PROCESS FOR IN-LINE EXTRUSION OF COATINGS ONTO ROOFING SHINGLES DURING MANUFACTURING AND ROOFING SHINGLES MADE BY THE PROCESS

摘要

A process for in-line extrusion of polymeric coatings onto roofing shingles during manufacturing includes moving a web of shingle substrate material in a downstream direction and extruding a liquefied coating of polymeric material onto at least one surface of the moving web to form a thin film. The liquefied coating may be a molten polymeric material that forms a thin film on a back surface of the shingle material to prevent sticking and eliminate the need for a traditional back dusting with material such as powdered stone. The polymeric film further may be applied to the substrate material in lieu of a saturation coating of asphalt, thus reducing cost and weight while providing a comparable moisture barrier and a lighter more flexible shingle.

主权项

1. A method of fabricating roofing shingles comprising the steps of:
(a) conveying a mat of substrate material having a first and a second surface in a downstream direction; (b) ejecting a stream of molten polymeric material onto the first surface of the mat of substrate material as the mat is conveyed in the downstream direction to deposit a film of polymeric material on the first surface; (c) cooling the film of polymeric material to cure the film, bond the polymeric material to the mat of substrate material, and form a waterproof coating on the mat of substrate material; (d) coating the second surface of the mat of substrate material with a bituminous coating that is at least partially molten; (e) embedding ceramic-coated granules into the bituminous coating to form a protective layer; (f) cutting the resulting mat to form individual shingles; and (g) bundling the individual shingles for storage and shipment.