CA2181505A1 - Cutting and laminating process and apparatus - Google Patents

Abstract

An apparatus and process for cutting a continuous linear web of composition roofing material includes water knives that cut the web into strips. A first linear incision is cut in the web with a water knife to cut the web into two strips having linear edges as the web as it is transported past the knife. Adhesive is applied to a portion of one surface of one strip of the web. The strips are then spatially aligned and laminated. The laminated strip is then cut along a non-linear path by a water knife that is movable relative to the moving strip, and which moves through a predetermined pattern at a controlled rate. A
controller continuously determines the rate of web movement past the movable water knife, and in response to the determined rate of web movement, controls the rate at which the water knife moves relative to the strip. The system cuts a desired serrated pattern in the laminated strips to produce two continuous laminated strips, each having one linear edge and one serrated edge. A knife cuts the linear laminated strips into desired lengths for shingles.

Description

218~5 ~U'l'LlNG AND T~TN~TING PROCESS AND APPARATUS

TECHNICAL FIELD
This invention relates to roofing shingles, and more specifically to a process and apparatus for cutting and laminating roofing shingles from a continuous web of composition roofing material.

R~CKGROUND INFORMATION
One common type of roofing shingle is the conventional three tab shingle. These shingles consist of a rectangular sheet of asphalt-based composition material that typically has two slits cut into one marginal edge of the sheet to produce multiple "tabs" on each shingle. When applied to a roof, the tabs on one shingle overlap the tabs on the next underlying shingle, giving the roof a multi-shingled appearance. Because each shingle is a single layer of sheet material, the roof has a regular and uniform planar appearance.
Unlike the planar appearance of a roof of three tab shingles, wooden shake roofing has many desirable visual attributes, including a more irregular surface that has greater thickness and depth. The irregular surface creates shadow lines on the roof, adding to the aesthetic appearance of the roof. Many attempts have been made to make an asphalt-based composition shingled roof have a more irregular appearance that more closely approximates the appearance of wood shakes. One approach has been to develop shingles having multiple layers of composition material laminated together. Such laminated shingles are sometimes called "dimensional,"
or "architectural" shingles. Laminated shingles take on many forms, most of which include a second or third layer of composition material laminated to a first base layer. As a result, each shingle is thicker. When the laminated shingles are applied to a roof the finished roof has increased thickness and irregularity, with a less regular pattern. This increases the effect of shadow lines on the roof, providing an appearance more 21815~
akin to wooden shakes. Thus, the irregularity and added thickness of laminated shingles greatly improves the aesthetic appearance of the roof.
Laminated shingles are well known in the art, and are generally of similar or equal size to conventional three tab shingles. The shingles typically include a base sheet of composition roofing material and one or more additional sheets of the same material laminated to the base sheet. Interdigitating tabs are cut into one side edge of one or more of the laminated sheets. The tabs may be slits, as with conventional three tab shingles, or more commonly may be wider cut out portions that tend to add to the irregular appearance of the shingle.
Asphalt composition materials from which traditional three tab shingles and laminated shingles are produced are well known in the art. This material may be briefly described as comprising a substrate of nonwoven felted fibers such as glass fibers that have been saturated with an asphalt (bituminous) waterproofing compound.
The asphalt composition often is modified with various additives to produce a shingle having improved handling characteristics and improved durability. After the asphalt has been applied to the fiber substrate, and while the asphalt is still hot and in a plastic state, a layer of granular material is deposited onto the weather-exposed surface of the asphalt composition web and is embedded therein. The granular material, which functions to block damaging ultraviolet radiation and thus improve the life of the roofing, also is colored to enhance the appearance of the product. The roofing materials manufactured in this manner are produced in continuous linear webs or membranes, which are either immediately processed into other products such as shingles or rolled for later processing.
Methods of manufacturing laminated shingles from continuous asphalt webs are likewise well known in the art.
In one example, a continuous linear web of composition roofing material is cut lengthwise into four linear strips with a series of knifes carried on a single rotating drum. Portions of the strips are aligned and laminated onto one another. According to this process, two continuous linear outer side edge strips are cut with knife blades carried on a rotating drum from the outer edges of the web, producing a center strip and the two outer edge strips. In most cases, the blades cut the web material from the bottom side of the composition material, which for purposes herein is the side of the web that does not have granular material embedded therein.
The two outer side edge strips will eventually serve as the base, or underlying layer of the laminated shingle. Another knife blade, carried on the same rotating drum as the knife blades just described, cuts a zig-zag or tabbed pattern in the center strip of the web. The blades of this knife are set in the pattern that is desired to be cut in the tabbed layer of the laminated shingle, and cut the center strip of the web into two continuous strips, each having a reciprocating tabbed pattern according to the pattern of the knife blades.
After the web is cut as described into four strips, adhesive is applied to a portion of the underside of each tabbed strip. The four strips thus produced, the two outer side edge strips and the two tabbed strips, each of which has adhesive applied to a portion of the underside, are aligned such that the outer edge strips underlie the adhesive coated portion of the tabbed strips in a desired manner. The tabbed strips are then laminated to the underlying base strips between joiner rolls to produce two continuous laminated strips comprising a tabbed strip laminated to a base strip.
A knife blade which is typically carried on a rotating circular drum then cuts the continuous laminated strips into shingles having an appropriate length dimension, which is typically around one meter.
The shingles thus produced are then stacked and bundled in a conventional manner for shipment.

~18~QS
A second kind of laminated shingle is made by first cutting one linear edge strip from the web with a first cutting blade carried on a rotating drum, resulting in two linear strips, one wider than the other. Adhesive is applied to a central portion of the underside of the wider strip, and the narrower strip is then aligned with the glue coated portion such that the center lines of the two strips align, and the strips are laminated together between joiner rolls.
The laminated strips are then cut into two separate strips with a knife set in a zig-zag pattern to produce two continuous strips having reciprocal interdigitating tabs on one marginal edge. The opposite marginal edge is linear. The continuous strips are cut into shingles of appropriate length as described above. It will be appreciated that with this method the tabbed portions of the shingles have two layers with a complete cut out portion between the tabs, and that the zig-zag knife must cut substantially through two layers of the sheet material, and also a layer of adhesive.
One laminating system similar to those discussed above, and which utilizes knife blades to cut the continuous web is disclosed in U.S. Patent No.
4,233,100.
Laminating systems such as those just described are prone to many limitations and problems. One significant problem is that generally there must be separate laminating systems for each different style of shingle described above.
There are other limitations as well. For example, knife blades are known to dull and foul easily and regularly when cutting composition material, which as noted comprises asphaltic materials combined with various fibers and granular coatings. In particular, the circular knife blades that cut the two outer edge strips from the continuous web become dull quite rapidly because the composition material is quite dense, and also due to the granular materials found on one side of the web. As a result, these knife blades must be changed with regular frequency.

2181~5 Another significant problem is with the knife blades that cut the center strip into the tabbed strips. These blades, like the other blades in the system, require replacement for sharpening at regular intervals because the composition material dulls the blades rapidly.
Moreover, the knife blades on these tab cutting knives have an irregular pattern that necessarily has many angular portions including right angles between the various knife blades that are combined on the cylindrical drum to produce the tabbed portions of the shingles. It is difficult to sharpen blades having such angular patterns, and as such the sharpening process is labor intensive. Blades such as these having angular patterns are also prone to fouling with composition material, particularly at the angular intersections between two separate blades, which mandates cleaning at regular intervals. Also, these zig-zag blades may dull at a faster rate than the circular blades, which in one embodiment described above are carried on the same rotating drum. This creates an inefficient situation where one blade may require sharpening before the other blades in the system.
The tab cutting blades also must be changed any time the desired tab pattern is to be changed. This requires that the processing line be shut down.
Another limitation with traditional laminating systems is that in most instances the adhesive must be applied to the tabbed strips after being cut by the tab cutting blades. This is because the knife blades that cut the tabbed portion of the strip, which as noted cut the center strip of the web from the lower side, would quickly become fouled if the adhesive were applied prior to the cutting operation. As a result, adhesive cannot be applied to the entire underside surface of the tab strips and the tabbed strips are therefore not adhered completely to the underlying base strips when the tabbed strips are laminated to the base strips. This becomes a concern in the finished shingles because the unglued portions of the tabbed strips are prone to being blown upwardly when the shingles are applied to a roof, for ` 21~1~05 example, by a strong wind. The unglued portions are also prone to being physically lifted away from the underlying strip, and damaged, for example during processing, packaging, shipping or when being applied to the roof.
Other limitations of traditional laminating systems include the shingles forming an undesired visible pattern on the roof, which is sometimes called a "zipper" pattern. This occurs when different batches of shingles, the tabs of which may have been cut with different tab cutting blades having slight differences in dimensions, are applied immediately adjacent to one another on a roof. Slight differences between the size and or shape of the tabs on individual shingles produced by different blades may produce distinctly visible patterns on the roof, which detract from the aesthetic appearance of the roof.
Another problem inherent with traditional manufacturing lines for laminated shingles is that the granular roofing material that is present on the weather-exposed surface of the composition material, referred to herein as the "upper" side, often is knocked out of the composition material by the knife blades.
This loose granular material, which has come to be known as "hitchhikers," tends to accumulate at various places in the processing line, resulting in the need for frequent cleaning. Cleaning requires that the processing line be shut down, which is costly and inefficient.
There exists a need therefore for a laminating system for the manufacture of dimensional roofing shingles that overcomes these and other problems inherent in traditional mechanical cutting systems.
Specifically, there exists a need for a laminating process and apparatus that is capable of cutting a predetermined pattern in a continuous moving web of material.

` 2181-503 SUMMARY OF THE lNv~L.llON
This invention relates to a process and apparatus for manufacturing laminated roofing shingles. The process and apparatus provide a more efficient method cutting the roofing materials and for laminating the cut pieces together. The process and apparatus of the present invention provide more flexibility in the manufacturing process than prior systems, with comparatively less down time for cleaning equipment and sharpening mechanical knife blades.
The invention is embodied in a laminating system that utilizes a series of water jets, or water knives, to cut a continuous web of composition roofing material as the web is conveyed past the water knives. In a first embodiment of the invention, a single fixed water jet at a first cutting station is mounted in close proximity to the lower surface of the moving web and cuts a linear incision in the web to produce two linear strips, one wider than the other, and each having parallel, linear side edges. Adhesive is applied to a central portion of the underside of the wider strip, and the narrower strip is aligned beneath the adhesive-coated portion of the wider strip and is laminated thereto. A second, movable water jet at a second cutting station downstream from the first cutting station then cuts the interdigitating tabbed pattern through the laminated portion of the strip, producing two reciprocally tabbed laminated strips with fully cut-out tabs. Each strip has one side edge having tabbed portions, and an opposite linear side edge.
The movable water knife is mounted such that it is movable at a controlled rate through a predetermined pattern relative to the moving center strip, thereby cutting the center strip into two separate strips along a non-linear path.
In a second embodiment, two stationary water knives at the first cutting station cut two outer edge strips from the web as the web moves past the water knives, resulting in three continuous strips, one wider than either of the other two, and each having linear side 21~1~05 edges. Adhesive is applied to the a central portion of the underside surface area of the wider strip as it is conveyed past an adhesive applicator downstream of the first cutting station. The wider strip is conveyed through the second cutting station past the movable water knife, which moves through a predetermined pattern at a controlled rate as described above, and a cutting stream of fluid is directed onto the lower surface of the strip, cutting the strip through the adhesive coated portion along a non-linear path. Each strip cut by the moving water knife has one linear side edge and one non-linear, tabbed side edge. The two tabbed strips cut by this water knife will eventually form the tabbed part of the laminated shingle.
Four strips are thus produced in this embodiment:
two continuous edge strips (or base strips) having linear, parallel side edges and a desired width dimension, and two continuous tabbed strips, each having one linear side edge and an opposite side edge cut along a non-linear path in the desired tabbed pattern, and each having a portion of the lower surface coated with adhesive. The base strips are then aligned each with a tabbed strip in a desired spacial relationship and are laminated thereto.
For each embodiment, a controller measures the rate at which the web is being conveyed past the movable water knife at the second cutting station. In response to the measured rate, the controller adjusts the rate at which the movable water knife moves through the predetermined pattern. The controller continuously measures the rate of web travel, and continuously adjusts the rate of movement of the movable water knife through its predetermined pattern in response to the measured rate of web travel to ensure that the non-linear incision cut into the web by the moving waterknife is consistent regardless of the rate at which the web is moving, and regardless of fluctuations in the rate at which the web is moving.
After the cutting operations are complete, standard mechanical knife blades then cut the continuous 218~505 laminated strips into shingles of desired length. The shingles thus produced are stacked and bundled.

BRIEF DESCRIPTION OF THE DRAWINGS
Fig. lA is a perspective view of one kind of a laminated roofing shingle manufactured according to the subject invention.
Fig. lB is a perspective view of a second kind of a laminated roofing shingle manufactured according to the subject invention.
Fig. 2 is a side elevation view of the laminating system and apparatus of the present invention, configured for manufacture of the shingle shown in Fig.
lA.
Fig. 3 is a top view of the laminating system and apparatus illustrated in Fig. 2, with portions of the apparatus cut away.
Fig. 4 is a side elevation view of the laminating system and apparatus of the present invention, configured for manufacture of the shingle shown in Fig.
lB.
Fig. 5 is a top view of the laminating system and apparatus illustrated in Fig. 4, with portions of the apparatus cut away.
Fig. 6 is a cross sectional, elevation view of the water knife at the first cutting station, taken along the line 6-6 of Fig 3.
Fig. 7 is a detailed view of the movable water knife of the present invention, taken along the line 7-7 of Fig. 3.
Fig. 8 is a second detailed view of the movable water knife shown in Fig. 7, taken along the line 8-8 of Fig. 7.
Fig. 9 is a series of incision patterns that the movable water knife shown in Figs. 7 and 8 could cut into a web according to the present invention.
Fig. 10 is a diagram of one predetermined pattern that the movable water knife of the present invention would follow to produce a tabbed strip having the pattern shown in the shingles shown in Figs. lA and lB.

2181~0~
Fig. 11 is a schematic diagram showing the movement of the movable water knife through one repetition of the movement pattern shown in Fig. 10.
Fig. 12 is a block diagram illustrating the individual programmed operations under the control of the programmable controller.

DESCRIPTION OF THE PREFERRED EMBODIMENTS
Figs. 2 through 5 show an embodiment of a laminating system 10 in accordance with the present invention for producing laminated shingles 12, two examples of which are illustrated in Figs. lA and lB respectively.
Referring to Fig. lA, each laminated shingle 12a comprises a base sheet 14a and a relatively wider upper sheet 16a that is adhered to the upper surface of base sheet 14a to form a laminated sheet that is generally rectangular. Thus, shingle 12a has two opposed parallel end edges 18a and two opposed parallel side edges 20a.
One side edge 20a is cut along a non-linear path to produce spaced apart cut-out portions 22a that alternate with tabs 24a. For purposes herein, the width dimension of shingle 12a is referenced with the letter X, and a the length dimension is referenced with the letter Y, as shown in Fig. lA.
A second type of laminated shingle having width dimension X and length dimension Y is illustrated in Fig. lB. In the shingle shown in Fig. lB, each shingle 12b comprises a base sheet 14b that is adhered to a relatively wider upper sheet 16b. The Fig. lB shingle is generally rectangular, having opposed parallel end edges 18b and opposed parallel longitudinal side edges 20b. Unlike the shingle illustrated in Fig. lA, base sheet 14b of shingle 12b does not have cut-out portions.
However, one side edge of upper sheet 16a is cut along a non-linear path and thus has spaced apart cut-out portions 22b that alternate with tabs 24b. Base sheet 14b is adhered to the lower surface of upper sheet 16b such that the outer edges of tabs 24b on sheet 16b are aligned with one marginal side edge 20b of sheet 14b.

~181~0a As such, as shown in Fig. lB, the cut-out portions 22b in sheet 16b do not extend through base sheet 14b.
In many instances, the laminated shingle will also include a strip of adhesive material on either the upper or lower surface of the shingle that is intended to act as a sealing strip between the shingle and the next overlying shingle. Although not illustrated herein, such a "seal down" strip is positioned on either the upper or lower surface of a shingle such that it adheres to the adjacent surface of an overlying (or underlying) shingle when applied to a roof.
The material used to manufacture shingles 12 is well known composition-type roofing material, which was described briefly above. In the embodiment described in this invention, and for purposes of reference herein, the granular material that is embedded into the asphaltic material is embedded into what is referred to as the upper surface 25a and 25b of upper sheets 16a and 16b of Figs. lA and lB, respectively, and the upper surfaces 23b of base sheets 14a and 14b (the upper surface 23b is not visible in shingle 12a of Fig. lA).
The surfaces referred to herein as the lower surfaces of the composition material do not have granular material embedded therein, although there may be a fine powder material or sand applied to the lower surface in processing. When the finished shingle is applied to a roof, it is the granular coated upper layer that is visible and exposed to the weather.
The two shingles 12a and 12b illustrated in Figs. lA
and lB, respectively, are just two examples of dimensional, laminated roofing shingles, and many alterations in the shape could be made according to the present invention. For example, the incision in the sheet or sheets that results in the tabs could be cut in a sinusoidal pattern. Another alternative would be to cut the tabs in a variable pattern. Several such additional patterns are illustrated in Fig. 9, and are discussed below. In addition, the appearance of the shingle may be varied by altering the position at which upper sheet 16 is adhered to base sheet 14. Additional 21~1~05 layers could also be laminated together, either in the base sheet 14 or in the upper sheet 16, or both, to provide a thicker laminated shingle that provides more contrast and shadow on the roof.
Regardless of which particular style shingle is desired, the shingles are manufactured on the laminating system 10 of the present invention. As described below, the manufacturing process varies according to the particular style that is being made. Laminating system 10 comprises a number of subsystems that cooperate in the manufacturing and laminating process and which are controlled by a programmable controller. Each such subsystem and the programmable controller are described in detail below with reference to two possible shingle configurations as shown in Figs. lA and lB.

Overview of SYstems A brief overview of the major subsystems in the laminating system follows.
Figs. 2 and 3 show one embodiment of the laminating system 10 of the present invention, configured to manufacture the style of shingle 12a illustrated in Fig.
lA. The same laminating system 10 is shown in Figs. 4 and 5; however, in Figs. 4 and 5 the laminating system is configured to manufacture the shingle 12b illustrated in Fig. lB. One advantage of the present invention is that both the shingles shown in Figs. lA and lB may be made on the same laminating system with little change-over required.
Referring generally to Figs. 2 through 5, a continuous linear web or membrane of composition roofing material (referred to as web 26) is fed into laminating system 10 from a manufacturing line (not shown) that produces the web, or from roll stock of the web. The various components of laminating system 10 that convey the web through the laminating system are referred to herein as the web handling system, only portions of which are illustrated. The web handling system includes pull rolls or drive rolls that are driven in a well known manner to move the continuous web through the 2181~()S

laminating system. The continuous web of roofing material is conveyed by the web handling system through the laminating system of the present invention in one direction only, that is, the direction illustrated by arrow A in Figs. 2 through 5, although in practice the direction of the web may vary at different locations in the system. However, for reference the direction of web movement defines an axis of longitudinal movement of the web, which for purposes herein is defined in the direction of arrow A in the Figures.
Web 26 has a specified width dimension, which is typically in the range of approximately thirty (30) inches to about thirty six (36) inches, but could vary widely depending upon the product being manufactured.
15 For the purposes herein, a reference plane is defined by the plane of the upper surface of the web 26 as it moves through the various components of the laminating system.
A length of continuous web 26 is accumulated over a series of accumulator rolls 28 located upstream (with 20 respect to the direction of movement A) of the various subsystems of laminating system 10. The first subsystem, or most upstream of which when referring to the direction of travel, A, is the first cutting station 100. Cutting station 100 includes a pair of water knives 104 and 106 (one of which is shown in Fig. 6).
Each water knife is selectively operable, and each is fixed in relation to web 26 when the system is in operation.
Regardless of the particular style of shingle that 30 is being manufactured, at least a portion of the web continues through a second cutting station 200 in which a movable water knife 204 (Figs. 7, 8) is mounted.
Water knife 204, which is described in detail below, is mounted within cutting station 200 in close proximity to 35 the lower side of web 26 and is positioned to direct a cutting stream of fluid, again typically water, against the lower surface of the web. Water knife 204 is mounted for movement relative to the moving web, and is controlled to move through a predetermined pattern at a 40 controlled rate relative to web 26, to cut the web into 'Z1~1 ~05 a pair of continuous strips, each of which has one linear side edge and an opposite side edge which is cut along a non-linear path by the cutting action of water knife 204.
As described below with reference to the specific shingles shown in Figs. lA and lB, the strips are laminated together, if not already laminated before conveyance through cutting station 200, and cut to form the individual shingles.
The laminating system of the present invention is monitored and controlled by a programmable controller 300, as illustrated in Fig. 12, which is a schematic flow chart illustrating the steps in the programmed, controlled operation of the laminating system 10.
Programmable controller 300 is part of a control system 350, which is shown schematically in Fig. 12 by the dashed box enclosing the controlled operation. The controlled operation is detailed below. However, generally speaking, controller 300 is a standard programmable servo controller that monitors and controls the cutting and laminating process. A significant part of that control includes continuously measuring the rate at which web 26 is being conveyed past movable water knife 204 and in response to the measured rate, adjusting the rate at which water knife 204 moves through its predetermined pattern so that the non-linear pattern cut by water knife 204 is consistently the same regardless of the rate of web movement past the water knife.
Description of First Cuttinq Station 100 A detail of first cutting station 100 is shown in Fig. 6. Web 26, which is travelling in the direction of arrow A in Fig. 6, enters protective enclosure 102 of cutting station 100 through an entry port 108 on the upstream side of enclosure 102. Web 26 exits cutting station 100 on the downstream side thereof through an exit port 110. Two pairs of guide rolls 112 are mounted to support brackets (not shown) in the interior of protective enclosure 102, one pair adjacent to entry port 108 and one pair adjacent exit port 110 for guiding web 26 therebetween, and for stabilizing the web as it moves through the protective enclosure.
A pair of water knives 104 and 106 (only one of 5 which is shown in Fig. 4) are mounted to mounting brackets 114 within protective enclosure 102 beneath the lower surface of web 26. Both water knives 104 and 106 are slidably mounted on tracks 114 such that they may be adjusted in the direction that is transverse to the direction of web travel through enclosure 102. However, the position of the knives may be fixed when the knives are operating, and the position of these water knives is always fixed when actually cutting.
Water knives 104 and 106 are selectively operable 15 depending upon the particular style of shingle being manufactured. Thus, only one of the two water knives 104 or 106 may be selectively activated, the other being selectively deactivated. When the shingle shown in Fig.
lA is being made, only one of the two water knives 104 20 or 106 is activated. On the other hand, when the shingle shown in Fig. lB is being made both knives 104 and 106 are activated, as described below.
Water knives 104 and 106 are plumbed to a source of high pressure fluid 116, typically water, and are mounted on brackets 114 such that the nozzle 118 of each water knife is maintained in continual close, cutting proximity to the lower side of web 26. Typically, a single source of high pressure fluid is utilized to supply pressurized fluid to each of the water knives in 30 laminating system 10, and a series of T-fittings or other divergence valves are used to direct the fluid to the water knives utilized in the system.
Water knives 104 and 106 are standard commercially available water knives that include a nozzle such as a 35 conventional sapphire nozzle for handling high pressure fluid cutting operations. The fluid utilized in the cutting system of the present invention is typically provided at a working pressure in the range of approximately 45,000 to 60,000 lbs. per square inch, and preferably approximately 55,000 lbs. per square inch.

~1815~S
It will be understood by those skilled in the art that at working pressures in this range the protective enclosure 102 must be suitably constructed to prevent any access thereto, for example by maintenance workers, 5 while the system is in operation.
A valve 124, which in the preferred embodiment is remotely operated in an on/off manner either manually or through controller 300, is plumbed in-line in the fluid line that carries the high pressure fluid, upstream of each water knife in the system. Appropriate pressure reduction apparatus may be utilized in the high pressure fluid lines to reduce pressure in the system when valves 124 are in the closed position, such as a pressure accumulator. A valve 124 is plumbed into the fluid line that runs to each water knife 104 and 106. The valves may be selectively operated so that fluid is flowing to only one of the water knifes 104 or 106.
When activated, water knives 104 and 106 each direct a high pressure stream of fluid 120 against the underside of web 26. Because water knives 104 and 106 are stationary when activated, each makes a linear longitudinally extending incision through web 26 as it is transported past and over water jets 104 and 106 in direction A.
Web 26 is relatively inflexible and stiff. As such, web 26 is maintained between guide rolls 112 with a minimal amount of displacement caused by the fluid stream 120 from water knives 104 and 106 as the streams impact the lower surface of the web. The combination of guide rolls 112 and the stiffness of web 26 effectively eliminates flutter caused by the impact of the fluid streams against the web, allowing for clean, linear incisions.
The water knives are sufficiently pressurized to cut 35 cleanly through the web, and are operated at sufficient pressure to cut through at least two layers of web.
However, the granular material that is embedded into the upper side of web 26 typically is not cut by the stream of fluid imparted by the water knives on the web.
Instead, the granular material is blasted upwardly by 21~1~QS

the force of stream 120 as it impacts upon the granular material, causing the granular material to be ejected upwardly away from the upper surface of the web. A
convex deflector shield 122 is mounted to the interior of protective enclosure 102 above water knives 104, 106.
The ejected granular material ("hitchhikers") impacts on deflector shield 122 and is deflected to the outer portions of protective enclosure 102, away from web 26.
In this manner, there is a reduced amount of granular material that accumulates on the web as it moves through cutting station 100, and this reduces the amount of down time necessary to remove the granular material from the system. A collection system (not shown) is provided within enclosure 102 to collect the ejected granular material. In addition, blowers could be positioned to direct a blast of air onto the upper surface of the web within the enclosure downstream of the water knives to blow the loose granular material off the moving web before it exits the enclosure.
Given the high fluid pressures at which the water knives 104 and 106 operate, protective enclosure 102 is well insulated and is closed off as much as possible to reduce environmental noise from the operation of the water knives and the actual cutting operation. Various screens and the like may be applied near the entry and exit ports to limit access to the system, and to reduce environmental noise.

Adhesive Applicator As illustrated schematically in Figs. 2 through 5, an adhesive applicator 30 is positioned downstream from cutting station 100 between station 100 and cutting station 200. As explained below, depending upon the type of shingle being manufactured, adhesive is applied to a portion of the lower surface of the web as the web is conveyed past the adhesive applicator. Adhesive applicator 30 may be any standard applicator such as a roll or cylinder-type applicator that includes an adhesive reservoir 32 and an adhesive applicator roll 34. When a roll-type applicator is used, the portion of 218~S~5 the continuous web to which adhesive is to be applied travels in close proximity over the rotating applicator roll and adhesive is thus applied to a desired portion of the lower surface of the web. Other suitable methods 5 for applying adhesive include, for example, spray-type applicators. The relative surface area of the web that is coated with adhesive varies depending upon the style of laminated shingle being manufactured. As such, the adhesive applicator is adjustable both in the width of the applied band of adhesive, and in the location at which the adhesive is applied to the web so that adhesive is applied only to a desired portion of the web.
Any suitable and well known adhesive may be utilized 15 to produce laminated shingles. Typically, the adhesives used for laminated shingles are asphaltic based products that are applied while in a hot, plastic state.

Description of The Second Cutting Station A second cutting station 200 is located downstream from adhesive applicator 30, as shown in Figs. 2 through 5. Figs. 7 and 8 are detailed illustrations of the second cutting station, which includes a protective enclosure 202 that is similar and analogous to the protective enclosure 102 of cutting station 100.
Protective enclosure 202 includes an entry port 206 on the upstream side of the enclosure through which web 26 enters the enclosure and an exit port 208 on the downstream side of protective enclosure 202 through 30 which web 26 exits the enclosure. Likewise, two pairs of guide rolls 210 are positioned in the enclosure, one pair adjacent to entry port 206 and one pair adjacent exit port 208. Guide rolls 210 guide web 26 as it is transported through protective enclosure 202, and 35 support and stabilize the web during the cutting operation.
A movable water knife 204 is mounted within protective enclosure 202 such that the water knife is movable relative to web 26. (See Figs. 7 and 8.) 40 Movable water knife 204 is mounted on an X-Y table 218150~

apparatus that is referred to generally with numeral 212, and which includes an upper slider beam 214 and a lower slider beam 216 that underlies the upper slider beam. Slider beam 214 is mounted for reciprocal 5 movement on a pair of spaced apart parallel shafts 218, the terminal ends of which are fixed to the interior wall of protective enclosure 202. Shafts 218 extend through bores formed in the opposite ends of slider beam 214 such that the slider beam may be moved in a back and forth manner along the shafts. Typically, a friction reducing collar (not shown) is fitted into the bores in the slider beams through which the shafts extend to reduce frictional forces therebetween. As shown in the figures, upper slider beam 214 is mounted for back and 15 forth reciprocating movement in the direction transverse to the direction of web movement, A. For reference, the back and forth direction in which slider beam 214 moves is defined herein as the Y direction (Fig. 8) .
Lower slider beam 216 is similar in structure to the 20 upper slider beam 214, and is mounted in a similar manner. Thus, the lower slider beam 214 iS mounted for reciprocating movement on a pair of spaced apart parallel shafts 220, the terminal ends of which are fixed to the interior wall of the protective enclosure.
25 Shafts 220 extend through bores formed in the opposite ends of slider beam 216 such that the slider beam may be moved in a back and forth manner along the shafts.
Again, typically a friction reducing collar (not shown) is fitted into the bores in the slider beams through which the shafts extend to reduce frictional forces therebetween. As shown in the figures, lower slider beam 216 is mounted for back and forth reciprocating movement in the direction of web movement, arrow A. For reference, the back and forth direction in which slider 35 beam 216 moves is defined herein as the X direction, which is at a right angle to the direction of reciprocation of upper slider beam 214 (Fig. 8) (i.e., the Y direction).
Each slider beam includes a slotted opening 222 that 40 extends through the beam. Because upper slider beam 214 21~1~0S

is mounted such that it overlies lower slider beam 216 and at right angles thereto, there is defined at the intersection between the two slider beams an opening 224 through which the barrel 226 of water knife 204 extends.
Typically, the slotted openings 222 are lined with a friction reducing substance to reduce frictional forces between the walls of the slotted openings and the shaft of the water knife as the water knife moves in operation.
Slider beams 214 and 216 are independently reciprocated in the X and Y directions, respectively, to alter the position of movable water knife 204. In this manner, X-Y table 212 is utilized to control the position of movable water knife. Each slider beam is 15 reciprocated by a separate drive motor, which drives the slider beam with a rack and pinion gear. The drive motors are reversible electric motors, such as servo motors. A feature of the servo motors is that they are capable of operating in a system having a control 20 feedback mechanism according to which controller 300 may determine the relative position of the motor (and thus the drive shaft) and to thereby control the position and operation of the motors. In addition, the rotational speed and direction of the motors must be readily 25 determinable, adjustable and controllable by controller 300.
A rack gear 228 is attached to an end portion of upper slider beam 214, and engages a pinion gear 230 that is journalled to drive shaft 232 of Y servo motor 234. Y servo motor 234 is mounted to the exterior of protective enclosure 202 and drive shaft 232 extends through an opening in the enclosure. Pinion gear 230 is connected by a finger 236 to a grooved roller wheel 238 that is disposed between the upper surface of rack gear 238 and shaft 218 such that shaft 218 runs through the groove in the roller wheel. As rack gear 228 is driven in a back and forth manner by the Y servo motor, roller wheel 238 rolls in a back and forth manner across the upper surface of rack gear 228, and stabilizes the 40 slider beam mechanism.

2181~5 Similarly, with regard to lower slider beam 216, a rack gear 240 is attached to an end portion of lower slider beam 216, and engages a pinion gear 242 that is journalled to drive shaft 244 of X servo motor 246.
Pinion gear 242 is connected by a finger 248 to a grooved roller wheel 250 that contacts the upper surface of rack gear 240 such that shaft 220 runs through the groove in the roller wheel. Roller wheel 250 on lower slider beam 216 serves the same function as roller wheel 238 on upper slider beam 214.
As illustrated in Fig. 8, a pair of openings are formed in the wall of protective enclosure 202 through which a terminal portion of rack gears 228 and 240 respectively may protrude. Alternatively, the 15 protective enclosure could be enlarged such that the rack gears are entirely enclosed within the enclosure.
Referring to Fig. 7, movable water knife 204 is plumbed to a source of high pressure fluid 116, which typically is the same source of fluid for water knives 104 and 106, and which is supplied through a fluid line 256. Like water knives 104, 106, water knife 204 also is a conventional water knife that includes a nozzle 252, again typically a standard sapphire nozzle. The high pressure fluid 116 is supplied to water knife 204 25 at the same working pressures as water knives 104 and 106, sufficient to cut cleanly through at least two layers of the web.
A valve 254 is plumbed into the high pressure water line 256, and like valves 124 is remotely operable in an 30 on/off manner either manually or by controller 300.
Appropriate pressure reduction apparatus such as a pressure accumulator is utilized to reduce pressure in the system when valve 254 iS in the closed position.
Water line 256 is flexible, and includes a coiled 35 portion 258. The combination of the flexible water line and the coiled portion reduces stresses at the fittings where the water line is connected to the water knife, caused by the movement of the water knife.
Cutting station 200 also includes a convex deflector 40 shield 220 (Fig. 7) which deflects hitchhikers that are 2t81~05 ejected from the upper surface of web 26 as it is cut, away from the working portions of the system, as described in detail in reference to cutting station 100.
A mechanism for determining the rate of web travel is utilized in cooperation with controller 300 to control the rate at which movable water knife 204 moves through a predetermined pattern. Several alternative mechanisms are useful for this purpose. In one preferred embodiment, a tachometer 260 is connected to one of the drive rolls that drive web 26 through the laminating system. The tachometer 260 (Figs. 2 through 4) is connected to controller 300, which is described below, and transmits a signal to the controller representing the number of revolutions of the drive roll over a set time period. The controller is programmed to calculate a value based on the data received from the tachometer that corresponds to a rate of web travel.
Alternatively, an encoder 262 (shown schematically in Fig. 7) may be mounted in proximity to protective enclosure 202. Like tachometer 225, encoder 262, when used, is used in combination with controller 300 to determine the rate at which web 26 is moving. Encoder 262 is typically a rotary-type encoder, which briefly described, includes a wheel that is maintained in continual contact with the upper surface of web 26. As web 26 moves past the encoder, the wheel rotates a shaft in the encoder to generate a specific number of electrical pulses. These pulses are communicated to the controller 300, which calculates from the number of received pulses over a set time a value corresponding to the rate at which the web is moving past the encoder.
Encoder 262 could also comprise an optical-type encoder that transmits impulses to controller 300 based on the encoder scanning indicia on web 26 to generate the pulses. A radar-type encoder could be used where indicia on web 26 are not feasible.

Confiquration And Operation For Shinqle 12a of Fiq. lA
The operation of the laminating system will now be described with reference to the two different styles of 2 1 ~ 5 laminated shingles shown in Figs. lA and lB, respectively, including a detailed description of the operation and control of movable water knife 204.
The laminating system is set up differently when making shingle 12a of Fig. lA than when making the style of shingle shown in Fig. lB. The Fig. lA shingle set up is shown in Figs. 2 and 3 and will now be described.
The operation of laminating system 10 is controlled by controller 300 which is illustrated schematically in the Figures. It includes a programmable servo controller that is programmed to control the operation of the laminating system of the present invention. Fig.
12 is a block diagram showing individual steps of the controlled operation 350. In the following discussion, the controlled steps are identified with reference numerals in parentheses, as in Fig. 12.
There are an unlimited number of serrated or non-linear patterns that could be cut into the strip with movable water knife 204 to produce the tabbed portions of the shingle, with each different serrated pattern resulting in a finished shingle having a different appearance. Several possible serrated patterns are illustrated in Fig. 9, at 301, 303, 305, 307 and 309.
For each different pattern, the movable water knife 204 moves through a corresponding predetermined, repetitive pattern, so that the linear movement of the web combined with the repetitive movement of the movable water knife produces the desired non-linear incision in the strip that corresponds to the selected pattern (301, 303, 305, 307 or 309, etc.). As described in detail below, the specific pattern through which water knife 204 moves is controlled in one embodiment by the servo motors 234, 246 that drive the X-Y table on which movable water knife 204 is mounted.
Controller 300 is programmed to control the rate at which water knife 204 moves through its selected pattern in response to the rate at which the web is moving past the water knife. The rate at which water knife 204 moves through its pattern is controlled by controlling the rotational speed of servo motors 234, 246, which ~181~0~

drive water knife 204 as detailed above. This manner of controlling the rate at which water knife 204 moves through a predetermined pattern in response to the rate at which web 26 is moving ensures that a consistent 5 serrated pattern is cut in the strip.
Preliminarily, the desired pattern program (302) is selected from the range of possible programs in controller 300. That is, one of the patterns 301, 303, etc. is selected. For the purposes of this discussion, it is assumed that the pattern number 301 has been selected. This pattern will result in laminated shingles having the appearance illustrated in Figs. lA
and lB. When pattern 301 is selected, the water knife 204 is repeatedly moved by servo motors 234, 246 through 15 the X-like pattern shown in Fig. 10. It will be appreciated that the incision produced by the combined movement of web 26 in the direction of arrow A and the repetitive movement of water knife 204 through the X-like pattern shown in Fig. 10 produces an incision along 20 the non-linear path shown in Fig. 3 (e.g., pattern 301 of Fig. 9). In order to cut the strip consistently with the chosen serrated pattern, the rate at which water knife 204 moves through its predetermined pattern must be controlled depending upon the rate at which web 26 is 25 moving past the water knife. In addition, the rate at which water knife 204 moves must vary in response to variations in the rate at which web 26 is moving past the water knife.
When the desired pattern program has been selected at (302), controller 300 automatically calculates a maximum rate of web travel ( 304) for the selected pattern program. The maximum rate ( 304) is the maximum rate of web travel past water knife 204 beyond which water knife 204 cannot reliably and consistently cut the 35 desired non-linear pattern without, for example, unnecessarily rounding the edges of the serrated tabs.
Controller 300 calculates the maximum rate of web travel based on the pattern program selected at (302) and the known maximum rotational speed at which servo motors 234, 246 can move movable water knife 204 precisely through the selected pattern, and the known maximum rate at which the rotational direction of the servo motors may be reversed. Any rate of web travel that is less than the maximum rate is referred to as a "within limit rate."
Once the maximum rate is calculated, controller 300 automatically calculates the coordinates for a home position and the cut coordinates (305). The home position is the position of movable water knife 204 in the direction transverse to the direction of web travel at which the zig-zag cutting operation begins. In the described example, the home position is defined by the coordinates on the X-Y table where movable water knife 204 is directly below the centerline (C/L) of the B' strip, which also is the center of the X illustrated in Fig. 10. This is an arbitrary position, but is used as a reference point.
Controller 300 also calculates each of the cut coordinates, which are labelled C1, C2, C3 and C4, respectively in Figs. 10 and 11. These coordinates are specific to each different pattern program ~e.g., 301, 303, 305 etc.), and correspond to the corner positions of movable water knife 204 as it is moved through the repetitive pattern for the selected pattern program.
The description that follows assumes that pattern program 301 has been selected. Referring to Fig. llA, cut coordinate C1 is illustrated. Coordinate C1 is a set of X-Y coordinates on the X-Y table that controller 300 recognizes as corresponding to the position at which movable water knife 204 is positioned in one corner of the pattern through which the water knife is moved. In the example of Figs. 10 and 11, coordinate C1 is located in the lower left corner of the Figure llA. As noted above, a control feedback mechanism allows controller 300 to identify the position of the drive shafts of the servo motors, and thus to determine the relative position of the slider beams on the X-Y table. To move the water knife 204 to the C1 coordinate position, controller 300 activates Y servo motor 234 to drive slider beam 214 in the Y direction (Fig. 8) until 21815~
controller 300 recognizes that the position in the Y
direction corresponding to C1 has been attained. At the same time, controller 300 also activates X servo motor 246 to drive slider beam 216 in the X direction to the 5 position that corresponds to C1.
Position C2 (Fig. llB) is the next position to which movable water knife 204 is moved. Upon instruction from controller 300, servo motor 246 drives slider beam 216 in the X direction to the coordinates that correspond to the C2 position (the lower right in Fig. llB). Servo motor 234 is not activated by controller 300 during this part of the routine because the position of slider beam 214 and water knife 204 in the Y direction at C2 is the same as at C1, and controller 300 recognizes it as such.
Position C3 (Fig. llC) is attained by slider beam 216 moving in the X direction to the coordinates that correspond to the C3 position (the upper left in Fig.
llC). Simultaneously, servo motor 234 is activated to drive slider beam 216 in the Y direction to the correct 20 coordinates.
Position C4 is next (Fig. llD), and is attained by servo motor 246 driving slider beam 216 in the X
direction (to the right in Fig. llD) to the proper coordinates that correspond to this position. Servo 25 motor 234 is not activated during this part of the routine because the position of slider beam 214 and water knife 204 in the Y direction at C4 is the same as at C3.
One cycle of movable water knife 204 is completed by 30 moving the water knife back to the C1 position (lower left in Fig. llA). To move the water knife to the C1 position the X servo motor 246 drives slider beam 216 in the X direction to the C1 position. Y servo motor 234 is simultaneously activated by controller 300 to drive 35 slider beam 214 in the Y direction to the C1 position.
At this point a new cycle is initiated by moving water knife 204 from the C1 coordinates through another cycle in the manner described.
Controller 300 calculates the cut coordinates based 40 upon the specific pattern program that has been selected ~18~505 at (302). The coordinates for pattern 301 of Fig. 9 were described above. As a further example, assume pattern program 303 were selected. In that case the non-linear incision follows a variable path as opposed to the regular path of pattern program 301. To produce this effect the cut coordinates are calculated by controller 300, but an acceptable range of coordinate positions in the X and Y directions are calculated for each cut coordinate. It will be appreciated that the cut coordinate into which the slider beams are moved at each step of a cycle are randomly selected from the available coordinates within the calculated range.
Another alternative manner in which the non-linear pattern of pattern program 303 could be produced is to vary the rate at which the movable water knife moves in relation to the determined rate of web movement. Thus, in this alternate, controller 300 would monitor the rate of web movement and vary the rate of water jet movement in response to the determined rate of web movement to produce the desired non-linear pattern.
As detailed below, when the system is in actual operation, controller 300 is continually monitoring the rate at which web 26 is moving (arrow A in Figs. 10 and 11), and each servo motor drives the movable water knife between coordinates at a rate that is dependent upon and calculated from the determined rate of web movement, and is correspondingly adjusted.
With these preliminary selections made, the water knife at first cutting station 100 is adjusted. Only one of the two water jets 104, 106 at first cutting station 100 is activated to make the shingle of Fig. lA.
The position of the selected water jet, for example water jet 104, is adjusted in the direction transverse to the direction of web travel and is fixed in a position to cut two strips, labelled A and B' in Fig. 3, in which the B' strip has a width dimension Wb that is roughly twice the width dimension X of Fig. lA. The A
strip has a width Wa. The position of water jet 104 is fixed relative to the web 26, and accordingly both the A
and B' strips have parallel linear side edges.

2181~0~

The position of adhesive applicator 30 and the width of the band of adhesive applied is adjusted so that adhesive is applied to only to a central portion of the underside of the B' strip having width roughly equal to 5 Wa/ which is the width of the A strip, and which is shaded in Fig. 3.
With these adjustments made, web 26 is fed through the laminating system to continue the set up procedure.
As shown in Figs. 2 and 3, in cutting station 100 an edge strip A is cut from web 26 by water knife 104, resulting in two strips, A and B'. After exiting protective enclosure 102 through exit port 110 the path of strip A is diverted such that it bypasses adhesive applicator 30, while the B' strip passes over the 15 adhesive applicator, where the adhesive is applied to the desired portion of the lower side. The A strip is then diverted in a direction transverse to web travel with canted rolls (not shown) so that the A strip is aligned in a desired spacial relationship below the B' 20 strip. In this regard, the A strip is aligned with the adhesive coated portion of the B' strip. The aligned A
and B' strips then pass through joiner rolls 35 to press the strips together and laminate them to one another.
Stated otherwise, both the A strip and the B' strip have 25 centerlines, labelled C/L in the Figures. The strips are aligned such that the centerlines of the strips are coincident and in alignment, and the strips are fed through joiner rolls to laminate the strips together.
As illustrated in Figs. 2 and 3, the lineal distance 30 of travel of the A strip is initially greater than the B' strip since the A strip is routed past the adhesive applicator. This distance is compensated for when the system is initially started up.
The laminated strips (A and B') are next fed into 35 and through cutting station 200 and past movable water knife 204 where the non-linear incision will be cut into the strip as described above. The strips are then fed through the remaining components of the web handling system.

` 2l81S~5 Once the web is fed through the laminating system and the set up complete, the run mode is then entered at (306). At this point the controller activates the web feeding mechanisms at (308) to begin the web moving 5 automatically through the laminating system. Water knife 204 is moved into the home position.
With web 26 actively moving through laminating system 10 controller 300 calculates the rate of web travel at (310) based upon the signals received from tachometer 225. If the rate of web travel at (312) is greater than the maximum calculated at (304) (i.e., out of limit), the rate of web travel is again calculated, on a continual basis, at (310) until the rate is determined to be within the operational limits, that is, 15 less than the maximum rate ( 304) .
If on the other hand the calculated rate of web travel ( 312) is less than or equal to the maximum rate (304) (i.e., controller 300 detects a within limit rate), the system is ready to initiate the cutting 20 operations and all of the water knives in the system (104, 106, and 204) are activated at step (316), which begins the cutting operations. Alternatively, the valves that initiate the cutting operations could be opened manually by the operator. The cutting fluid is 25 discharged through the water knives with sufficient force to cut cleanly through the two-layer laminate that is being fed through the second cutting station.
As the cutting operation begins, servo motors 234 and 246 move movable water knife 204 from the initial 30 home position through the repetitive pattern described above (from cut coordinate Cl to C2 to C3 to C4, etc.) at a controlled rate that is directly related to the determined rate of web movement past the movable water knife. By monitoring the rate of web movement, and in 35 response to that rate controlling the rate at which movable water knife 204 moves from one cut coordinate to the next in the predetermined pattern, the movable water knife continually cuts with precision the selected non-linear pattern into the web. Because each servo motor 40 is independently controllable based upon the continual ` -determination of the rate of web travel, the non-linear incision is precisely controlled.
The rate of web travel increases gradually from a dead stop until an operating speed is reached, or until 5 the maximum rate of the system is reached. As the rate of web travel of the web ramps up, the tachometer 225 (or encoders) continually transmits data to controller 300, which continually calculates a rate of web travel value based upon the transmitted data. Based upon this determined value, controller 300 continually adjusts the rate at which movable water knife 204 moves through the repetitive pattern.
Cutting continues as the rate of web travel increases or decreases. Controller 300 continually 15 calculates the rate of web travel at (318) based upon the information from tachometer 225, and if the calculated rate value is less than the maximum determined at (304) at step (320), cutting continues with controller 300 continually adjusting the rotational 20 speed and direction of the servo motors that drive water knife 204, at step (322), to control the position of the water knife as it moves through the selected pattern.
This continual monitoring of the rate of web travel to determine within limit conditions, and corresponding 25 adjustment of the rate at which water knife 204 moves from cut coordinate to cut coordinate, and adjustment of the cut coordinates if needed based upon the determined rate of web travel, continues until either an out of limit condition is detected or the run is completed.
If the rate of web travel is calculated and determined to be greater than the maximum at step ( 320), controller 300 deactivates the water knives at step (326) to stop the cutting operation, and the routine returns to step (310) until a within limit rate is 35 detected. When the controller detects that the run has been completed at step (324), which can be in response to a predetermined time period or predetermined lineal length of web that has traveled through laminating system 10, the operation is stopped.

2181~35 With the control system operating as described, fluctuations in the rate of web travel are compensated for by independently adjusting the rate at which servo motors 234, 246 drive the slider beams 214, 216 to the respective coordinates, thus controlling the rate at which movable water knife 204 moves through its repetitive pattern. This results in a consistent serrated pattern cut into the B' strip. A further control mechanism is the ability of controller 300 to adjust the cut coordinates to compensate for varying rates of web travel. Thus, for example, when pattern 301 has been selected controller 300 may alter the cut coordinates in the X direction to compensate for variations or fluctuations in the rate of web travel.
Referring to Fig. 3, two continuous laminated strips are thus produced, each having one linear side edge and one non-linear side edge. These two strips are labelled E and F in Figs. 2 and 3. The continuous strips are then separated by the web handling system and are cut into shingles with either mechanical knife blades or a further water knife. The shingles are then stacked and bundled.

Confiquration For Shin~le 12 of Fi~. lB
The operation of the laminating system 10 of the present invention will be described separately with regard to shingle 12b of Fig. lB, as illustrated in Figs. 4 and 5. The pattern program needed to make the shingle 12b also is pattern 301 (Fig. 9), and accordingly movable water knife 204 is driven through the same X-like pattern as described above with reference to the shingle 12a. The control of these movements is identical as well, and is not repeated here.
In the embodiment illustrated in Figs. 4 and 5, both water knives 104 and 106 at cutting station 100 are operational. The position of these water knifes in the direction transverse to web travel (arrow A) is adjusted such that each knife cuts a linear incision in web 26 to produce three linear strips, A, B and B'. The combined 2181~5 -width of the A and B strips is shown as width Wab. After this cutting step, adhesive applicator 30, which has been positioned in the desired location and adjusted as described above to apply the correct amount of adhesive, applies adhesive to a central portion of the lower side of the B' strip having width Wab as well. While in Figs.

3 and 4 the A and B strips are shown travelling in the same path as the B' strip (over adhesive applicator 30 and through second cutting station 200), the A and B
strips could alternatively be separated from the B' strip prior to the point where the B' strip has adhesive applied to the underside thereof (illustrated as shading in Fig. 5). For example, guide rolls located downstream of cutting station 100 and upstream of adhesive applicator 30 could direct one or both of the A and B
strips either above or below adhesive applicator 30. In the illustrated embodiment, the adhesive is applied before the B' strip is fed into the second cutting station 200.
As illustrated, the three strips are then fed through cutting station 200 where movable water knife 204 cuts the B' strip in the same manner as described above with reference to the Fig. lA shingle. As illustrated in Fig. 5, water knife 204 cuts through the adhesive on the lower side of the B' strip to cut the B' strip along a non-linear path according to the desired pattern. Four strips are thus produced, labelled A, B, C and D in Fig. 5. The C and D strips are the tabbed strips and have one linear side edge and one non-linear side edge.
The web handling system then separates the C and D
strips and aligns the D strip with the B strip in the desired spacial relationship, and the C strip and the A
strip likewise, and the strips thus paired are laminated together between joiner rolls. It will be appreciated that according to the described system, adhesive is applied to the underside of the C and D strips where they are laminated to the underlying A and B strips.
The continuous laminated strips are then cut into the desired lengths with either standard mechanical knives 2181~

on circular drums, or water jets. The cut shingles are then stacked and bundled.
As an alternative, in the set up for manufacturing the shingle illustrated in Fig. lB, the adhesive could be applied to the B' strip downstream of the second cutting station. In this case the alignment and joining of the strips would be adjusted accordingly.
Various alternative embodiments of the present invention are possible, in addition to those already described. As one example, multiple layers of the web may be laminated together in either the base sheet or the tabbed sheet, or both, prior to cutting to produce a laminated shingle having more than two layers. The increased thickness creates even more depth and shadow on the roof, and adds to the durability of the roof.
As another alternative embodiment, the shingle of Fig. lB could be produced by cutting the A and B strips each from a side edge of web 26 at cutting station 100 instead of cutting both the A and B strips from the same edge of web 26.
While the present invention has been described in accordance with preferred embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the claims.

OYEN WIGGS GREEN & ~UTALA
480 - 601 W. Cordova Street Vancouver, B.C., V6B lGl Tel: (604) 669-3432 Agents for the Applicant

Claims (48)

1. An apparatus for cutting a strip of web material as the strip moves along a path, comprising:
a fluid jet positioned to direct a stream of fluid from the jet onto the strip with sufficient force to cut the strip;
means for imparting relative motion between the stream of fluid and the strip such that the fluid cuts the strip along a non-linear path;
means for measuring the rate at which the strip moves along the path and for controlling the relative motion between the stream of fluid and the strip in response to the measured rate.

2. The apparatus of claim 1 wherein the means for imparting relative motion between the stream of fluid and the strip includes means for moving the fluid jet through a predetermined pattern.

3. The apparatus of claim 2 wherein the rate at which the fluid jet moves through the predetermined pattern is varied in response to the measured rate so that the non-linear cut in the strip follows a predetermined pattern.

4. The apparatus of claim 1 wherein the fluid jet cuts the strip into two strips, each strip having one linear side edge and one non-linear side edge.

5. The apparatus of claim 1 further including at least one fixed fluid jet for cutting the strip along a linear path.

6. The apparatus of claim 5 wherein the at least one fixed fluid jet cuts the strip along a linear path before the strip is cut along the non-linear path, thereby producing plural strips, at least one of which has two linear side edges.

7. The apparatus of claim 1 wherein adhesive is applied to a portion of the lower surface of the strip prior to the web being cut by the fluid jet.

8. The apparatus of claim 6 wherein the at least one strip having two linear side edges is laminated to another strip in a desired spacial relationship.

9. An apparatus for cutting a moving strip of composition roofing material, comprising:
a fluid jet mounted to direct a stream of fluid onto the strip with sufficient force to cut an incision in the strip, the fluid jet mounted for movement relative to the strip so that the incision in the strip is non-linear; and a controller to determine the rate of movement of the strip past the jet and to control the movement of the jet relative to the strip in response to the rate of movement of the strip.

10. The apparatus of claim 9 wherein the non-linear incision follows a predetermined pattern.

11. The apparatus of claim 9 further including at least one fixed fluid jet for cutting the strip along a linear path to produce plural strips, at least one of which has two linear side edges, the at least one strip having two linear side edges being cut by the fixed fluid jet before the movable fluid jet cuts the strip.

12. The apparatus of claim 11 wherein adhesive is applied to a portion of one strip having two linear side edges and another strip is laminated thereto before the strip is cut by the fluid jet mounted for movement.

13. The apparatus of claim 12 wherein the fluid jet mounted for movement cuts the laminated strip into two strips, each having one linear side edge and one non-linear side edge.

14. The apparatus of claim 9 further including two fluid jets, each for cutting the strip along linear paths to produce three strips, each having linear side edges, and wherein the fluid jet mounted for movement cuts one of the three strips along the non-linear path to produce two strips, each having one linear side edge and one non-linear side edge.

15. The apparatus of claim 14 wherein adhesive is applied to the one strip that is cut by the fluid jet mounted for movement prior to being cut by such fluid jet.

16. The apparatus of claim 15 wherein the strips having two linear side edges are aligned with the strips having one linear side edge and one non-linear side edge in a desired spacial relationship and laminated thereto.

17. The apparatus of claim 9 wherein the controller determines the rate at which the strip is moving past the movable fluid jet, and in response to the determined rate controls the rate of movement of the fluid jet to produce a non-linear incision having a desired pattern.

18. The apparatus of claim 9 wherein the controller stops the stream of fluid through the jet when the determined rate of movement exceeds a predetermined maximum.

19. A method of cutting a strip of web material as the web moves along a path, the method comprising the steps of:
positioning the web in proximity to a fluid jet;
imparting relative motion between the fluid jet and the moving web;

cutting the web along a non-linear path with a stream of fluid from the jet;
measuring the rate at which the web moves along the path and controlling the relative motion between the fluid jet and the moving web in response to the rate.

20. The method of claim 19 including the step of varying the rate of movement of the fluid jet in response to the measured rate of web movement.

21. The method of claim 19 wherein the non-linear path is preselected and the movement of the fluid jet is controlled to cut the non-linear path along the preselected non-linear path.

22. The method of claim 19 including the step of cutting the strip along a linear path with at least one fixed fluid knife to produce at least one strip having two linear side edges and at least two other strips, each having one linear side edge and one non-linear side edge.

23. The method of claim 22 wherein the at least one strip having two linear side edges is aligned in a desired spacial relationship with at least one of the other strips and laminated thereto.

24. A method of cutting a moving strip of composition roofing material, comprising the steps of:
mounting a fluid jet for movement relative to the strip and in proximity to the strip;
moving the fluid jet relative to the moving strip and directing a stream of fluid from the jet onto the moving strip with sufficient force to cut the strip along a non-linear path;
determining the rate at which the strip is moving past the jet and controlling the movement of the jet in response to the determined rate.

25. The method of claim 24 wherein the fluid jet moves through a predetermined pattern, and the rate of movement of the jet through the repetitive pattern is varied in reponse to the rate of strip movement.

26. The method of claim 25 wherein the rate of movement of the fluid jet is controlled to produce an incision having a non-linear, repetitive pattern.

27. An apparatus for cutting and laminating roofing shingles from a continuous linear web of composition roofing material having an upper and lower surface, the upper surface being coated with granular material, comprising:
a web handling system for moving and conveying the web;
a first cutting station comprising a pair of fixed water knives mounted adjacent to the web and in proximity thereto so that each water knife at the first cutting station imparts a cutting stream of fluid onto the lower side of the web, thereby cutting the web into three continuous strips, each having linear side edges, and one strip having a greater width than either of the other two;
an adhesive applicator for applying adhesive to a portion of the lower surface of the one wider strip;
a second cutting station comprising a water knife mounted for movement at a predetermined rate through a predetermined pattern and mounted adjacent to the one wider strip such that the water knife imparts a cutting stream of fluid onto the adhesive-coated portion of the lower surface of the one wider strip to cut the one wider strip along a non-linear path into two strips, each such strip having one linear side edge and an opposite non-linear side edge; and a controller for determining the rate of movement of the web past the movable water knife, and for controlling the rate at which the movable water knife moves through the predetermined pattern in response to the rate of movement of the web.

28. The apparatus according to claim 27 including means for positioning one of the strips having two linear side edges in a desired spacial relationship with one strip having a non-linear edge, and for laminating the positioned strips together.

29. The apparatus according to claim 28 including means for cutting the laminated strips into shingles having predetermined lengths.

30. A method for cutting and laminating roofing shingles from a continuous linear web of composition roofing material having an upper and lower surface, the upper surface being coated with granular material, comprising the steps of:
cutting the web with a pair of water knives into three continuous linear strips, each having linear side edges and one strip being wider than either of the other two;
applying adhesive to a portion of the lower surface of the wider strip;
cutting the wider strip along a non-linear path by directing a stream of fluid onto the adhesive-coated portion of the wider strip through a water knife that is moving relative to the wider strip through a predetermined pattern and at a predetermined rate, thereby cutting the wider strip into two strips, each having one linear side edge and an opposite non-linear side edge;
determining the rate of movement of the web past the moving water knife and controlling the rate at which the water knife moves through the predetermined pattern in response to the rate of movement of the web;
positioning the strips having two linear side edges in a desired spacial relationship with the strips having one non-linear side edge;
laminating together the positioned strips in the desired spacial relationship to produce two continuous laminated strips; and cutting the continuous laminated strips into predetermined lengths.

31. An apparatus for cutting a continuous web having an upper surface that defines a plane, comprising:
a conveyer that moves the web to define an axis of movement;
a fluid jet movable relative to the web and positioned to direct a cutting stream of fluid onto the web, the fluid jet movable through an arc of 360°
relative to the axis in the plane.

32. The apparatus of claim 31 including a controller that determines the rate of web movement.

33. The apparatus of claim 32 wherein the fluid jet is movably mounted for moving the fluid jet relative to the web to cut the web along a non-linear path, the fluid jet being movable through a repetitive pattern at a rate that is varied in response to the rate of web movement.

34. An method for cutting a continuous web, comprising the steps of:
moving the web in one direction along a plane to define an axis of movement;
positioning a fluid jet in proximity to the moving web and mounting the fluid jet for movement through an arc of 360° relative to the axis in the plane;
directing a stream of fluid from the fluid jet onto a surface of the web while moving the fluid jet through a predetermined repetitive pattern to cut the web along a non-linear path that follows a predetermined pattern.

35. The method of claim 34 including the step of determining the rate of web movement.

36. The method of claim 35 further including the step of varying the rate at which the fluid jet moves through the repetitive pattern in response to variations in the rate of web movement.

37. An apparatus for cutting a web as the web moves along a path, comprising:
laminating means for joining two strips of web in a desired spacial relationship;
a fluid jet positioned to direct a stream of fluid onto the joined strips with sufficient force to cut the strips;
means for imparting relative motion between the stream of fluid and the strips such that the fluid cuts the strips along a non-linear path.

38. The apparatus of claim 37 including means for measuring the rate at which the strips move along the path and for controlling the relative motion between the stream of fluid and the strips in response to the measured rate.

39. The apparatus of claim 37 wherein the means for imparting relative motion between the stream of fluid and the strips includes means for moving the fluid jet through a predetermined pattern.

40. The apparatus of claim 39 wherein the rate at which the fluid jet moves through the predetermined pattern is varied in response to the measured rate so that the non-linear cut in the strips follows a predetermined pattern.

41. An apparatus for cutting a strip of web material as the web moves along a linear path, comprising:
a fluid jet positioned to direct a stream of fluid from the jet onto the strip with sufficient force to cut the strip, the fluid jet movable relative to the strip such that the fluid cuts the strip along an non-linear path;

a fluid jet drive system that moves the fluid jet through a predetermined pattern;
a controller to determine the rate at which the web moves along the linear path and to control the rate at which the fluid jet moves through the predetermined pattern in response to the measured rate.

42. An apparatus for cutting and laminating roofing shingles from a continuous linear web of composition roofing material having an upper and lower surface, the upper surface being coated with granular material, comprising:
a web handling system for conveying the web;
a first cutting station comprising at least one fixed water knife mounted adjacent to the web and in proximity thereto so that the at least one water knife imparts a cutting stream of fluid onto the lower side of the web, thereby cutting the web into two continuous strips, each having linear side edges, and one strip having a greater width than the other;
an adhesive applicator for applying adhesive to a central portion of the lower surface of the wider strip;
a laminator for laminating the two strips together in a desired spacial relationship;
a second cutting station comprising a movable water knife mounted for movement at a predetermined rate through a predetermined pattern and mounted adjacent to the laminated strips such that the movable water knife imparts a cutting stream of fluid onto the strips to cut the strips along a non-linear path into two strips, each such strip having one linear side edge and an opposite non-linear side edge; and a controller for determining the rate of movement of the web past the movable water knife, and for controlling the rate at which the movable water knife moves through the predetermined pattern in response to the rate of movement of the web.

43. The apparatus according to claim 42 including a knife for cutting the strips into shingles having predetermined lengths.

44. An apparatus for cutting a continuous web of composition roofing material having a coating of granular material embedded in only one side thereof, comprising:
a fluid jet positioned to direct a stream of fluid onto the roofing material with sufficient force to cut through the roofing material; and means for imparting relative motion between the stream of fluid and the roofing material such that the fluid cuts the roofing material along a non-linear path.

45. An apparatus for cutting a continuous web of composition roofing material, the web having plural layers of the composition material laminated together, comprising:
a conveyer for moving the web along a path; and a fluid jet positioned to direct a cutting steam of fluid onto the web with sufficient force to cut through the plural layers.

46. The apparatus according to claim 45 wherein the fluid jet cuts the web along a non-linear path.

47. The apparatus according to claim 46 wherein the fluid jet is movable relative to the moving web and moves through a predetermined pattern.

48. The apparatus according to claim 47 including a controller that determines the rate of web travel, and in response to the determined rate controls the rate at which the fluid jet moves through the predetermined pattern.