CA2041200A1 - Method and apparatus for making roofing shingles - Google Patents
Method and apparatus for making roofing shinglesInfo
- Publication number
- CA2041200A1 CA2041200A1 CA 2041200 CA2041200A CA2041200A1 CA 2041200 A1 CA2041200 A1 CA 2041200A1 CA 2041200 CA2041200 CA 2041200 CA 2041200 A CA2041200 A CA 2041200A CA 2041200 A1 CA2041200 A1 CA 2041200A1
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- Canada
- Prior art keywords
- web
- deposits
- granules
- adhesive
- granule
- Prior art date
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Abstract
ABSTRACT OF THE DISCLOSURE
A method and apparatus for making asphalt shingles and particularly for applying varying overlay patterns of granular material to a web of roofing material to produce shingles of randomly varied appearance when the web is cut into shingles. Pattern variation is achieved by several techniques, including the use of irregular overlay imprint shapes and spacings, the staggered omission of one or more overlay imprints from the web shingle lanes, and the random omission of one or more granule drops during coverage of each pattern to change a randomly selected imprint from a predetermined granule color to the backfall mixture shade.
The apparatus includes provisions for automatically changing the granule flow rate to accommodate speed changes. Pro-vision is further made for resiliently supporting the web to prevent web damage during the cyclical granule drop.
A method and apparatus for making asphalt shingles and particularly for applying varying overlay patterns of granular material to a web of roofing material to produce shingles of randomly varied appearance when the web is cut into shingles. Pattern variation is achieved by several techniques, including the use of irregular overlay imprint shapes and spacings, the staggered omission of one or more overlay imprints from the web shingle lanes, and the random omission of one or more granule drops during coverage of each pattern to change a randomly selected imprint from a predetermined granule color to the backfall mixture shade.
The apparatus includes provisions for automatically changing the granule flow rate to accommodate speed changes. Pro-vision is further made for resiliently supporting the web to prevent web damage during the cyclical granule drop.
Description
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- - - ` 1 PATENT
METIIOD AND APPARATUS FOR MAKING ROOFING SHINGLES
BACKGROUND OF THE INVENTION
l. Field of the Invention The present invention relates generally to the manufacture of asphalt roofing shingles and relates more particularly to a method and apparatus ~or applying random overlay patterns of contrasting granular material to a granular surfaced shingle web to produce shingles having a widely varying appearanca.
2. DescriPtion of the Prior Art ~' , A variety of methods have been proposed in the manufacture of asphalt shingles to achieve a shingle appearance suggesting that of wood shake or shingles.
In U.S. Patent 1,791,571, issued February 10, 1931, the shingle tabs formed by the tab slo~s were each coated with a different color or shade of granule to mimic the appearance of individual shingles. This patent further taught the method of employing a color pattern length different from the shingle length to provide a variety of different shingles depending on the number of color bands in the pattern.
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In U.S. Patent 2,074,147, issued March 16, 1937, :
a plurality oE colors were utilized for the shingle tabs, but the color boundaries were not limited to the shingle tab slots. This patent discloses the use of overlay granule stripes on the tab portions of the shingles with the dividing lines between differently color stripes occurring on the face of the shingle tabs.
In U.S. Patent 2,074,131, issued March 16, 1937, the method was disclosed of applying transverse overlay stripes of different colored granular material at spaced intervals.
U.S. Patent 2,661,303, issued December 1, 1953, discloses the application of a pattern of stripes of different colored granules deposited transversely on a web of roofing material, and the cutting of the shingles to a length different than the pattern length to achieve a variation in shingle appearance.
These concepts are also employed~in U.S. Patents 4,295,445, issued October 20, 1981, and 4,352,837, issued October 5, 1982, which disclose an apparatus and method for producing spaced overlay bars of varying color shades on tab portions of a shingle web and cutting the web to a shingle length different than the pattern length.
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SUMMARY OE THE INVENTION
The present invention provides a method and apparatus for making asphalt shingles and particularly for r ~ J ~ ~
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applying overlay patterns of granular material to a web of rooEinq material previously surfaced with a first layer of yranular material to produce shingles of randomly varied appearance. The overlay patterns are produced by print wheels having adhesive applying bars of establishing deposits different shapes, sizes and spacings. Further varlation is achieved by the staggered omission of one or more print bars from the print wheels. Additionally, the random omission of granule drops of predetermined colors provides a granule color change to to the backfall mixture shade on randomly selected deposits oE each drop cycle.
The invention further includes apparatus for automatically changing the overlay granule ~low rate to ij accommodate web speed changes. This arrangement includes a parallelogram linkage connection of the hopper roll gate control levers to a master control lever, the position of which is automatically changed in accoxdance with web speed changes by means of a linear actuator controlled`by a web roll tachometer.
The invention further provides apparatus for resiliently supporting the web of roofing material during the cyclical overlay granule drop, the resilient support comprising the use of a table resiliently supported by pneumatic springs or actuators.
i It is accordingly a first object of the present invention to provide a method and apparatus for making -~
roofing shingles having a random appearance.
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. ., ; An additional object of the invention is to provide a method and apparatus as described which provides the random shingle appearance by the application of overlay patterns of colored granule material to a roofing web having a first layer of granul~r material adhesively applied thereto.
A further object of the invention is to provide a method and apparatus as described which can be added to conventional roofing equipment with minimal modification thereto.
i A further object of the invention is to provide an improved apparatus for making overlay type roofing shingles comprising an improved means for supporting the web during the cyclic granule drop.
Still another object of the invention is to provide apparatus for controlling the granule feed means of an overlay type roofing apparatus and automatically,adjusting the granule feed rate in accordance with web speed changes.
Another object of the invention is to provide apparatus as described of a relatively simple construction and which, when operating, requires relatively little manual control or oversight.
Additional objec~s and advantages of -the invention will be more readily apparent from the following detailed description of an embodiment thereof when considered in -~
conjunction with the accompanying drawings.
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BRI~F DESCRIPTION OF T~IE DRAWINGS
Figs. la and lb taken together comprise a schematic side elevational view of asphalt shingle manufacturing equipment which incorporates the apparatus and employs the method of the present invention;
Fig. 2 is an enlarged side elevational view of the portion of Fig. lb outlined in dot/dash lines, the apparatus shown in Fig. 2 comprising the overlay section of the shingle manufacturing equipment;
Fig. 3 is a perspective view of the print wheel of the apparatus shown in Fig. 2;
Fig. 4a is an enlarged plan view taken along line 4-4 of Fig. 2, showing the imprint pattern produced on the web by the print wheel and showing in broken lines the coverage areas of the dropped granules;
Fig. 4b is a side elevational view of the web shown in Fig. 4a, schematically showing the mechanism for feeding granules onto the bars at the correct spacing;
Fig. 5 is a view similar to Fig. 4b showing additional details of the granule feed means and particularly the mechanism for automatically adjusting the granule flow rate upon change of speed of the web;
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Fig. 6 is an enlarged sectional view of the area enclosed in dot/dash lines in Fig. 6 showing one of the .
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granule feed mechanisms; and Fig. 7 is a schematic view showing the manner of driving and controlling the print wheel drive rolls and the granule feed mechanisms.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Figs. la and lb show schematically the manner in which conventional roofing shingle manufacturing equipment can be modified to incorporate the apparatus of the present invention which is disposed principally in the region enclosed by dot/dash lines in Fig. lb and shown in the enlarged view of Fig. 2. Since the apparatus shown in Figs.
la and lb aside from that portion depicted in Fig. 2 is conventional, it is illustrated schematically and will be only briefly described.
Starting at the left hand end of Fig. la, the shingle manufacturing equipment generally designated 10 includes a dry felt unwind stand 12 on which a roll of felt 14 is rotatably disposed and from which a web 16 of felt is fed into a dry felt looper-18. The looper serves as a reservoir of felt which can be drawn upon to permit the periodic replacement of the felt supply roll 14. From the looper 18, the web 16 passes into saturator tank 20 which is filled with asphalt 22. The web then passes through the strike in drum section 24 and thence into the saturated felt looper 26 wherein the asphalt saturated web is permitted to cool. If the web is formed of fiberglass rather than felt, the asphalt saturation step is omitted.
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The web next passes into a coater 28 wherein an adhesive material such as asphalt/mineral dust mixture is applied to both sides of the web by coating rolls. From the coater, the web passes into what is known as the slate section 30 wherein colored granular material of various shades is stored in hoppers 32 for delivery to a blender 34 disposed above the web. The blender provides a predetermined drop pattern of the particulate material onto the web upper -surface. Web areas not covered by the blender 34 are covered by a mixture of granular material from a back fall bin 36 which collects granules falling from the web after passage around a surfacing roll 38 which serves to embed the granules in the adhesive web coating. The web is divided longitudinally into lanes, conventionally four lanes, each lane later being cut transversely at uniform intervals into individual shingles. As is conventional, a different granular material is deposited on the head lap portion of the shingle lanes than on the exposed tab portion of the lanes.
Powdered talc, mica, sand or other mineral release material is applied at 40 to the back of the web to prevent the web from sticking to the equipment as it passes through the remaining sections. Upon passage of the web over reversing roll ~2, the release material is embedded in the adhesive coating of the web and provides a smooth, non-stick web under surface. The web then travels to the cooling section 44 comprising a plurality of looping rolls. Partway through the cooling section 44, the web is directed into the overlay section 46 which is shown in Fig. 2 and considered in detail below. The web returns to the cooling section 4~ from .
the overlay section 46 and thence passes into the finished product looper 48 t thence to a cutter 50 wherein the web is sliced longitudinally and cut transversely into discrete roofing shingles. Stacking and packaging equipment (not shown) is provided downstream of the cutter.
The overlay section 46 wherein the novel method of the invention is carried out and wherein the novel apparatus of the invention is disposed, is illustrated in Fig. 2. With reference to that figure, the web 16 is seen rising vertically from the cooling section 44 and passes around turning roll 52 into a horizontal run 54 with the granular material coated face presented downwardly. The web run 54 passes over a pair of print wheels 56 and 58 mounted in spaced relation on a common shaft 59. The web engages print bars 60 and 62 peripherally disposed respectively on the print wheels 56 and 58 to receive spaced adhesive deposits on imprints thereon. As shown in Fig. 3, the bar 60 and 62 are of irregular shapes and sizes as described more fully hereinafter.
The print wheels 56 and 58 are driven in rotation at a speed commensurate with the speed of the wek such that the peripheral speed of the bars matches the speed of the web surface engaged therewith. The rotating print wheels are disposed within adhesive pan 64 and are partially immersed in an adhesive 66 such as hot liquid asphalt within the pan.
Suitable heating means (not shownj are provided in the pan to maintain the asphalt in a liquid condition. The print wheels and pan are mounted on a car 68 having wheels 70 engaged with transverse tracks 72 mounted on frame assembly 74. The pan , , .
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and print wheels may accordingly be moved transversely out from under the web when necessary for service, repairs or replacement. Means (not shown) are provided for accurately positioning the print wheels transversely on the shaft 59 and the car 68 on the tracks 72 to provide the correct transverse registration of the adhesive imprints on the web.
Following passage over the print wheels, the web 16 passes around th~ reversing roll 76 and then passes onto the horizontal t`able 78 which is resiliently supported above horizontal frame assembly 80 by pneumatic actuators 82 disposed at each of the four table corners. ~ suitable pneumatic actuator for this purpose is sold by Firestone Tire and Rubber Co. under the trademark AIR STROXE. By varying the pneumatic pressure in the actuators, the height o~ the table or one side of the table may be adjusted, and accordingly the table may be lowered entirely or one side of the table may be lowered as desired during the threading of the web as well as for cleaning, repair or general maintenance of the granular material feed means disposed just above the table as described below. The normal table operating height may be established and maintained by the threaded stop members 84 which extend from the table downwardly through the frame assembly 80 and comprise adjustable stop nuts 86 on the lower ends thereof.
Disposed above and closely adjacent the table 78 and the web 16 passing thereover are a plurality of granule feed means 88a-i. The number of granule feed means is equal to the number of rows of bars 60 and 62 spaced around the print wheels 56 and 58, and the spacing of the granule feed _g_ .
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means longitudinally along the web run is exactly the same as the peripheral spacing of the print wheel bars, which it will be noted are not uniform. This arrangement per~its a cyclical simultaneous granule feed from the feed means 88a-i onto the web 16 when the feed means are in aligned juxtaposition to the adhesive imprints provided on the web surface by the print wheel bars.
Fig. 4a provides a plan view of the web with the imprint pattern of adhesive deposits advanced along the table to the point at which the granule drop is just starting. The web 16 is in the illustrated embodiment of a width equal to the width of four shingles and accordingly comprises four lanes which in Fig. 4a are designated as lanes A~D, which lanes are divided in the s~itting and cutting operation at the cutter 50 along the broken lines 90, 92 and 94 of Fig.
4a. Each web lane is cut transversely at the cutter 50 into discrete shingles and the size of a~shingle is shown in Fig.
4a at 96 wherein it may be seen that the shingle length is substantially shorter than the pattern laid down in one revolution of the print wheels. The tab portion 98 of the shingle 96 is divided from the head lap portion 100 thereof by a broken line 102. As earlier indicated, the granule application in the slate section 30 which establishes a first granule layer on the web is conventionally carried out such that the head lap portion loo of the shingles is covered with a different type of granule (typically uncolored and hence less expensive) than the tab portion 98 which is exposed to view when the shingle is applied to a roof. Accordingly, the overlay pattern established in the overlay section ~6 of the . .
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apparatus is laid down only on the portions of the lanes which will become the tab portion of the shingles. The adhesive imprints established by the print wheel bars 60 and 62 appear respectively in Fig. 4a as adhesive deposits 104a-i and 106a-i. The deposits 104a-i straddle the dividing line 90 between lanes A and B in order to cover the tab portions of the shingles cut from those lanes, the tab portions of the eventual shingles of lane A abutting the tab portions of the eventual shingles of lane B. Similarly, the deposits 106a-i straddle the dividing line 94 between lanes C and D to cover only the abutting tab portions of the shingles of those lanes.
In order to obtain greater variation in shingle appearance, one or more of the deposits are preferably omitted in each of the longitudinal rows of adhesive deposits by omitting one or more bars 60 or 62 from the print wheels 56 and 58. As may be seen in Fig. 3, there is no counterpart bar 62 on wheel 58 which corresponds with the second bar from the top in wheel 56. With reference to Fig. 4, this creates a void transversely opposite the deposit 104c, or stated differently, there is no deposit 106c.
Similarly, in the row of deposits 104a-i, 104g is omitted by eliminating the bar 60 on the print wheel 56 which would normally be present to produce a deposit at this point.
Accordingly, there is no counterpart to the deposit 106g in the longitudinal row of deposits which straddles lanes A and B.
To gain even further variation in shingle , appearance, the individual deposit shapes vary in each row and do not correspond with the deposit transversely aligned therewith in the other row. For example, the shapes of each of the deposits 104a-i (104g omitted) are different, as are those of deposits 106a-i (106c omitted). Also, the shape of deposit 104a differs from that of its transverse counterpart 106a, 104b differs from 106b, etc. Each deposit may be irregularly shaped by utilization of transverse edges which are asymetrical with respect to the lane dividing 90 and 94.
Although the deposit shapes illustrated in Fig. 4a provide mirror images across the lines 90 and 94, the transverse deposit edges could comprise diagonals or irregular edge lines such that the deposits on adjacent shingles would not be mirror images.
The employment of adhesive deposits having irregular transverse borders is permissible in view of the granule drop coverage provided by the granule feed means 88a-i which is somewhat more extensive both transversely and longitudinally than the adhesive deposits. The deposits 104a-i are covered as shown schematically in Fig. 4a by the dash line outlines by granule coverages 108a-i (108g omitted). Similarly, the deposits 106a-i are covered by granule coverages llOa-g (llOc omitted). Although the width of the granule drop coverage is the same in each case, it will be noted that the length of each deposit (considered longitudinally of the run) varies with the size of the adhesive deposit and its location on the web. For example, the granule coverage 108b is significantly longer than coverage 108a to accommodate the larger size of the deposit 104b than the deposit 104a. Also, the deposit 108b is J ~ ~
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somewhat longer than the deposit 104b in view of the position of the deposit 106b which is somewhat to the right of the deposit 104b as viewed in Fig. 4a.
At the extreme right end of Fig. 4a, deposits 104a' and 106a' which were covered in the previous granule drop cycle are schematically shown as covered with granules only on the adhesive deposit. In reality, loose granules would be present around the periphery of each of the deposits in view of the surplus coverage of the deposits as described above.
As described below, these granules will be collected and reused.
The details of the feed means 88a-i are shown in Figs. 2, 4b, 5, 6 and 7. the feed means 88a-i are substantially identical and include a fluted granule roll 112a-i extending substantially the width of the web as shown in Fig. 7 and disposed above the table 78 closely adjacent the web surface. The rolls are intermittently driven in rotation by a mechanism described beIow. The granule feed rolls as shown in Figs. 4b, 5 and 6 when rotated move counterclockwise as viewed in those figures and serve to deliver granules onto an adjacent guide plate 114a-i which is preferabIy of a cycloidal shape with its lower edge closely spaced to the upper surface of the web. The cycloidal guide plate shape serves to~urge the granules in the direction of sheet travel to avoid bouncing and scattering of the granules. The rapid intermittent rotation of the granule rolls 112a-i actually impels the granules along the guide plates and thus augments the effect of gravity to shorten the granule descent time. The guide plates further serve to .., .
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' protect the granule rolls from asphalt deposits during theweb lace-up or in the event of a web breakage.
As shown most clearly in Fig. 7, a pair of hoppers is disposed over each granule roll 112 in transverse alignment with the rows of deposits 104 and 106 on the web.
Hoppers 116a-i are provided in transverse alignment with the deposits lO~a-i and hoppers 118a-i are provided in alignment with the deposits 106a-i. Since the deposits 104g and 106c have been omitted, hoppers 116g and 118c likewise are omitted.
As shown in Fig. 6, the hoppers each have a transverse opening 120 closely adjacent the roll surface, the size of which is selectively controlled by means of the sliding gate 122 having rack 124 thereon in engagement with the gear 126 fixedly mounted to shaft 128. The described hopper gate control components are common to each of the hoppers 116a-i and 118a-i. The shafts 128 link the hoppers disposed above a common granule roll 112; for example, the shaft 128a shown in Fig. 6 extends transversely and al50 controls the gate of hopper 118a.
Control levers 130a-i are fixedly mounted to the shafts 128a-i such that movement of the levers 130a-i to the left as viewed in Figs. 5 and 6 will result in an increased opening of the hopper gates 122a-i. Conversely, movement of the levers to the right will cause a decrease in the opening of the hopper gates.
To provide an automatic regulation of the hopper , ,:
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openings commensurate with the speed changes of the web, a master speed control lever 132 pivotally mounted at its lower end at 13~ to the machine frame is provided. Links 136a-i join the master control lever with the upper ends of the speed control levers 130a-i to form a plurality of parallelogram linkages such that a movement of the master control lever will result in a commensurate movement of the levers 13Oa-i and a consequent commensurate opening or --closing of the hopper gates. Turnbuckles 138a-i are provided in the links 136a-i to permit individual adjustment of the hopper flow rates. A plurality of attachment holes are also provided at the upper end of the levers 130a-i to permit alternate attachment positions for the links if necessary to establish the desired individual rate flow of a given hopper.
The position of the master control lever 132 is controlled by a linear actuator 140 mounted on the machine frame and attached to the master control lever 132 by means of actuator connecting rod 142. A tachometer 144 mounted on a web roll senses the web speed and sends a signal through a transducer 146 to the linear actuator 140 to effect a hopper opening commensurate with web speed. A higher web speed will require a larger hopper opening which is obtained by a movement of a master control lever 132 to the left as viewed in Fig. 5. A slowing of the web speed will necessitate a closure of the hopper openings which is obtained by actuator movement of the lever 132 to the right.
As shown in Fig. 2, the hoppers 116a-i and 118a-i are maintained in a filIed condition with granules from larger sized supply bins generally designated 14~ which are '. :
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connected to the hoppers by granule feed hoses 150a-i.
The web 16 after passing under the granule feed means ~a-i advances to the slate drum 152 (Fig. 2) which serves to embed the granules in the adhesive deposits. The slate drum further serves to entrap the loose granules on the web which are not disposed over an adhesive deposit and these fall from the inverted web after passage over the slate drum and drop into the backfall hopper 15~ which thus accumulates a mixture of the various granule colors. A continuous curtain of this backfall mixture is returned to the web by the feed roll 156 associated with the hopper 154 to cover any adhesive deposits which may have escaped coverage by the feed means ~8a-i. A granule feed hose 158 connects the hopper 154 with a supply bin 160 to assure a continuous supply of granules in the hopper 154.
In order to provide a still more random appearance of the shingles and secondarily to utilize the supply of backfall granules accumulated in the hopper 154, random ones of the feed means 88a-i are interrupted from feeding granules during the cyclical pattern granule drops. This random omission is controlled by a computer 162 (Fig. 7) governed by an algorithm which preferably does not sequentially repeat the omission of a given feed means operation. The algorithm further may be written so as to randomly select no feed means to be interrupted in a given pattern granule drop since this would maximize the random effect to be achieved. The adhesive deposits which are not covered by the selected inactivated feed means will be covered by the curtain laid down by the backfall hopper feed roll 156. Since this will .
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provide a color blend different from that supplied by the interrupted feed means, a variation in the appearance of the overlay pattern will result~
Following passage over the slate roll 152, the web passes around draw roll 163. As shown in Fig. 7, a speed changer 164 is provided in a drive mechanism between these rolls to adjust the web tension hetween the rolls and to accommodate the recirculated granules trapped between the slate roll and the web which increase the effective diameter of the roll. Adjustment of the speed changer permits the adjustment of the degree of embedment of the granules into the adhesive deposits ~y controlling the pressure of the web against the slate drum.
From the draw roll 163, the web passes over roll 164 into the loose granule reclaim hopper 166 wherein it is engaged by a whipper 168 comprising rotating flexible elements which slap the underside of the moving web to provide dislodgement of loos~ granules which fall to the bottom of the hopper 166 for collection and reuse.
The web then passes sequentially over rolls 172, 174, 176 and 178 and returns~to the cooling section 44 for eventual passage into the finished product looper 48 and the cutter 50.
, With reference to Fig. 7, the manner in which the rotating components of the overlay section are driven and controlled is schematically illustrated. A motor 180 provides power to directly drive the slate drum 152 through :: .
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schematically illustrated shaft connection 182 and chain or timing belt 184. ~n additional chain or timing belt con-nection 186 to shaft 188 provides a direct drive of the reversing roll 76 at the same speed as the slate drum 152.
The speed changer 164 is driven through shaft 182 by chain or timing belt connection 190 and, as previously mentioned, permits adjustment of the drive speed of the draw roll 163 to permit adjustment of the web tension around the slate drum 152.
The print wheels 56 and 58 are rotated on their common shaft 59 by the connection thereof to the shaft 182 through chain or timing belt connection 192. A speed changer 194 is provided in this drive connection to permit the accurate correlation of the print wheel peripheral speed with the web speed.
The granule feed rolls 112a-i are driven through the shaft 182 by means of chain or timing belt drive 196 through electrically controlled clutches 198a-i which are in turn controlled as schematically indicated in Fig. 7 by the computer 162. The computer is appropriately programmed to energize the clutches 198a-i to rotate the granule rolls 112a-i at the precise moment when the pattern of adhesive deposits is presented therebeneath, which moment is shown in Figs. 4a and 4b. The computer is also programmed to maintain the rotation of the rolls 112a-i selectively to provide the coverage required ~or the deposit shapes presented. For example, the roll 112b must be rotated for a time period longer than 112a or 112c since the granule coverage required is substantially greater to cover the large adhesive deposits , , 104b and 106b. Accordingly~ the computer must be programmed to provide the proper operation interval for each of the granule rolls 112a-i.
In order to facilitate start-up after maintenance, cleaning and reassembly of the overlay section components, a phase shifter 200 is provided linked by timing belt or chain 202 to the print wheel shaft drive. The phase shifter is linked with,a trigger switch 204 connected to the computer to permit manual adjustment to reorient the controls and reestablish synchronous placement of the granule coverage with the adhesive deposit pattern upon actuation of the trigger switch 204 to initiate granule flow.
The operation of the apparatus components have already been described and will accordingly be only briefly summarized. The web 16 moving over the print wheels 56 and 58 receives adhesive deposits of hot asphalt from the bars 60 and 62 of the print wheels. The bars 60 and 62 vary in size, shape, and spacing and, as shown in Figs. 3 and 7, one bar may be omitted from the pattern provided by each print wheel.
The deposit pattern necessarily has a length equal to the circumference of the print wheels taken around the bars thereon. The length of the pattern is shown in Fig. 4a and, it will be noted, is substantially longer than a shingle, in fact, is preferably more than twice as long as an individual shingle.
When the pattern of deposits arrives beneath the granule feed means 88a-i in correct alignment therewith as shown in Figs. ~a and 4b wherein the lower end o~ the guide .. _ _ . , _ . ....... .
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plates ll~a-i are aligned with the leading edges of the intended granule coverage patterns 108a-i and llOa-i, the computer 162 actuates the clutches 198a-i to simultaneously begin rotation oE the granule feed rolls 112a-i. As indicated, the feed roll rotation length is determined by the needed granule coverage. Since the granule drop occurs simultaneously from all of the granule feed means, it is advantageous to resiliently support the web to prevent web damage and for this reason, the pneumatic table supports 82 are provided.
The flow rate of the granules onto the deposits can be selectively controlled by means of the gate control adjustments illustrated in Fig. 5 tc assure the precise predetermined rate of flow of granules onto each deposit.
The parallelogram linkage also permits the automatic change in granule flow rate upon variation in the web speed.
The colors of the granules supplied by the feed means 88a-e are of a contrasting color to the first layer of granules already adhesively applied to the web. The term "color" when used in connection with the granules does not mean that each granule in a given hopper is identical in color since in fact various blends of colored granules are used to provide the desired overlay shades. Accordingly, the use of the word "color" should be interpreted broadly to include mixtures of colored granules which, when viewed from a distance particularly, give the effect of different color shades or intensities.
The several disclosed techniques for providing , 2 ~ ;3 variety to the appearance of the finished shingles can be used either individually or in combination to achieve the desired shingle random variation. Preferably, the techniques are combined as in the preferred embodiment described to achieve the maximum degree of random shingle efEect. These techniques include the described use of irregular shapes o~
the overlay deposits, the omissions of selected ones of the deposits from the patterns, and the computer determined random omission of the predetermined color coverage of certain of the deposits to permit the coverage of the omitted deposits by the backfall curtain.
Utilizing all three of these techniques, the preferred embodiment disclosed will produce a considerable variation in shingle appearance and, although a repetition of a particular shingle overlay pattern is possible, it will be widely spaced and, in the context of a roofing application, should be unnoticeable.
The technique of providing irregular shapes, sizes and spacings of the print wheel bars has already been described in detail. Similarly, the technique of omitting the ones of the bars from the print wheel rows has been illustrated and described. The third technique, the omission of randomly chosen granule drops is not readily illustrated but as pxeviously mentioned, involves simply the programmin~
of the computer to~omit the rotation of one of the granule rolls 112a-i during each granule drop cycle. For example, in one cycle the computer may randomly omit the rotation of roll 112b, thus permitting the deposits 104b and 106b to be covered by the backfall roll 156 rather than the granules in .....
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hoppers 116b and 118b. In the next pattern cycle, roll 112h may be randomly selected and the deyosits 104h and 106h would then similarly be covered by the backfall mixture rather than the predetermined color in the hoppers 116h and 118h. In the next pattern drop, the computer may decide not to omit any of the drops, and so forth.
Although the overlay section 46 of the equipment is shown located above the cooling section 44, it will be apparent that this may also be located at ground level.
Manifestly, changes in details of construction can be effected by those skilled in the art without departing from the invention.
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- - - ` 1 PATENT
METIIOD AND APPARATUS FOR MAKING ROOFING SHINGLES
BACKGROUND OF THE INVENTION
l. Field of the Invention The present invention relates generally to the manufacture of asphalt roofing shingles and relates more particularly to a method and apparatus ~or applying random overlay patterns of contrasting granular material to a granular surfaced shingle web to produce shingles having a widely varying appearanca.
2. DescriPtion of the Prior Art ~' , A variety of methods have been proposed in the manufacture of asphalt shingles to achieve a shingle appearance suggesting that of wood shake or shingles.
In U.S. Patent 1,791,571, issued February 10, 1931, the shingle tabs formed by the tab slo~s were each coated with a different color or shade of granule to mimic the appearance of individual shingles. This patent further taught the method of employing a color pattern length different from the shingle length to provide a variety of different shingles depending on the number of color bands in the pattern.
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In U.S. Patent 2,074,147, issued March 16, 1937, :
a plurality oE colors were utilized for the shingle tabs, but the color boundaries were not limited to the shingle tab slots. This patent discloses the use of overlay granule stripes on the tab portions of the shingles with the dividing lines between differently color stripes occurring on the face of the shingle tabs.
In U.S. Patent 2,074,131, issued March 16, 1937, the method was disclosed of applying transverse overlay stripes of different colored granular material at spaced intervals.
U.S. Patent 2,661,303, issued December 1, 1953, discloses the application of a pattern of stripes of different colored granules deposited transversely on a web of roofing material, and the cutting of the shingles to a length different than the pattern length to achieve a variation in shingle appearance.
These concepts are also employed~in U.S. Patents 4,295,445, issued October 20, 1981, and 4,352,837, issued October 5, 1982, which disclose an apparatus and method for producing spaced overlay bars of varying color shades on tab portions of a shingle web and cutting the web to a shingle length different than the pattern length.
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SUMMARY OE THE INVENTION
The present invention provides a method and apparatus for making asphalt shingles and particularly for r ~ J ~ ~
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applying overlay patterns of granular material to a web of rooEinq material previously surfaced with a first layer of yranular material to produce shingles of randomly varied appearance. The overlay patterns are produced by print wheels having adhesive applying bars of establishing deposits different shapes, sizes and spacings. Further varlation is achieved by the staggered omission of one or more print bars from the print wheels. Additionally, the random omission of granule drops of predetermined colors provides a granule color change to to the backfall mixture shade on randomly selected deposits oE each drop cycle.
The invention further includes apparatus for automatically changing the overlay granule ~low rate to ij accommodate web speed changes. This arrangement includes a parallelogram linkage connection of the hopper roll gate control levers to a master control lever, the position of which is automatically changed in accoxdance with web speed changes by means of a linear actuator controlled`by a web roll tachometer.
The invention further provides apparatus for resiliently supporting the web of roofing material during the cyclical overlay granule drop, the resilient support comprising the use of a table resiliently supported by pneumatic springs or actuators.
i It is accordingly a first object of the present invention to provide a method and apparatus for making -~
roofing shingles having a random appearance.
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. ., ; An additional object of the invention is to provide a method and apparatus as described which provides the random shingle appearance by the application of overlay patterns of colored granule material to a roofing web having a first layer of granul~r material adhesively applied thereto.
A further object of the invention is to provide a method and apparatus as described which can be added to conventional roofing equipment with minimal modification thereto.
i A further object of the invention is to provide an improved apparatus for making overlay type roofing shingles comprising an improved means for supporting the web during the cyclic granule drop.
Still another object of the invention is to provide apparatus for controlling the granule feed means of an overlay type roofing apparatus and automatically,adjusting the granule feed rate in accordance with web speed changes.
Another object of the invention is to provide apparatus as described of a relatively simple construction and which, when operating, requires relatively little manual control or oversight.
Additional objec~s and advantages of -the invention will be more readily apparent from the following detailed description of an embodiment thereof when considered in -~
conjunction with the accompanying drawings.
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BRI~F DESCRIPTION OF T~IE DRAWINGS
Figs. la and lb taken together comprise a schematic side elevational view of asphalt shingle manufacturing equipment which incorporates the apparatus and employs the method of the present invention;
Fig. 2 is an enlarged side elevational view of the portion of Fig. lb outlined in dot/dash lines, the apparatus shown in Fig. 2 comprising the overlay section of the shingle manufacturing equipment;
Fig. 3 is a perspective view of the print wheel of the apparatus shown in Fig. 2;
Fig. 4a is an enlarged plan view taken along line 4-4 of Fig. 2, showing the imprint pattern produced on the web by the print wheel and showing in broken lines the coverage areas of the dropped granules;
Fig. 4b is a side elevational view of the web shown in Fig. 4a, schematically showing the mechanism for feeding granules onto the bars at the correct spacing;
Fig. 5 is a view similar to Fig. 4b showing additional details of the granule feed means and particularly the mechanism for automatically adjusting the granule flow rate upon change of speed of the web;
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Fig. 6 is an enlarged sectional view of the area enclosed in dot/dash lines in Fig. 6 showing one of the .
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granule feed mechanisms; and Fig. 7 is a schematic view showing the manner of driving and controlling the print wheel drive rolls and the granule feed mechanisms.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Figs. la and lb show schematically the manner in which conventional roofing shingle manufacturing equipment can be modified to incorporate the apparatus of the present invention which is disposed principally in the region enclosed by dot/dash lines in Fig. lb and shown in the enlarged view of Fig. 2. Since the apparatus shown in Figs.
la and lb aside from that portion depicted in Fig. 2 is conventional, it is illustrated schematically and will be only briefly described.
Starting at the left hand end of Fig. la, the shingle manufacturing equipment generally designated 10 includes a dry felt unwind stand 12 on which a roll of felt 14 is rotatably disposed and from which a web 16 of felt is fed into a dry felt looper-18. The looper serves as a reservoir of felt which can be drawn upon to permit the periodic replacement of the felt supply roll 14. From the looper 18, the web 16 passes into saturator tank 20 which is filled with asphalt 22. The web then passes through the strike in drum section 24 and thence into the saturated felt looper 26 wherein the asphalt saturated web is permitted to cool. If the web is formed of fiberglass rather than felt, the asphalt saturation step is omitted.
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The web next passes into a coater 28 wherein an adhesive material such as asphalt/mineral dust mixture is applied to both sides of the web by coating rolls. From the coater, the web passes into what is known as the slate section 30 wherein colored granular material of various shades is stored in hoppers 32 for delivery to a blender 34 disposed above the web. The blender provides a predetermined drop pattern of the particulate material onto the web upper -surface. Web areas not covered by the blender 34 are covered by a mixture of granular material from a back fall bin 36 which collects granules falling from the web after passage around a surfacing roll 38 which serves to embed the granules in the adhesive web coating. The web is divided longitudinally into lanes, conventionally four lanes, each lane later being cut transversely at uniform intervals into individual shingles. As is conventional, a different granular material is deposited on the head lap portion of the shingle lanes than on the exposed tab portion of the lanes.
Powdered talc, mica, sand or other mineral release material is applied at 40 to the back of the web to prevent the web from sticking to the equipment as it passes through the remaining sections. Upon passage of the web over reversing roll ~2, the release material is embedded in the adhesive coating of the web and provides a smooth, non-stick web under surface. The web then travels to the cooling section 44 comprising a plurality of looping rolls. Partway through the cooling section 44, the web is directed into the overlay section 46 which is shown in Fig. 2 and considered in detail below. The web returns to the cooling section 4~ from .
the overlay section 46 and thence passes into the finished product looper 48 t thence to a cutter 50 wherein the web is sliced longitudinally and cut transversely into discrete roofing shingles. Stacking and packaging equipment (not shown) is provided downstream of the cutter.
The overlay section 46 wherein the novel method of the invention is carried out and wherein the novel apparatus of the invention is disposed, is illustrated in Fig. 2. With reference to that figure, the web 16 is seen rising vertically from the cooling section 44 and passes around turning roll 52 into a horizontal run 54 with the granular material coated face presented downwardly. The web run 54 passes over a pair of print wheels 56 and 58 mounted in spaced relation on a common shaft 59. The web engages print bars 60 and 62 peripherally disposed respectively on the print wheels 56 and 58 to receive spaced adhesive deposits on imprints thereon. As shown in Fig. 3, the bar 60 and 62 are of irregular shapes and sizes as described more fully hereinafter.
The print wheels 56 and 58 are driven in rotation at a speed commensurate with the speed of the wek such that the peripheral speed of the bars matches the speed of the web surface engaged therewith. The rotating print wheels are disposed within adhesive pan 64 and are partially immersed in an adhesive 66 such as hot liquid asphalt within the pan.
Suitable heating means (not shownj are provided in the pan to maintain the asphalt in a liquid condition. The print wheels and pan are mounted on a car 68 having wheels 70 engaged with transverse tracks 72 mounted on frame assembly 74. The pan , , .
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and print wheels may accordingly be moved transversely out from under the web when necessary for service, repairs or replacement. Means (not shown) are provided for accurately positioning the print wheels transversely on the shaft 59 and the car 68 on the tracks 72 to provide the correct transverse registration of the adhesive imprints on the web.
Following passage over the print wheels, the web 16 passes around th~ reversing roll 76 and then passes onto the horizontal t`able 78 which is resiliently supported above horizontal frame assembly 80 by pneumatic actuators 82 disposed at each of the four table corners. ~ suitable pneumatic actuator for this purpose is sold by Firestone Tire and Rubber Co. under the trademark AIR STROXE. By varying the pneumatic pressure in the actuators, the height o~ the table or one side of the table may be adjusted, and accordingly the table may be lowered entirely or one side of the table may be lowered as desired during the threading of the web as well as for cleaning, repair or general maintenance of the granular material feed means disposed just above the table as described below. The normal table operating height may be established and maintained by the threaded stop members 84 which extend from the table downwardly through the frame assembly 80 and comprise adjustable stop nuts 86 on the lower ends thereof.
Disposed above and closely adjacent the table 78 and the web 16 passing thereover are a plurality of granule feed means 88a-i. The number of granule feed means is equal to the number of rows of bars 60 and 62 spaced around the print wheels 56 and 58, and the spacing of the granule feed _g_ .
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means longitudinally along the web run is exactly the same as the peripheral spacing of the print wheel bars, which it will be noted are not uniform. This arrangement per~its a cyclical simultaneous granule feed from the feed means 88a-i onto the web 16 when the feed means are in aligned juxtaposition to the adhesive imprints provided on the web surface by the print wheel bars.
Fig. 4a provides a plan view of the web with the imprint pattern of adhesive deposits advanced along the table to the point at which the granule drop is just starting. The web 16 is in the illustrated embodiment of a width equal to the width of four shingles and accordingly comprises four lanes which in Fig. 4a are designated as lanes A~D, which lanes are divided in the s~itting and cutting operation at the cutter 50 along the broken lines 90, 92 and 94 of Fig.
4a. Each web lane is cut transversely at the cutter 50 into discrete shingles and the size of a~shingle is shown in Fig.
4a at 96 wherein it may be seen that the shingle length is substantially shorter than the pattern laid down in one revolution of the print wheels. The tab portion 98 of the shingle 96 is divided from the head lap portion 100 thereof by a broken line 102. As earlier indicated, the granule application in the slate section 30 which establishes a first granule layer on the web is conventionally carried out such that the head lap portion loo of the shingles is covered with a different type of granule (typically uncolored and hence less expensive) than the tab portion 98 which is exposed to view when the shingle is applied to a roof. Accordingly, the overlay pattern established in the overlay section ~6 of the . .
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apparatus is laid down only on the portions of the lanes which will become the tab portion of the shingles. The adhesive imprints established by the print wheel bars 60 and 62 appear respectively in Fig. 4a as adhesive deposits 104a-i and 106a-i. The deposits 104a-i straddle the dividing line 90 between lanes A and B in order to cover the tab portions of the shingles cut from those lanes, the tab portions of the eventual shingles of lane A abutting the tab portions of the eventual shingles of lane B. Similarly, the deposits 106a-i straddle the dividing line 94 between lanes C and D to cover only the abutting tab portions of the shingles of those lanes.
In order to obtain greater variation in shingle appearance, one or more of the deposits are preferably omitted in each of the longitudinal rows of adhesive deposits by omitting one or more bars 60 or 62 from the print wheels 56 and 58. As may be seen in Fig. 3, there is no counterpart bar 62 on wheel 58 which corresponds with the second bar from the top in wheel 56. With reference to Fig. 4, this creates a void transversely opposite the deposit 104c, or stated differently, there is no deposit 106c.
Similarly, in the row of deposits 104a-i, 104g is omitted by eliminating the bar 60 on the print wheel 56 which would normally be present to produce a deposit at this point.
Accordingly, there is no counterpart to the deposit 106g in the longitudinal row of deposits which straddles lanes A and B.
To gain even further variation in shingle , appearance, the individual deposit shapes vary in each row and do not correspond with the deposit transversely aligned therewith in the other row. For example, the shapes of each of the deposits 104a-i (104g omitted) are different, as are those of deposits 106a-i (106c omitted). Also, the shape of deposit 104a differs from that of its transverse counterpart 106a, 104b differs from 106b, etc. Each deposit may be irregularly shaped by utilization of transverse edges which are asymetrical with respect to the lane dividing 90 and 94.
Although the deposit shapes illustrated in Fig. 4a provide mirror images across the lines 90 and 94, the transverse deposit edges could comprise diagonals or irregular edge lines such that the deposits on adjacent shingles would not be mirror images.
The employment of adhesive deposits having irregular transverse borders is permissible in view of the granule drop coverage provided by the granule feed means 88a-i which is somewhat more extensive both transversely and longitudinally than the adhesive deposits. The deposits 104a-i are covered as shown schematically in Fig. 4a by the dash line outlines by granule coverages 108a-i (108g omitted). Similarly, the deposits 106a-i are covered by granule coverages llOa-g (llOc omitted). Although the width of the granule drop coverage is the same in each case, it will be noted that the length of each deposit (considered longitudinally of the run) varies with the size of the adhesive deposit and its location on the web. For example, the granule coverage 108b is significantly longer than coverage 108a to accommodate the larger size of the deposit 104b than the deposit 104a. Also, the deposit 108b is J ~ ~
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somewhat longer than the deposit 104b in view of the position of the deposit 106b which is somewhat to the right of the deposit 104b as viewed in Fig. 4a.
At the extreme right end of Fig. 4a, deposits 104a' and 106a' which were covered in the previous granule drop cycle are schematically shown as covered with granules only on the adhesive deposit. In reality, loose granules would be present around the periphery of each of the deposits in view of the surplus coverage of the deposits as described above.
As described below, these granules will be collected and reused.
The details of the feed means 88a-i are shown in Figs. 2, 4b, 5, 6 and 7. the feed means 88a-i are substantially identical and include a fluted granule roll 112a-i extending substantially the width of the web as shown in Fig. 7 and disposed above the table 78 closely adjacent the web surface. The rolls are intermittently driven in rotation by a mechanism described beIow. The granule feed rolls as shown in Figs. 4b, 5 and 6 when rotated move counterclockwise as viewed in those figures and serve to deliver granules onto an adjacent guide plate 114a-i which is preferabIy of a cycloidal shape with its lower edge closely spaced to the upper surface of the web. The cycloidal guide plate shape serves to~urge the granules in the direction of sheet travel to avoid bouncing and scattering of the granules. The rapid intermittent rotation of the granule rolls 112a-i actually impels the granules along the guide plates and thus augments the effect of gravity to shorten the granule descent time. The guide plates further serve to .., .
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' protect the granule rolls from asphalt deposits during theweb lace-up or in the event of a web breakage.
As shown most clearly in Fig. 7, a pair of hoppers is disposed over each granule roll 112 in transverse alignment with the rows of deposits 104 and 106 on the web.
Hoppers 116a-i are provided in transverse alignment with the deposits lO~a-i and hoppers 118a-i are provided in alignment with the deposits 106a-i. Since the deposits 104g and 106c have been omitted, hoppers 116g and 118c likewise are omitted.
As shown in Fig. 6, the hoppers each have a transverse opening 120 closely adjacent the roll surface, the size of which is selectively controlled by means of the sliding gate 122 having rack 124 thereon in engagement with the gear 126 fixedly mounted to shaft 128. The described hopper gate control components are common to each of the hoppers 116a-i and 118a-i. The shafts 128 link the hoppers disposed above a common granule roll 112; for example, the shaft 128a shown in Fig. 6 extends transversely and al50 controls the gate of hopper 118a.
Control levers 130a-i are fixedly mounted to the shafts 128a-i such that movement of the levers 130a-i to the left as viewed in Figs. 5 and 6 will result in an increased opening of the hopper gates 122a-i. Conversely, movement of the levers to the right will cause a decrease in the opening of the hopper gates.
To provide an automatic regulation of the hopper , ,:
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openings commensurate with the speed changes of the web, a master speed control lever 132 pivotally mounted at its lower end at 13~ to the machine frame is provided. Links 136a-i join the master control lever with the upper ends of the speed control levers 130a-i to form a plurality of parallelogram linkages such that a movement of the master control lever will result in a commensurate movement of the levers 13Oa-i and a consequent commensurate opening or --closing of the hopper gates. Turnbuckles 138a-i are provided in the links 136a-i to permit individual adjustment of the hopper flow rates. A plurality of attachment holes are also provided at the upper end of the levers 130a-i to permit alternate attachment positions for the links if necessary to establish the desired individual rate flow of a given hopper.
The position of the master control lever 132 is controlled by a linear actuator 140 mounted on the machine frame and attached to the master control lever 132 by means of actuator connecting rod 142. A tachometer 144 mounted on a web roll senses the web speed and sends a signal through a transducer 146 to the linear actuator 140 to effect a hopper opening commensurate with web speed. A higher web speed will require a larger hopper opening which is obtained by a movement of a master control lever 132 to the left as viewed in Fig. 5. A slowing of the web speed will necessitate a closure of the hopper openings which is obtained by actuator movement of the lever 132 to the right.
As shown in Fig. 2, the hoppers 116a-i and 118a-i are maintained in a filIed condition with granules from larger sized supply bins generally designated 14~ which are '. :
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connected to the hoppers by granule feed hoses 150a-i.
The web 16 after passing under the granule feed means ~a-i advances to the slate drum 152 (Fig. 2) which serves to embed the granules in the adhesive deposits. The slate drum further serves to entrap the loose granules on the web which are not disposed over an adhesive deposit and these fall from the inverted web after passage over the slate drum and drop into the backfall hopper 15~ which thus accumulates a mixture of the various granule colors. A continuous curtain of this backfall mixture is returned to the web by the feed roll 156 associated with the hopper 154 to cover any adhesive deposits which may have escaped coverage by the feed means ~8a-i. A granule feed hose 158 connects the hopper 154 with a supply bin 160 to assure a continuous supply of granules in the hopper 154.
In order to provide a still more random appearance of the shingles and secondarily to utilize the supply of backfall granules accumulated in the hopper 154, random ones of the feed means 88a-i are interrupted from feeding granules during the cyclical pattern granule drops. This random omission is controlled by a computer 162 (Fig. 7) governed by an algorithm which preferably does not sequentially repeat the omission of a given feed means operation. The algorithm further may be written so as to randomly select no feed means to be interrupted in a given pattern granule drop since this would maximize the random effect to be achieved. The adhesive deposits which are not covered by the selected inactivated feed means will be covered by the curtain laid down by the backfall hopper feed roll 156. Since this will .
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provide a color blend different from that supplied by the interrupted feed means, a variation in the appearance of the overlay pattern will result~
Following passage over the slate roll 152, the web passes around draw roll 163. As shown in Fig. 7, a speed changer 164 is provided in a drive mechanism between these rolls to adjust the web tension hetween the rolls and to accommodate the recirculated granules trapped between the slate roll and the web which increase the effective diameter of the roll. Adjustment of the speed changer permits the adjustment of the degree of embedment of the granules into the adhesive deposits ~y controlling the pressure of the web against the slate drum.
From the draw roll 163, the web passes over roll 164 into the loose granule reclaim hopper 166 wherein it is engaged by a whipper 168 comprising rotating flexible elements which slap the underside of the moving web to provide dislodgement of loos~ granules which fall to the bottom of the hopper 166 for collection and reuse.
The web then passes sequentially over rolls 172, 174, 176 and 178 and returns~to the cooling section 44 for eventual passage into the finished product looper 48 and the cutter 50.
, With reference to Fig. 7, the manner in which the rotating components of the overlay section are driven and controlled is schematically illustrated. A motor 180 provides power to directly drive the slate drum 152 through :: .
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schematically illustrated shaft connection 182 and chain or timing belt 184. ~n additional chain or timing belt con-nection 186 to shaft 188 provides a direct drive of the reversing roll 76 at the same speed as the slate drum 152.
The speed changer 164 is driven through shaft 182 by chain or timing belt connection 190 and, as previously mentioned, permits adjustment of the drive speed of the draw roll 163 to permit adjustment of the web tension around the slate drum 152.
The print wheels 56 and 58 are rotated on their common shaft 59 by the connection thereof to the shaft 182 through chain or timing belt connection 192. A speed changer 194 is provided in this drive connection to permit the accurate correlation of the print wheel peripheral speed with the web speed.
The granule feed rolls 112a-i are driven through the shaft 182 by means of chain or timing belt drive 196 through electrically controlled clutches 198a-i which are in turn controlled as schematically indicated in Fig. 7 by the computer 162. The computer is appropriately programmed to energize the clutches 198a-i to rotate the granule rolls 112a-i at the precise moment when the pattern of adhesive deposits is presented therebeneath, which moment is shown in Figs. 4a and 4b. The computer is also programmed to maintain the rotation of the rolls 112a-i selectively to provide the coverage required ~or the deposit shapes presented. For example, the roll 112b must be rotated for a time period longer than 112a or 112c since the granule coverage required is substantially greater to cover the large adhesive deposits , , 104b and 106b. Accordingly~ the computer must be programmed to provide the proper operation interval for each of the granule rolls 112a-i.
In order to facilitate start-up after maintenance, cleaning and reassembly of the overlay section components, a phase shifter 200 is provided linked by timing belt or chain 202 to the print wheel shaft drive. The phase shifter is linked with,a trigger switch 204 connected to the computer to permit manual adjustment to reorient the controls and reestablish synchronous placement of the granule coverage with the adhesive deposit pattern upon actuation of the trigger switch 204 to initiate granule flow.
The operation of the apparatus components have already been described and will accordingly be only briefly summarized. The web 16 moving over the print wheels 56 and 58 receives adhesive deposits of hot asphalt from the bars 60 and 62 of the print wheels. The bars 60 and 62 vary in size, shape, and spacing and, as shown in Figs. 3 and 7, one bar may be omitted from the pattern provided by each print wheel.
The deposit pattern necessarily has a length equal to the circumference of the print wheels taken around the bars thereon. The length of the pattern is shown in Fig. 4a and, it will be noted, is substantially longer than a shingle, in fact, is preferably more than twice as long as an individual shingle.
When the pattern of deposits arrives beneath the granule feed means 88a-i in correct alignment therewith as shown in Figs. ~a and 4b wherein the lower end o~ the guide .. _ _ . , _ . ....... .
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plates ll~a-i are aligned with the leading edges of the intended granule coverage patterns 108a-i and llOa-i, the computer 162 actuates the clutches 198a-i to simultaneously begin rotation oE the granule feed rolls 112a-i. As indicated, the feed roll rotation length is determined by the needed granule coverage. Since the granule drop occurs simultaneously from all of the granule feed means, it is advantageous to resiliently support the web to prevent web damage and for this reason, the pneumatic table supports 82 are provided.
The flow rate of the granules onto the deposits can be selectively controlled by means of the gate control adjustments illustrated in Fig. 5 tc assure the precise predetermined rate of flow of granules onto each deposit.
The parallelogram linkage also permits the automatic change in granule flow rate upon variation in the web speed.
The colors of the granules supplied by the feed means 88a-e are of a contrasting color to the first layer of granules already adhesively applied to the web. The term "color" when used in connection with the granules does not mean that each granule in a given hopper is identical in color since in fact various blends of colored granules are used to provide the desired overlay shades. Accordingly, the use of the word "color" should be interpreted broadly to include mixtures of colored granules which, when viewed from a distance particularly, give the effect of different color shades or intensities.
The several disclosed techniques for providing , 2 ~ ;3 variety to the appearance of the finished shingles can be used either individually or in combination to achieve the desired shingle random variation. Preferably, the techniques are combined as in the preferred embodiment described to achieve the maximum degree of random shingle efEect. These techniques include the described use of irregular shapes o~
the overlay deposits, the omissions of selected ones of the deposits from the patterns, and the computer determined random omission of the predetermined color coverage of certain of the deposits to permit the coverage of the omitted deposits by the backfall curtain.
Utilizing all three of these techniques, the preferred embodiment disclosed will produce a considerable variation in shingle appearance and, although a repetition of a particular shingle overlay pattern is possible, it will be widely spaced and, in the context of a roofing application, should be unnoticeable.
The technique of providing irregular shapes, sizes and spacings of the print wheel bars has already been described in detail. Similarly, the technique of omitting the ones of the bars from the print wheel rows has been illustrated and described. The third technique, the omission of randomly chosen granule drops is not readily illustrated but as pxeviously mentioned, involves simply the programmin~
of the computer to~omit the rotation of one of the granule rolls 112a-i during each granule drop cycle. For example, in one cycle the computer may randomly omit the rotation of roll 112b, thus permitting the deposits 104b and 106b to be covered by the backfall roll 156 rather than the granules in .....
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hoppers 116b and 118b. In the next pattern cycle, roll 112h may be randomly selected and the deyosits 104h and 106h would then similarly be covered by the backfall mixture rather than the predetermined color in the hoppers 116h and 118h. In the next pattern drop, the computer may decide not to omit any of the drops, and so forth.
Although the overlay section 46 of the equipment is shown located above the cooling section 44, it will be apparent that this may also be located at ground level.
Manifestly, changes in details of construction can be effected by those skilled in the art without departing from the invention.
Claims (25)
1. A method of making overlay roofing shingles comprising the steps of;
providing a web having a first layer of granular material adhesively applied thereto, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, transversely cutting said web to form shingles having a length different than said pattern length, randomly selecting one or more of the deposits of each said deposit pattern application, omitting the covering of each selected one of said deposits with the granular material of a predetermined color, and covering said selected deposits with granular material of a different color than said predetermined color.
providing a web having a first layer of granular material adhesively applied thereto, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, transversely cutting said web to form shingles having a length different than said pattern length, randomly selecting one or more of the deposits of each said deposit pattern application, omitting the covering of each selected one of said deposits with the granular material of a predetermined color, and covering said selected deposits with granular material of a different color than said predetermined color.
2. The invention as claimed in claim 1, wherein said granular material of a different color comprises a mixture of said granular materials of predetermined colors.
3. The invention as claimed in claim 1, wherein said step of randomly selecting does not sequentially repeat the selecting of the same one or mone of said deposits.
4. A method of making overlay roofing shingles comprising the steps of:
providing a web having a first layer of granular material adhesively applied thereto, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, a plurality of said deposits within said pattern having one or more transverse edges which are not perpendicular to the longitudinal axis of said web thereby rendering said deposits non-rectangular, said deposits being of non-uniform size and spacing, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, and transversely cutting said web to form shingles having a length different form said pattern length.
providing a web having a first layer of granular material adhesively applied thereto, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, a plurality of said deposits within said pattern having one or more transverse edges which are not perpendicular to the longitudinal axis of said web thereby rendering said deposits non-rectangular, said deposits being of non-uniform size and spacing, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, and transversely cutting said web to form shingles having a length different form said pattern length.
5. The invention as claimed in claim 4, wherein said web is continuously moving at a substantially uniform rate during said adhesive applying and covering steps, and wherein said covering step is carried out by the dropping of granules on said deposits, the dropping of said granules on said web being timed to drop granules ahead of each said deposit and terminate said granule drop after passage of each said deposit.
6. The invention as claimed in claim 5, wherein the granules are dropped on each of said deposits of each pattern simultaneously.
7. A method of making overlay roofing shingles comprising the steps of;
providing a web having a first layer of granular material adhesively applied thereto, said web having a width equal to the width of an even number of roofing shingles, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, said deposits straddling the lanes from which individual shingles are to be cut, said adhesive deposits extending transversely across the tab portions of the shingles of said lanes, a plurality of said deposits having one or more transverse edges which are not perpendicular to the longitudinal axis of said web, thereby rendering said deposits non-rectangular, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, and transversely and longitudinally cutting said web to form shingles having a length different than said pattern length.
providing a web having a first layer of granular material adhesively applied thereto, said web having a width equal to the width of an even number of roofing shingles, applying adhesive on said web first layer in a repeating pattern of spaced adhesive deposits, said deposits straddling the lanes from which individual shingles are to be cut, said adhesive deposits extending transversely across the tab portions of the shingles of said lanes, a plurality of said deposits having one or more transverse edges which are not perpendicular to the longitudinal axis of said web, thereby rendering said deposits non-rectangular, covering each said deposit with a granular material of a predetermined color which provides a visual contrast with said granular material of said first layer, and transversely and longitudinally cutting said web to form shingles having a length different than said pattern length.
8. The invention as claimed in claim 7, wherein said web has a width equal to the width of four shingles.
9. The invention as claimed in claim 8, wherein two rows of deposits are applied to said web, each roil of deposits being applied to the abutting tab portions of shingles to be formed from said web.
10. The invention as claimed in claim 9, wherein said deposits are transversely aligned, and wherein said pattern omits one or more of said deposits from each said row of deposits, said omitted deposits being non-aligned.
11. The invention as claimed in claim 10, wherein the transversely aligned deposits differ in size and shape.
12. Apparatus for applying overlay patterns of granules to a moving web of roofing material comprising;
means for applying adhesive deposits in a repeating, predetermined pattern on one surface of said web, a substantially planar support table for receiving a substantially horizontal run of said web, said table having a length exceeding the length of said deposit pattern, means for moving said web across said table at a substantially constant predetermined rate with said deposits disposed on the upper web surface, feed means disposed above said table for simul-taneously dropping granules onto a plurality of said adhesive deposits, and means for resiliently supporting said table to absorb the impact of said dropping granules.
means for applying adhesive deposits in a repeating, predetermined pattern on one surface of said web, a substantially planar support table for receiving a substantially horizontal run of said web, said table having a length exceeding the length of said deposit pattern, means for moving said web across said table at a substantially constant predetermined rate with said deposits disposed on the upper web surface, feed means disposed above said table for simul-taneously dropping granules onto a plurality of said adhesive deposits, and means for resiliently supporting said table to absorb the impact of said dropping granules.
13. The invention as claimed in claim 12, wherein said means for resiliently supporting said table comprises a plurality of pressurized pneumatic support means.
14. The invention as claimed in claim 12, wherein said means for resiliently supporting said table comprises a plurality of pneumatic actuators.
15. The invention as claimed in claim 14, wherein said pneumatic actuators are disposed at the four corners of said table, and actuating means for selectively actuating said actuators to raise and lower said table or to tilt said table.
16. The invention as claimed in claim 15, wherein said table comprises stop means for establishing a normal raised operating position of said table.
17. Apparatus for making overlay roofing shingles comprising;
means for advancing a web having a first layer of granular material adhesively applied thereto into an overlay section, means in said overlay section for supporting said web in substantially horizontal disposition, means for applying adhesive deposits in a repeating predetermined pattern over said web first layer prior to passage of said web over said means for supporting said web, a plurality of feed means above said means for supporting said web for simultaneously dropping granules of a predetermined color onto each of said adhesive deposits when each deposit pattern is presented therebeneath, means for randomly selecting one or none of said deposits in each said pattern, means for interrupting the feed means corresponding to each randomly selected one of said deposits to prevent granule coverage of said selected deposits with their predetermined colors, and means for covering said selected deposits with granular material of a different color.
means for advancing a web having a first layer of granular material adhesively applied thereto into an overlay section, means in said overlay section for supporting said web in substantially horizontal disposition, means for applying adhesive deposits in a repeating predetermined pattern over said web first layer prior to passage of said web over said means for supporting said web, a plurality of feed means above said means for supporting said web for simultaneously dropping granules of a predetermined color onto each of said adhesive deposits when each deposit pattern is presented therebeneath, means for randomly selecting one or none of said deposits in each said pattern, means for interrupting the feed means corresponding to each randomly selected one of said deposits to prevent granule coverage of said selected deposits with their predetermined colors, and means for covering said selected deposits with granular material of a different color.
18. The invention as claimed in claim 17, wherein said means for covering said selected deposits with granular material of a different color comprises means for collecting loose granules of said predetermined colors from said web, and means for applying a mixture of said collected loose granules to said selected deposits.
19. The invention as claimed in claim 17, wherein said means for randomly selecting one or none of said deposits does not sequentially repeat the selection of the same one or none of said deposits.
20. Apparatus for applying overlay granules to a moving web of roofing material comprising;
a frame, means on said frame for supporting said moving web, a plurality of granule hoppers on said frame disposed above said moving web, a granule feed roll disposed below each said hopper, an opening in each said hopper, adjustable closure means for selectively varying the size of each said hopper opening, a control lever connected to each said adjustable closure means, movement of said control lever effecting a resultant movement of said closure means, a master control lever pivotally mounted on said frame, means connecting each said control lever with said master control lever to effect a commensurate movement of each said control lever upon movement of said master control lever, an actuator for controlling movement of said master control lever, and means responsive to changes in speed of said moving web for controlling said actuator to thereby effect a positioning of said master control lever, said plurality of said control levers, and said closure means in accordance with web speed.
a frame, means on said frame for supporting said moving web, a plurality of granule hoppers on said frame disposed above said moving web, a granule feed roll disposed below each said hopper, an opening in each said hopper, adjustable closure means for selectively varying the size of each said hopper opening, a control lever connected to each said adjustable closure means, movement of said control lever effecting a resultant movement of said closure means, a master control lever pivotally mounted on said frame, means connecting each said control lever with said master control lever to effect a commensurate movement of each said control lever upon movement of said master control lever, an actuator for controlling movement of said master control lever, and means responsive to changes in speed of said moving web for controlling said actuator to thereby effect a positioning of said master control lever, said plurality of said control levers, and said closure means in accordance with web speed.
21. The invention as claimed in claim 20, wherein said means connecting each said control lever with said master control lever comprises an adjustable link.
22. The invention as claimed in claim 20, wherein said means response to changes in speed of said web comprises a tachometer associated with a roll around which passes said moving web.
23. Apparatus for applying overlay patterns of granules to a moving web of roofing material comprising;
an adhesive pan for containment of a liquid adhesive, a pair of print wheels rotatably disposed within said adhesive pan for partial immersion in the liquid adhesive container therein, a plurality of spaced bars on the periphery of each of said print wheels, the bars of said print wheels being arranged in transverse alignment, one bar on each said print wheel being omitted, the omitted bars not being transversely aligned, means for rotating said print wheels at a peripheral speed equal to the speed of said moving web, means for directing said web into engagement with said print wheels to provide deposits of adhesive on said web in repeating patterns, said deposits having the shapes of said print wheel bars, and means for applying granules to said deposits to provide a coverage of said deposits with granules of a predetermined color.
an adhesive pan for containment of a liquid adhesive, a pair of print wheels rotatably disposed within said adhesive pan for partial immersion in the liquid adhesive container therein, a plurality of spaced bars on the periphery of each of said print wheels, the bars of said print wheels being arranged in transverse alignment, one bar on each said print wheel being omitted, the omitted bars not being transversely aligned, means for rotating said print wheels at a peripheral speed equal to the speed of said moving web, means for directing said web into engagement with said print wheels to provide deposits of adhesive on said web in repeating patterns, said deposits having the shapes of said print wheel bars, and means for applying granules to said deposits to provide a coverage of said deposits with granules of a predetermined color.
24. The invention as claimed in claim 23, wherein a plurality of said print wheel bars are formed in a non-rectangular shape.
25. The invention as claimed in claim 24, wherein said means for applying granules to said deposits applies a plurality of rectangular granule coverages to said web aligned with said deposits, said coverages extending transversely and longitudinally beyond said deposit edges to assure a complete granule coverage of said deposits.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US514,408 | 1983-07-18 | ||
| US51440890A | 1990-04-26 | 1990-04-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2041200A1 true CA2041200A1 (en) | 1991-10-27 |
Family
ID=24047004
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2041200 Abandoned CA2041200A1 (en) | 1990-04-26 | 1991-04-25 | Method and apparatus for making roofing shingles |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2041200A1 (en) |
-
1991
- 1991-04-25 CA CA 2041200 patent/CA2041200A1/en not_active Abandoned
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Dead |