at a
`material comprising the steps of depositing tab material at a
`plurality of locations substantially made of a polymer mate
`plurality of locations substantially made of a polymer mate-
`rial in a liquid state onto a transfer surface, the transfer
`rial in a liquid state onto a transfer surface, the transfer
`surface receiving the tab material for deposition onto the
`surface receiving the tab material for deposition onto the
`roo?ng material.
`roofing material.
`In accordance with another preferred embodiment of the
`In accordance With another preferred embodiment of the
`invention, there is disclosed a roofing material, which com-
`invention, there is disclosed a roo?ng material, Which com
`prises a substrate roo?ng material or composite roo?ng
`prises a substrate roofing material or composite roofing
`material and tab material substantially made of a polymer
`material and tab material substantially made of a polymer
`material in a liquid state deposited onto the surface of the
`material in a liquid state deposited onto the surface of the
`roofing material at a plurality of locations, the tab material
`roo?ng material at a plurality of locations, the tab material
`solidifying and adhering to the surface of the base substrate
`solidifying and adhering to the surface of the base substrate
`material or saturated or coated material wherein the tab
`material or saturated or coated material Wherein the tab
`material is deposited on the roo?ng material by a print roll
`material is deposited on the roofing material by a print roll
`having an engraved pattern for holding the tab material.
`having an engraved pattern for holding the tab material.
`In accordance with another preferred embodiment of the
`In accordance With another preferred embodiment of the
`invention, there is disclosed a roofing material, which com-
`invention, there is disclosed a roo?ng material, Which com
`prises a base substrate material or a saturated or coated
`prises a base substrate material or a saturated or coated
`material and a plurality of thermoplastic, thermosetting,
`material and a plurality of thermoplastic, thermosetting,
`adhesive or elastomer tabs deposited onto the surface of the
`adhesive or elastomer tabs deposited onto the surface of the
`base substrate, saturated or coated material at a plurality of
`base substrate, saturated or coated material at a plurality of
`locations, wherein the tabs are deposited on the saturated or
`locations, Wherein the tabs are deposited on the saturated or
`coated material by a print roll having an engraved pattern for
`coated material by a print roll having an engraved pattern for
`holding the thermoplastic, thermosetting, adhesive or elas
`holding the thermoplastic, thermosetting, adhesive or elas-
`tomer tab material.
`tomer tab material.
`Other advantages of the present invention Will become
`Other advantages of the present invention will become
`apparent from the following descriptions, taken in connec-
`apparent from the folloWing descriptions, taken in connec
`tion With the accompanying draWings, Wherein, by Way of
`tion with the accompanying drawings, wherein, by way of
`illustration and example, embodiments of the present inven
`illustration and example, embodiments of the present inven-
`tion are disclosed.
`tion are disclosed.
`The drawings constitute a part of this specification and
`The draWings constitute a part of this speci?cation and
`include exemplary embodiments to the invention, which
`include exemplary embodiments to the invention, Which
`may be embodied in various forms. It is to be understood
`may be embodied in various forms. It is to be understood
`that in some instances various aspects of the invention may
`that in some instances various aspects of the invention may
`be shown exaggerated or enlarged to facilitate an under-
`be shoWn exaggerated or enlarged to facilitate an under
`standing of the invention.
`standing of the invention.
`
`25
`25
`
`30
`30
`
`35
`35
`
`40
`40
`
`The invention is to the print method, a gravure, rotogra-
`The invention is to the print method, a gravure, rotogra
`vure or gravure-like transfer printing (the “gravure process”)
`vure or gravure-like transfer printing (the "gravure process")
`or offset printing, of an appropriately viscous and substan-
`or offset printing, of an appropriately viscous and substan
`tially polymeric material onto roofing material, or onto a
`tially polymeric material onto roo?ng material, or onto a
`continuous transfer material and then transferred, including
`continuous transfer material and then transferred, including
`utiliZing a laminating process, onto the roo?ng material, in
`utilizing a laminating process, onto the roofing material, in
`a continuous process. The gravure process employs a print
`a continuous process. The gravure process employs a print
`cylinder Which has etched or engraved cells of varying
`cylinder which has etched or engraved cells of varying
`depth, Width and shape and Which cells can be varied to
`depth, width and shape and which cells can be varied to
`apply differing amounts of tab material as a means of
`apply differing amounts of tab material as a means of
`controlling the pattern and other attributes of the resultant
`controlling the pattern and other attributes of the resultant
`