(12) United States Patent
`Miller et al.
`
`(10) Patent No.: US 6,228,785 B1
`(45) Date of Patent: May 8, 2001
`
`US006228785B1
`
`(54) ROOFING MATERIAL HAVING IMPROVED
`IMPACT RESISTANCE
`
`(75) Inventors:
`
`David George Miller, Pickerington;
`Carla A. Miller, Newark, both of OII
`(US)
`
`(73) Assignee:
`
`Owens Corning Fiberglas Technology,
`Inc., Summit, IL (US)
`
`(*) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21)
`
`Appl. No.: 09/223,578
`
`(22)
`
`Filed:
`
`Dec. 30, 1998
`
`(51)
`(52)
`
`(58)
`
`(56)
`
`Int. CI.7 ...................................................... B32B 27/04
`U.S. Cl ........................... 442/148; 442/104; 442/167;
`442/170; 442/171; 442/’381; 442/389; 442/390
`Field of Search ..................................... 442/390, 167,
`442/171, 170, 389, 381, 104, 148
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`3,813,280
`3,937,640
`4,055,453
`4,091,135
`4,368,228
`4,374,687
`4,420,524
`4,529,625
`4,595,629
`4,599,258
`4,636,414
`4,714,651
`4,957,806
`5,082,720
`5,100,715
`5,195,290
`5,326,797
`5,456,785
`5,488,807
`5,508,093
`
`5/1974
`2/1976
`10/1977
`5/1978
`1/1983
`2/1983
`12/1983
`* 7/1985
`* 6/1986
`7/1986
`1/1987
`12/1987
`9/1990
`* 1/1992
`3/1992
`3/1993
`7/1994
`10/1995
`2/1996
`* 4/1996
`
`Olszyk et al ........................ 161/151
`Tajima et al ........................... 156/’71
`Tajima et al ......................... 156/279
`Tajima et al ........................... 428/’40
`Gorgati ................................ 428/110
`Yamamoto ............................. 156/’71
`Gorgati ................................ 428/110
`Reindenbach et al ............... 427/186
`Mays .................................... 428/286
`Hageman ............................. 428/140
`Tajima et al ........................... 428/’40
`Hartmann et al .................... 428/286
`Pangrazi et al ...................... 428/224
`Hayes ................................... 428/224
`Zimmerman et al ................ 428/147
`Hulett ..................................... 52/518
`Zimmerman et al .................. 524/’59
`Venable ................................ 156/229
`Terrenzio et al ...................... 52/555
`Mehdorn .............................. 428/219
`
`6/1996 Daurer et al ......................... 428/247
`5,525,413
`10/1996 Callaway et al ..................... 264/258
`5,569,430
`11/1996 Johnson ............................... 428/143
`5,571,596
`12/1996 Kiser .................................... 428/143
`5,580,638
`1/1997 Woiceshyn ........................... 428/236
`5,593,766
`10/1998 Frankoski et al ...................... 52/518
`5,822,943
`5,972,463 * 10/1999 Martin et al ........................... 428/’95
`
`FOREIGN PATENT DOCUMENTS
`
`0208918
`260 494 A1
`0441241
`0573363
`0668392
`2 720 772
`WO 97 00362
`
`1/1987 (EP).
`3/1988 (EP).
`8/1991 (EP).
`12/1993 (EP).
`8/1995 (EP).
`12/1995 (FR).
`1/1997 (WO).
`
`OTHER PUBLICATIONS
`
`Ellis, Roger L., et al., "Ballistic Impact Resistance of SMA
`and Spectra Hybrid Graphite Composifies." Journal of Rein-
`forced Plastics and Composites, vol. 17, No. 2, (1998), pp.
`147-164.
`
`* cited by examiner
`
`PrimalT Examiner--Tcrrcl Morris
`Assistant Examiner~Norca L. Torres
`(74) Attorney, Agent, or FirmMnger H. Eckert; James J.
`Dottavio
`
`(57)
`
`ABSTRACT
`
`An asphalt-based roofing material includes a substrate
`coated with an asphalt coating. The asphalt coating includes
`a lowcr rcgion that is positioncd bclow thc substratc whcn
`the roofing material is installed on a roof. A web is fused to
`the lower region of the asphalt coating. A portion of the web
`and of the asphalt coating have been intermingled by
`melting, thereby fusing the web and the asphalt coating. A
`method of manufacturing the asphalt-based roofing material
`includes the steps of coating a substrate with an asphalt
`coating, applying a web to the lower region of the asphalt
`coating, and intermingling a portion of the web and of the
`asphalt coating by melting, thereby fusing the web to the
`lower region of the asphalt coating.
`
`50
`
`&
`
`FAST FELT 2035, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 6,228,785 B1
`Page 2
`
`32 Claims, 6 Drawing Sheets
`
`FAST FELT 2035, pg. 2
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet I of 6
`
`US 6,228,785 B1
`
`FAST FELT 2035, pg. 3
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet 2 of 6
`
`US 6,228,785 B1
`
`FAST FELT 2035, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet 3 of 6
`
`US 6,228,785 B1
`
`FAST FELT 2035, pg. 5
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet 4 of 6
`
`US 6,228,785 B1
`
`O
`
`FAST FELT 2035, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet 5 of 6
`
`US 6,228,785 B1
`
`I
`
`FAST FELT 2035, pg. 7
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`May 8, 2001
`
`Sheet 6 of 6
`
`US 6,228,785 B1
`
`0
`O
`
`FAST FELT 2035, pg. 8
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 6,228,785 BI
`
`1
`ROOFING MATERIAL HAVING IMPROVED
`IMPACT RESISTANCE
`
`TECHNICAL FIELD AND INDUSTRIAL
`APPLICABILITY OF THE INVENTION
`
`This invention relates to asphalt-based roofing materials,
`and in particular to an asphalt-based roofing material includ-
`ing a web that is positioned and bonded in such a manner as
`to provide the roofing material with improved impact resis-
`tance.
`
`BACKGROUND OF THE INVENTION
`
`Asphalt-bascd roofing matcrials, such as roofing shinglcs,
`roll roofing and commercial roofing, are installed on the
`roofs of buildings to provide protection from the elements.
`Typically, the roofing material is constructed of a substrate
`such as a glass fiber mat or an organic felt, an asphalt coating
`on the substrate, and a surface layer of granules embedded
`in the asphalt coating.
`The typical roofing material constmction is suitable under
`most circumstances. However, sometimes a roofing material
`is subjected to forceful impacts, such as impacts from
`hailstones during storms, which may cause significant dam-
`age to the roofing material. For instance, the force of the
`impact may cause a puncture or tear in the roofing material.
`Accordingly, there is a need for a roofing material having
`improved impact resistance.
`
`Several patents disclose asphalt roofing materials con-
`structed with multiple substrates. For example, U.S. Pat. No.
`5,326,797 to Zirnmerman et al. discloses an asphalt-coated
`roofing shingle including a top mat of glass fibers and a
`bottom mat of polyester. The patent is related to a fire-
`resistant shingle, and there is no mention of improved
`impact resistance. Also, there is no suggestion of improved
`bonding between the polyester mat and the asphalt coating.
`
`U.S. Pat. No. 5,571,596 to Johnson discloses an asphalt-
`coated roofing shingle including an upper layer of direc-
`tional fiber such as Kevlar fabric, a middle layer of fibrous
`mat material such as glass fiber mat, and a lower layer of
`directional fiber such as E-glass fabric. The upper fiber layer
`is described as being important to shield the shingle from
`hail impact damagc. Thc lowcr laycr of E-glass fabric is not
`effective for improving impact resistance of the shingle.
`U.S. Pat. No. 5,822,943 to Frankoski et al. discloses an
`asphalt-coated roofing shingle including a scrim and a mat.
`The scrim is bonded to the mat with adhesive; there is no
`suggestion of improved bonding between the scrim and the
`asphalt coating. A scrim is not very effective for improving
`impact resistance of a shingle.
`A journal article, "Ballistic Impact Resistance of SMA
`and Spectra Hybrid Graphite Composites", Journal of Rein-
`forced Plastics and Composites, Vol. 17, 2/1998, by Ellis et
`al., discloses placing energy absorbing fibers on the back
`surface of a graphite composite. The fibers were found to
`provide only a slight improvement in the impact strength of
`the composite. The journal article is not related to roofing
`materials.
`Thus, the previous literature does not suggest the specific
`positioning and bonding of a web, and the selection of the
`right material for the web, to effectively dissipate the energy
`of impacts on the roofing material.
`It is known to manufacture roofing materials with robber-
`modified asphalt to provide some improvement in impact
`resistance. Unfortunately, roofing materials made with
`rubber-modified asphalt are more difficult to manufacture,
`
`2
`handle, store and install, and arc more expensive, than
`roofing materials made with conventional roofing asphalt.
`Also, the rubber-modified asphalt shingles are not very
`effective in resisting impacts. Accordingly, there is still a
`need for a roofing material having improved impact resis-
`tance.
`
`SUMMARY OF THE INVENTION
`
`Thc abovc objccts as wcll as othcrs not spccifically
`10 enumerated are achieved by an asphalt-based roofing mate-
`
`rial according to the present invention. The roofing material
`includes a substrate coated with an asphalt coating. The
`asphalt coating includes a lower region that is positioned
`below the substrate when the roofing material is installed on
`15 a roof. A web is fused to the lower region of the asphalt
`
`coating. Aportion of the web and of the asphalt coating have
`been intermingled by melting, thereby fusing the web and
`the asphalt coating.
`The present invention also relates to a method of manu-
`20 facturing the asphalt-based roofing material. The method
`
`includes the steps of coating a substrate with an asphalt
`coating, and applying a web to the lower region of the
`asphalt coating. A portion of the web and of the asphah
`coating are intermingled by melting, thereby fusing the web
`25 to the lower region of the asphalt coating. Another embodi-
`
`ment of the method includes the steps of applying a web to
`a substrate, coating the substrate and the web with an asphalt
`coating, where the web is in contact ~vith the lower region
`of the asphalt coating, and intermingling a portion of the
`3o web and of the asphalt coating by melting, thereby fusing the
`
`web to the lower region of the asphalt coating.
`Various objects and advantages of this invention will
`become apparent to those sMllcd in the art from the follow-
`35 ing detailed description of the preferred embodiments, when
`read in light of the accompanying drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a schematic view in elevation of apparatus for
`40 manufacturing an asphalt-based roofing material according
`to the invention.
`
`45
`
`FIG. 2 is a perspective view of part of the apparatus of
`FIG. 1, showing apparatus for applying webs to the lower
`surface of a sheet of roofing material.
`FIG. 3 is a schematic view in elevation of an alternate
`embodiment of part of the apparatus of FIG. 1, showing
`apparatus for applying a web to the loxver surface of a
`substrate before coating with asphalt.
`FIG. 4 is an enlarged cross-sectional view of a roofing
`s0 material according to the invention, including a substrate
`coated with an asphalt coating and a web fused to the lower
`surface of the asphalt coating.
`FIG. 5 is a further enlarged cross-sectional viexv of part of
`the roofing material of FIG. 4, showing a portion of the web
`that has bccn intermingled by melting with a portion of thc
`asphalt coating.
`FIG. 6 is an enlarged perspective view of a two-
`component film useful as a web in an asphalt-based roofing
`
`55
`
`6o material according to the invention.
`FIG. 7 is a further enlarged cross-sectional view of the
`film of FIG. 6 in contact with an asphalt coating, showing
`the second component of the film intermingled by melting
`with a portion of the asphalt coating.
`FIG. 8 is an enlarged perspective view of a sheath/core
`fiber of a web for use in an asphalt-based roofing material
`according to the invention.
`
`65
`
`FAST FELT 2035, pg. 9
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 6,228,785 BI
`
`3
`FIG. 9 is a further enlarged cross-sectional view of the
`sheath/core fiber of FIG. 8 surrounded by an asphalt coating,
`showing the sheath of the fiber that has been intermingled by
`melting with a portion of the asphalt coating.
`FIG. 10 is a top view of a sheet of roofing material
`manufactured with the apparatus of FIG. 1, showing the
`roofing material after being cut but before separation into
`roofing shingles.
`
`FIG. 11 is a perspective view of several three-tab roofing
`shingles according to the invention installed on the side of
`a roof.
`FIG. 12 is a perspective view of a hip and ridge roofing
`shingle according to the invention installed on the ridge of
`a roof.
`FIG. 13 is a perspective view of a laminated roofing
`shingle according to the invention.
`
`DETAILED DESCRIPTION AND PREFERRED
`EMBODIMENTS OF THE INVENTION
`
`Referring now to the drawings, there is shown in FIG. 1
`an apparatus 10 for manufacturing an asphalt-based roofing
`material according to the invention. The illustrated manu-
`facturing process involves passing a continuous sheet 12 in
`a machine direction (indicated by the arrows) through a
`series of manufacturing operations. The sheet usually moves
`at a speed of at least about 200 feet/minute (61 meters/
`minute), and typically at a speed within the range of between
`about 450 feet/minute (137 meters/minute) and about 800
`feet/minute (244 meters/minute). Although the invention is
`shown and described in terms of a continuous process, it
`should be understood that the invention can also be practiced
`in a batch process using discreet lengths of materials instead
`of continuous shccts.
`In a first step of the manufacturing process, a continuous
`sheet of substrate 12 is payed out from a roll 14. The
`substrate can be any type known for use in reinforcing
`asphalt-based roofing materials, such as a xveb, scrim or felt
`of fibrous materials such as mineral fibers, cellulose fibers,
`rag fibers, mixtures of mineral and synthetic fibers, or the
`like. Combinations of materials can also be used in the
`substrate. Preferably, the substrate is a nonwoven web of
`glass fibers.
`The sheet of substrate is passed from the roll through an
`accumulator 16. Thc accumulator allows timc for splicing
`one roll of substrate to another, during which time substrate
`wilhin the accumulator is fed to the manufacturing process
`so that the splicing does not interrupt manufacturing.
`Next, the sheet is passed through a coater 18 ~vhere an
`asphalt coating is applied to the sheet. The asphalt coating
`can be applied in any suitable manner. In the illustrated
`embodiment, the sheet is submerged in a supply of hot,
`melted asphalt coating to completely cover the sheet with
`the tacky coating. However, in other embodinaents, the
`asphalt coating could be sprayed on, rolled on, or applied to
`the sheet by other means. When an organic felt is used as the
`substratc, it may bc dcsirablc to first saturatc thc felt with a
`saturant asphalt, and then coat the upper and lower surfaces
`of the felt with an asphalt coating containing a filler.
`The term "asphalt coating" means any type of bituminous
`material suitable for use on a roofing material, such as
`asphalts, tars, pitches, or mixtures thereof. The asphalt can
`be either a manufactured asphalt produced by refining
`petroleum or a naturally occurring asphalt. The asphalt
`coating can include various additives and/or modifiers, such
`as inorganic fillers or nrineral stabilizers, organic materials
`
`4
`such as polymers, recycled strcan]s, or ground tire rubber.
`Preferably, the asphalt coating comprises asphalt and inor-
`ganic fillers or mineral stabilizers. Unlike some previous
`roofing nraterials, there is no need to modify the asphalt with
`5 robber or similar polymers to improve the impact resistance
`of the roofing material.
`
`The asphalt-coated sheet 20 is then passed beneath a
`granule dispenser 22 for the application of granules to the
`upper surface of the asphalt coating. After deposit of the
`10 granules, the sheet is turned around a slate drum 24 to press
`the granules into the asphalt coating and to temporarily
`invert the sheet.
`The asphalt-based roofing material of the present inven-
`tion includes a web 26 that is selected for the type of web,
`15 and that is positioned and bonded in such a manner, as to
`
`provide the roofing material with improved impact resis-
`tance to a variety of impacts. The improved impact resis-
`tance eliminates the occurrence of punctures or tears in the
`roofing material caused by impacts, and thereby maintains
`20 the integrity of the roofing material. The roofing material
`
`25
`
`3o
`
`35
`
`retains its ability to protcct thc building from thc clcmcnts so
`that, for example, water leaks are avoided. As shown in FIG.
`1, the web 26 is payed out onto the lower surface of the sheet
`20 while the sheet is inverted on the slate drum 24.
`FIG. 2 illustrates a preferred apparatus 30 for paying out
`continuous webs 26 onto the lower surface 32 of the sheet
`20. The webs are payed out from rolls 34. The webs are fed
`around first and second guide bars 36 and 38 to maintain
`tension on the webs. The second guide bar 38 is positioned
`adjacent and parallel with the slate dram 24, so that the webs
`are aligned properly with the sheet 20 when they are fed onto
`the lower surface 32 of the sheet. As the sheet turns around
`the slate drum, the asphalt coating is still hot, soft and tacky,
`so that the webs adhere to the lower surface of the asphalt
`coating and are pulled around the slate drum along with the
`sheet.
`The sheet can include single or multiple lanes. Four lanes
`32 are shown in the illustrated embodiment (indicated by the
`
`4o dotted lines), so that the sheet can be cut into roofing
`shingles. In the illustrated embodiment, each of the lanes 40
`includes a prime portion 42 that is normally exposed to the
`elements when the roofing shingle is installed on a roof, and
`a headlap portion 44 that is normally covered by adjacent
`
`45 shingles when the roofing shingle is installed on the roof.
`Preferably, the webs 26 arc appficd to the lower surface 32
`of the sheet in the prime portions, but not in the headlap
`portions. Application of the web beneath just the prime
`portion of the roofing material provides inrprovcd inrpact
`50 resistance to the portion of the roofing material exposed to
`the elements on a roof, while minimizing the overall cost of
`the roofing material.
`
`In an alternate embodiment shown in FIG. 3, the ~veb 26
`is payed out onto the lower surface of the substrate 12 prior
`55 to coating both the web and the substrate with asphalt
`coating. Preferably, the web is bonded to the substrate prior
`to the asphalt coating step, either intermittently or continu-
`ously along their lengths. Any suitable bonding apparatus 46
`can be used to bond the web to the substrate. Some examples
`6o of bonding methods include heat sealing, ultrasonic welding,
`pressure sensitive or hot melt adhesive, electrostatic
`bonding, and physical intertwining by such means as nee-
`dling or stitching. Bonding the web and substrate together
`fixes the position of the web relative to the substrate in both
`65 the machine and cross directions of the sheet. The bonding
`also helps to minimize any shrinkage or wrinkling of the
`web that may occur during the coating step.
`
`FAST FELT 2035, pg. 10
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 6,228,785 BI
`
`5
`As shown in FIGS. 4 and 5, the asphalt-based roofing
`material 28 includes a substrate 12 that is coated with an
`asphalt coating 48. A surface layer of granules 5!) is embed-
`ded in the asphalt coating. The asphalt coating includes an
`upper region 52 that is positioned above the substrate when
`the roofing material is installed on a roof, and a lower region
`54 that is positioned below the substrate when the roofing
`material is installed on the roof. For purposes of improved
`impact resistance, it is important to bond the web 26 to the
`lower region of the asphalt coating. The bonding of the web
`to the lower region of the asphalt coating, rather than the
`upper region, has been found to provide an unexpected
`improvement in resistance to a variety of impacts. Unlike the
`roofing shingle disclosed in U.S. Pat. No. 5,571,596 to
`Johnson, there is no need to add a layer of impact-resistant
`material to the upper region of the asphalt coating.
`The web can be bonded to the asphalt coating at any
`location in the lower region. The "lower region" 54 of the
`asphalt coating includes any location between the lower
`surface 56 of the substrate and the lower surface 58 of the
`asphalt coating. In the preferred eurbodiurent shown in FIG.
`4, the web is bonded to the lower surface of the asphalt
`coating. It has been found that bonding the web to the lower
`surface of the asphalt coating achieves a superior impact
`resistance.
`The present invention also provides a strong bond
`between the ~veb and the asphalt coating, to ensure that the
`web does not separate from the asphalt coating. If the web
`separates from the asphalt coating, it is not effective to
`dissipate the energy of an impact on the roofing material.
`The strong bond is achieved by fusing the web and the
`asphalt coating. Specifically, a portion of the web and of the
`asphalt coating are intermingled by melting, thereby fusing
`the web and the asphalt coating. "Intermingled" includes
`an}’ type of physical and/or chemical intermingling of the
`wcb and thc asphalt coating, to providc a strong mcchanical
`and/or chemical bond.
`The illustrated roofing material includes an interphase
`region 60 where intermingling by melting has occurred
`between a portion of the ~veb 26 and a portion of the lower
`region 54 of the asphalt coating, because of the partial
`miscibility of thc mcltcd wcb and thc mcltcd asphalt coating.
`The interphase region is usually a non-homogenous region
`including various concentrations of melted asphalt coating,
`partially or completely melted web, and mixtures of melted
`asphalt coating and melted web. The interphase region 60 is
`a different composition from either the remaining portion 61
`of the web or the remaining portion 63 of the lower region
`54 of the asphalt coating. Thus, the intermingling can
`include varied degrees of mixing between the web and the
`asphalt coating. In the illustrated embodiment, the intermin-
`gling also includes an irregular interface 62 or boundary
`between the interphase region 60 and the pure asphalt
`coating 63. The irregular interface 62 is comprised of peaks
`64 and valleys 66 that have resulted from interpenetration
`between the interphase region and the pure asphalt coating.
`The irregular interface enhances the bond between the web
`and the asphalt coating. Aportion 61 of the web 26 may have
`no intermingling with the asphalt coating, thereby forming
`an interface 67 between the intevphase region 60 and the
`portion 61 of the web.
`In a preferred embodiment, the fusing of the web and the
`asphalt coating is facilitated by the use of a two-component
`web. The two-component web is comprised of a first con>
`ponent having a first melting point, and a second component
`having a second melting point that is lower than the first
`melting point. During the nranufacture of the roofing
`
`~o
`
`material, at least a portion of the second component is
`intermingled with the asphalt coating by melting, thereby
`fusing the xveb and the asphalt coating. "At least a portion"
`means that some or all of the second component is inter-
`s mingled with the asphalt coating by melting. Some portion
`of the first component may also be intermingled by melting,
`so long as the web maintains enough of its structure to be
`effective to improve the impact resistance of the roofing
`materiah
`Preferably, the second component has a melting point at
`least about 50° F. (28° C.) lower than the melting point of the
`first component, and more preferably at least about 100° F.
`(56° C.) lower. The asphalt coating usually has a processing
`temperature within the range of between about 325° E (163°
`15 C.) and about 450° F. (232° C.). Preferably, the second
`component has a melting point not higher than about 400° F.
`(204° C.), and more preferably not higher than about 385°
`F. (196° C.), so that at least a portion melts in contact with
`the asphalt coating. Preferably, the first component has a
`20 melting point not lower than about 350° F. (177° C.) so that
`it remains snbstantially solid in contact with the asphah
`coating.
`FIGS. 6 and 7 illustrate a two-component film 68 that is
`useful as the web. As shown in FIG. 6, the film comprises
`2s a first layer 70 of a first component laminated to a second
`layer 72 of a second component. As shown in FIG. 7, the
`second layer 72 has been intermingled with the asphalt
`coating 48 by malting.
`In another embodiment, the web is comprised of two-
`3O component fibers. Preferably, the two-component web is a
`nonwoven web of sheath/core fibers. As shown in FIG. 8, a
`sheath/core fiber 74 includes a core 76 comprised of a first
`component, and a sheath 78 comprised of a second compo-
`nent having a lower melting point than the melting point of
`3s the first component. As shown in FIG. 9, the sheath 78 has
`
`4O
`
`been intermingled xvith the asphalt coating 48 by melting.
`A variety of different types of web are suitable for use in
`the present invention. The material and structure of the web
`arc choscn so that thc wcb is cffcctivc to improvc thc impact
`resistance of the roofing material. Specifically, the web is
`effective to dissipate the energy of an impact on the roofing
`material. Preferably, the material of the web has good tensile
`flexure properties, so that it can dissipate the impact energy.
`45 A glass mat is unsuitable for use as the web because of its
`limited elongation properties. Also preferably, the structure
`of the web is substantially continuous along its length and
`width so that it can transmit energy waves uninterrupted
`from the point of impact to the edges of the xveb. For this
`so reason, a scrim is not preferred for use as the web.
`The web is a material which has components that can fuse
`to thc asphalt coating by having a portion of thc xvcb mclt
`and intermingle with the asphalt coating. Thermoplastic
`polymer components are preferred for use in the web
`55 because they are capable of partially melting in contact with
`the hot asphalt coating. On the other hand, thermoset poly-
`mer components will not melt in contact with the coating.
`Usually, the web material is at least partially miscible with
`the asphalt coating.
`Preferably, the web can be cut cleanly and easily during
`the roofing material manufacturing process, such as when
`the sheet of roofing material is cut into shingles and when
`the tabs are cut in a shingle. The clean cutting means that no
`strings or other portions of thc ~vcb matcrial arc sccn
`65 protruding from the edges of the cut roofing material.
`It is preferred that the web does not substantially shrink in
`contact with the hot asphalt coating, thus providing total
`
`60
`
`FAST FELT 2035, pg. 11
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 6,228,785 BI
`
`7
`surface coverage. Also preferably, the material of the web
`has a coefficient of ~iction that prevents the roofing material
`from sliding off a roof during installation.
`Some materials that may be suitable for use as the web
`include mats, webs, films, fabrics, veils, scrims, similar
`structures, or combinations of these materials. The mats
`include, for example, airlaid spunbonds, netting, and
`hydroentangled fibers. The films include, for example, rigid
`polyvinyl chloride, flexible polyvinyl chloride,
`polycarbonate, ionomer resin (e.g., Surlyn®, and polyvi-
`nylidene chloride (e.g., Saran Wrap®).
`Apreferred material for use as the web is a nonwovcn web
`of twocomponent thermoplastic polymer fibers, such as the
`sheath/core fibers described above. Preferred webs of
`sheath/core fibers are conlmercially available from PGI Inc.,
`1301 E. 8th St., North Little Rock, Ark. 72114. For example,
`PGI 4103, PGI 4124 and PGI 4104 are nonwoven webs of
`sheath/core fibers, each fiber including a core of polyethyl-
`ene terephthalate and a sheath of polyethylene. The sheaths
`of the fibers are heat bonded together in the web to hold the
`wcb togcthcr. Thcsc products arc availablc in a varicty of
`nonwoven forms, including lofted and densified forms. A
`preferred form is densified to 1.0 ounce per square yard
`(33.9 grams per square meter). The web of sheath/core fibers
`fuses well to the asphalt coating.
`The web can be applied and fused to the lower region of
`the asphalt coating in any suitable manner. As described
`above, the preferred method is to coat the substrate with the
`asphalt coating, and then to apply the web to the lower
`surface of the coating. A portion of the web melts in contact
`with the hot asphalt coating and, because of the partial
`miscibility of the web and the coating, intermingles with the
`coating to fusc thc wcb and thc coating. It has bccn found
`that some types of web melt better if they are applied to the
`asphalt-coated sheet, instead of first being applied to the
`substrate and then coated along with the substrate. Some
`types of web will melt too well in the asphalt coater, which
`may cause them to shrink or tear.
`Ar3other method of fusing the web and the asphalt coating
`is to apply a web that does not initially melt in contact with
`the coating, but that is partially melted and intermingled
`with the coating later in the process by applying heat to the
`web and/or the coating. Another method is to extrude a
`molten film of the web material onto the lower surface of the
`asphalt-coatcd shcct, and thcn to solidify thc wcb by cool-
`ing. Another method is to apply a web to the asphalt-coated
`sheet, where the web is fully miscible with the asphalt
`coating, but where the heat history of the web limits the
`migration of the web into the asphalt coating. Still another
`method is to mix the material of the web with the asphalt
`coating during manufacture of the coating; when the asphalt
`coating is heated in the coater, the material of the web
`separates and migrates to the surface of the asphalt coating.
`Other suitable methods are also envisioned.
`It should be noted that the web can be manufactured
`separately before the shingle manufacturing process, or it
`can bc manufacturcd simultancously with manufacturing thc
`shingle. It should also be noted that release tapes can be
`incoq~orated into part of the web to facilitate separation of
`the roofing shingles from one another after packaging and
`shipping. Alternatively, a release material such as silicone
`can be integrated into the web in parts of the web.
`Referring again to FIG. 1, after the xveb 26 is applied, the
`sheet of asphalt-based roofing material 28 is reinverted, and
`then cooled by any standard cooling apparatus gl}, or
`allowed to cool at ambient temperature. The cooling hardens
`
`the asphalt coating and the melted porfion of the web,
`thereby setting the bond between the asphalt coating and the
`web.
`The sheet of asphalt-based roofing material 28 is then cut
`5 by a cutting apparatus g2 into individual shingles g4, into
`pieces to make laminated shingles, or into suitable lengths
`for commercial roofing or roll roofing. The roofing is
`material is then collected and packaged.
`FIG. 1~1 illustrates the sheet of roofing material 28 after it
`~0 has been cut into three-tab roofing shingles 84 but before
`
`20
`
`separating the shingles from the sheet. FIG. 11 illustrates
`several roofing shingles 84 installed on the side 86 of a roof.
`As shown in FIGS. l!l and 11, each roofing shingle includes
`a prime portion 42 that is normally exposed to the elements
`15 when the shingle is installed on the roof, and a headlap
`portion 44 that is normally covered by ac~iacent shingles on
`the roof. The web is positioned beneath the prime portion 42
`but not the headlap portion 44 of each shingle.
`FIG. 12 illustrates a hip and ridge roofing shingle 88
`according to the invention installed on the ridge 91} of a roof.
`The xveb is positioned beneath the entire shingle because the
`entire shingle is exposed to the elements on the roof.
`FIG. 13 illustrates a laminated roofing shingle 92 accord-
`2s ing to the invention. The laminated shingle is comprised of
`two pieces of roofing material, an overlay 94 and an under-
`lay 96, which are secured together by adhesive or other
`means. The laminated shingle includes a prime portion 98
`and a headlap portion I!l& The web is positioned beneath the
`3o p