MXPA96004890A - Ceiling material with tabs for integralme formed nails - Google Patents

Abstract

An enclosing composite material includes a lower end conditioner material that is bonded to the same appropriate rows of nail tabs, preferably made of a thermoplastic based material, such as a low density polyethylene material, and a Contrasting color to the lower layer material. A process is used to cause the nail tabs to transport the lower layer material in a continuous process beyond appropriate sets of nozzles that are coordinated with the conveying speed to deposit the tabs while in a liquid state and to form tabs of appropriate size and appropriate patterns through the surface of the lower layer. Each nozzle may include multiple orifices to control the width and thickness of the tabs formed. A similar process is disclosed for making other roofing construction materials that have rows of nail tabs that coincide with the conventional separation of pern.

Description

CEILING MATERIAL WITH TABS FOR NAILS INTEGRALLY FORMED Field of the Invention This invention relates to materials for roofing or other construction materials normally employed as roofing materials prior to the installation of roofing shingles or lining boards for the exterior finishing of buildings and, more specifically, to such roofing materials. which incorporate in them a plurality of tabs for integrally formed nails. Background of the Invention A tile roof installation generally comprises at least two distinctive layers. The first layer is a lower layer, usually a saturated asphalt material that attaches directly to the sheets of wood or cardboard material that holds the tiles. The second layer is made of the tiles themselves. Normally, the lower layer helps make the roof resistant to water intrusion. The initial material for the lower layer is a base material usually referred to as "dry felt". Examples of types of initial dry felt material are tow, paper and fiberglass, which are not exhaustive of the possible initial base materials. The initial base material that has been subject to experimentation today is a fibrous paper made from treated recyclable cardboard; however, this invention is not limited thereto. The term "dry felt" used herein is used generically for all suitable starting base materials. The dry felt material, when saturated with an asphalt material, produces a lower layer roofing material known in the art as "tar paper" or "saturated felt", which is produced in varying degrees, depending on the thickness and the weight. Regardless of the type of lower layer roofing material that is employed, the common practice in the installation industry has been to unwind a length of the lower layer material and fix each length to the support sheets or boards in a plurality of locations, so that it remains in place before the installation of the roof tiles. The fastening or fastening devices for this material are usually staples and nails. Staples and regular nails are easily applied by power devices; however, both are notoriously susceptible to being pulled out of the sheets or boards when there is an upward movement in the lower layer or, when the staples or nails remain in place, to the tearing of the roofing material in the holding places. . Even when the tiles are to be followed immediately, the lower layer can still expose itself to wind conditions and other adverse conditions, such as when the installers walk or crawl on the lower layer. Moreover, it is desirable that the lower layer be safely unit independently of the tiles, not only in the installation stage prior to the placement of tiles, but also in the final installation. This is because the tiles are blown or torn off under adverse weather conditions, and a lower layer installed safely, independently, will provide some interim protection of the climatic elements before roof repair. When the lower layer is not securely fastened, then the lower layer can be flown or torn off simultaneously with damage to the tiles. To securely install the lower layer and avoid the tear described above, it has long been a common practice to either use roofing nails with large heads or to use a large sheave or auxiliary tongue that lies below the nail head . Such large sheave or tab resists successfully being torn with a smaller nail head of regular size. The use of such a sheave or tongue, however, has not been totally satisfactory, since such use is time-consuming, expensive, and can be dangerous when the installation is in a fairly steep roof and / or the weather conditions are inclement. This is because it requires two hands to slide the sheave on the nail or hold down a tongue while driving the nail through. If the installer is having to achieve these maneuvers while alone he is holding on a boardIt can be uncomfortable and / or unstable as a result of being unable to use either hand for additional support when necessary. Moreover, nails with large heads, unconventional, are not recommended, both because they are expensive and because they can not be used in equipment of ordinary power. In the usual way, the power equipment for nailing nails can be loaded only with cartridges for conventional nails. U.S. Patent No. 5,365,709, from the same inventor as the present one, discloses an improved lower layer roofing material, which includes a plurality of suitable nail tabs bonded to a felt base. The concept described therein is to produce a roll of bottom layer having the tabs in place so that the installer does not have to separately handle a separate sheave or tab and nail. With the tabs in place, the installer would merely manipulate the tabs one by one with a nail gun of conventional power. Such installation would be many times faster than the previously described installation and would be less cumbersome to the installer since the nailing process would not require both hands when using a nail gun. However, the lower layer described in such patent has not been used commercially. In order to manufacture a dry felt material with glued tabs, as described in the cited patent, in the saturated felt material, it is required that the adhesive and the tongue material do not materially degrade during the asphalt saturation process. The high temperature of this process and the used rolls tend to melt the adhesive glue, melt the same tongue material, scrape the tabs, or a combination of the three above phenomena, any of which results in the saturated felt material , resulting is not reliable, if not inappropriate, for commercial use. It has been discovered, as described below, that permanently and reliably tabs can be fixed or bonded to the saturated felt material, avoiding many of the problems inherent in the attachment of tabs to the dry felt base material, as described in the aforementioned patent. . Moreover, it has been discovered that the process of producing suitable tabs on the saturated felt material can be automated using liquid thermoplastic tab material which solidifies rapidly and adheres or bonds to the surfaces of the saturated felt material. Also, importantly, it has been discovered that the production of tabs on the saturated felt material can be done immediately following the step of immersing or spraying the felt felt saturated with a mixture of hot, suitable asphalt to make the material of saturated felt. In this way, the conversion of dry felt into saturated felt can be combined in an automated process with the subsequent production of the tabs. In addition to the saturated felt material used in a siding application, suitable tabs that use liquid thermoplastic tongue material can also be similarly installed to other sheet or base sheet materials, such as lining board materials used to wrap the side of an armed house or other structure before attaching the finished lining boards. Accordingly, it is an aspect of the present invention to provide an improved lamination material having nail tabs produced directly on at least one of its surfaces. It is another aspect of the present invention to provide an improved underlay material which incorporates therein tenacious and deformable nails for nails which are produced directly on saturated felt material. It is still another aspect of the present invention to provide such an enclosing material of lower layer that incorporates in it tabs for nails that are of a reliable material when it is used in extreme conditions of environmental temperature found in typical installations. It is still another aspect of the present invention to provide an improved lower layer bedding material that utilizes an automated process for applying a liquid thermoplastic material to appropriate tongue positions using nozzles that are easily controlled in a programmable manner. It is still another aspect of the present invention to provide an improved lower layer material, where the overall process is continuous and automated to include the saturation of dry felt material to make saturated felt material, followed by the production of suitable nail tabs from material made of pressurized liquid thermoplastic or other hardening material subsequently and securely bond to the surface of the saturated felt material. Essence of the Invention A composite dressing material is made starting with a roll of dry felt material. In the preferred method of producing the underlaying sheeting material according to this invention, the felt felt material is introduced at the beginning of a continuous and automated process having a system of driven rolls for transporting the sheeting material through the sheet. process. First, the dry felt material undergoes conventional treatment to produce felt material saturated with asphalt from the dry felt material. Then, a material based on liquid thermoplastic or other suitable material is deposited on the saturated felt that moves quickly using nozzles or nozzle assemblies placed in an appropriate manner. The activation / deactivation operation of the nozzles or sets of nozzles and the movement of the saturated felt material is controlled and coordinated by one or more suitable programmable microprocessors. The thermoplastic based material may include an appropriate adhesive to ensure that it bonds to the surface of the saturated felt material upon cooling and quickly hardens to form the desired tabs or pads for nails. The thermoplastic based material may be reinforced with fibers, flakes or other similar particles, and such material may also include a color contrast pigment with respect to the color of the underlying saturated felt material, which is usually black. However, even without the extra pigment or dye, the tabs contrast in color and are easily visible. As soon as the felt material saturated with tabs reaches a "free-looping" stage, the tabs have sufficiently cooled and hardened at operating conditions. That is to say, they are tenacious, but flexible. The freewheel formation is followed by a final stage, where the lower layer material with tabs is wound to form rolls of conventional size. The freewheel formation continues this action without impacting on the previous continuous movement of the saturated felt transported during the previous stage of tab production operation.

As mentioned, the final composite, final composite material that has just been described is manufactured using a machine that includes one or more deposition nozzles at each location in the bead. The material based on liquid thermoplastic or equivalent material is normally supplied to the deposition nozzles under pressure. The nozzles are activated and deactivated to deposit the material in the correct amount and at the correct spacing, which preferably stacks the tabs across the width of the base felt material. The line speed of the conveyor determines, by means of the operation of a microprocessor, the durations of the "activation" and "deactivation" times. Each "nozzle" used to make the reservoirs is preferably either a plurality of narrowly spaced orifices in a common manifold housing, or an elongated slotted opening, so as to cover a sufficiently wide area to make the tabs of the preferred width dimension without forming a tongue that is too thick. When a plurality of holes are employed, the liquid material flowing from the individual orifices is mixed, cooled and hardened to form the individual tabs. Brief Description of the Drawings In order to make evident the way in which the aspects, advantages and objectives of the invention described above, as well as others that may be obvious, can be achieved, and can be understood in detail, a more detailed description will be made. particular of the invention briefly summarized in the foregoing by reference to the embodiment thereof which is illustrated in the accompanying drawings, which drawings form part of this description. However, it should be noted that the drawings illustrate only a preferred embodiment of the invention and therefore should not be considered as limiting the scope of the invention, since the invention can accept other equally effective embodiments. In the drawings: Figure 1 is a schematic side view of an automated process for manufacturing a composting material of the invention according to a preferred process. Figure 2 is a schematic top view of the nail tab production area of the automated process shown in Figure 1. Figure 3 is a schematic representation of a nozzle with a manifold housing having a plurality of holes used in the process of making the composite creping material shown in Figure 2; Figure 4 is a schematic representation of a nozzle having an elongated slot used in the manufacturing process of the composite creping material shown in Figure 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT The manufacture of the composite sealant material preferably employs a machine manufactured by Nordson Corp. of Estlake, Ohio, USA, which uses one or more nozzle assemblies to dispense multiple beads of viscous liquid, as shown in FIG. in US Pat. No. 5,335,825, which is incorporated herein by reference for all purposes. This machine has been used in the past, for example, to place small pearls of glue on cardboard material, which when later cut and folded produces boxes. Other suitable equipment may be used, if desired. The process illustrated in Figure 1 is generally a roller driven system that moves from left to right in the drawing. The end of a roller 10 of suitable dry felt material to be saturated is conveyed using an impulse roller 12 to a treatment area 14 to saturate the dry felt with asphalt in a conventional manner. This saturation treatment step is illustrated as a series of turns of the non-rolled felt material as it faithfully represents how the material is fed through the hot asphalt bath or cavity to saturate the dry felt material. The temperature of the asphalt that is typically applied is greater than 400 ° F. When the saturated felt material comes out of the saturation treatment stage, it can be cooled by use of a water-cooled flash quench roller 16. Other means for cooling the saturated felt can be used, if desired. For example, transporting the material through a long distance in a cool environment would produce the same cooling result. However, it has been discovered that the subsequent production of the nail tabs can be performed without detriment on the surface of the saturated felt material, although this material is at an elevated temperature close to the condition of temperature at which the area leaves. of treatment 14. In this way, there is no need to use a rapid cooling scheme for the saturated felt material. The only cooling that is required is for the felt material to cool sufficiently at the end of the process to allow it to be wound into rolls of conventional size, as will be described later. Upon leaving the felt the treatment area 14, it is already saturated felt material 17. The material 17 is driven in the direction 24 through the production area of nail tongues 18 by a plurality of driven rollers 22a, ••• / 22x Although only two rollers are shown in the illustration, for convenience, a real system will have multiple rollers in the area 18. These are driven by a motor and transmission system (not shown) well known in the art, at a speed that is selected. by an operator. The line speed of the felt material 17 in the area 18 is closely monitored by the microprocessor 29 connected to the roller 22a. The thermoplastic based material to be dispensed onto the surface of the saturated felt material in motion is dispensed from nozzles or nozzle assemblies 26, as supplied from a pressurized supply pump and tank system 28. It is also heated the typical thermoplastic based material to a liquid state in the system 28 or when being introduced to the system 28. A preferred example of a suitable thermoplastic based material is a low density polyethylene compound EA839, a patented mixture produced by Eastman Chemical Corp. Such a compound includes one or more suitable adhesives that improve the bond of the material to the surface of the saturated felt material. The composite may also include a suitable color contrast pigment, such as red, to cause the tabs to protrude against the normally black color of the saturated felt background. Without an added pigment, the material is amber, which contrasts naturally to some extent with black. Other suitable materials based on thermoplastic can be selected, such as ethylene vinyl acetate, or if desired, a thermosetting based material, such as a two component polyurethane. Color may also be provided independently of a pigment disposed in the thermo-plastic material. For example, the nozzle can be fed from a separate source to be combined with the thermoplastic material just before the dispensing nozzle and when the application takes place. Regardless of the nail tab material used, it must be fast cooling or quick setting so that it bonds and solidifies on the surface of the saturated felt before it leaves the line area 18. The tabs, when bonded to the material, are tenacious but remain flexible or deformable and non-brittle. Normal operating conditions for roof installations are below freezing environmental conditions, that is, below 32 ° F, above 120 ° F. The characteristics for the tabs should be as described above on this total temperature range. Returning to Figure 1, the liquid material to be dispensed from the nozzles 26 is dispensed at a temperature of about 350-450 ° F., preferably at around 425 ° F, and at a pressure between 1,300 and 1,500 psi. Each orifice opening is about 0.026 inches in diameter. Saturated felt material below the nozzles may have fallen only at about 315 ° F from the temperature of about 400 ° F of the treatment area 14 at the time the material is deposited on it from the nozzles 26. The tabs that are formed are identified by reference numerals 29a, 29b, ..., 29x. The on / off timing of the nozzle 26 and the speed of movement of the saturated felt material, i.e. the line speed, are programmably matched by the microprocessor 30, as will be more fully described hereinafter. However, generally, the microprocessor 30 controls the "activation" time and the "deactivation" time of the nozzles or sets of applicator nozzles 26 so that the dimensions and the spacing of the tabs are correct. The operation of the microprocessor 30 is coordinated in operation with the microprocessor 29 which monitors the line speed. By leaving the saturated felt with joined tabs the line area 18 passes through a slotted wheel 32. The grooves in the slotted wheel 32 allow the tabs to pass through without being subject to a possible scraping action. From the wheel 32, the felt enters "freewheel formation" 34 and from there to the roller area 36. The roller area 36 is where the final rolls are produced. Typically, a # 30 saturated felt material is cut and rolled into les of 70 feet and the # 15 weight material is cut and wound into les of 140 feet. The line speed of preference moves between 300 and 800 feet per minute. In this way, every 6 to 12 seconds for a movement of felt material of 700 feet per minute, the material is cut, a roll is finished and a new roll is started.

Now referring to Figure 2, a top view of saturated felt material 17 is shown in line area 18. Three nozzles 26a, 26b and 26c are shown to form three linear rows of tabs parallel to the elongated dimension of material 17. A sheet of saturated felt material is typically 3 feet wide. In actual practice, there may be more than three rows. The size of the tabs is exaggerated for purposes of illustration, but typically a row of tabs is produced near the front edge of the material 17, another row of tabs is produced near the trailing edge, and a third row of tabs is produced midway along the path between these rows of edge. The front row of tabs, including the tabs 29a and 29b, is produced from the liquid material dispensed from the first nozzle 26a. A preferred embodiment of a suitable nozzle is a manifold housing that is being opened in the form of a plurality of individual, but closely spaced orifices. Five or six such holes have been successfully used. These holes are shown in a line transverse to the direction of movement of the felt material 17; however, they may be in some other pattern, if desired. The number of these openings generally determines the width of a tab produced. Each of the nozzles 26a, 26b, and 26c is connected to the pressurized pump and tank system 28 and controlled in activation / deactivation operation by the microprocessor 30, which, in turn, is coordinated in operation closely with the line speed monitoring microprocessor 29. It will be noted that it is preferred that the production of tabs results in a stacked arrangement of the tabs across or transverse to the direction of movement of the felt 17. Preferably, the tabs are square, but they can be rectangular or other shape. In Figure 2, the length of a tongue is defined as "1". If the application time or "activation" time for a nozzle is defined as "t", and the line speed of the material is defined as "S", then the formula t = 1 / S applies, where t, 1 and S are expressed in consistent units. To calculate, for convenience, how long it would take to form a 1-inch long tongue for a line speed of 600 feet per minute, the answer would be around 0.0083 seconds. The preferred operation coordinates the operation of the nozzles with the line speed via the microprocessor 30 so that the line speed can vary, the lengths of the tabs will remain substantially uniform. However, line speed and controlled nozzle operation can be carried out separately, if desired. Alternatively, a single microprocessor can be used which combines the operations of microprocessors 29 and 30. The spacing of the tabs is determined by the time of "deactivation" of the nozzles. For convenience of calculations, the distance from the leading edge of the tongue 29a to the leading edge of the tongue 29b is defined as "L". The time between the tabs is defined as "T". Therefore, the following equation is applied to calculate the distance L: T = L / S. The preferred width and length dimensions of the tabs are between 0.75 and 1.5 inches. The thickness of a tongue is typically around 0.04 inches. The separation distance of the tabs is usually 1 to 3 feet. Figure 3 shows an approaching view of the tongue 29a being formed by dispensing material from a mouthpiece 26a having five in-line holes 40, 42, 44, 46 and 48. As the material of the orifices flows in a liquid state, the The tongue width becomes slightly larger than the distance between the outer end holes before it starts to harden. Also, note that the liquid from each of the orifices runs together with adjacent reservoirs so that the formed tab has a uniform thickness dimension upon hardening. A smaller or larger number of holes can be used if desired. Figure 4 illustrates an alternate nozzle structure where the nozzle 50 has a single elongated slit 52 which is positioned transverse to the movement of the felt material 17.

Although the above description has been in relation to providing tar paper or saturated felt material with integrally formed tabs, other sheets or cover boards of building materials can be treated in a similar manner. For example, cover sheets of lining board materials employed prior to installing the final lining or finishing boards may use suitable rows of stud tabs spaced in a manner compatible with the separation of the bolts. Bolt spacing is conventional in a room, as determined by local building codes, but bolts are typically spaced either 16 or 24 inches apart. Accordingly, rows of nails of the appropriate, predetermined conventional interval separation can be provided so that when the lining boards are in place, the rows of nails are centered on the bolts. An installer can then hold the lining boards in place quickly with a nail gun that targets the tabs, which will also aim for the bolts. Although the lining boards may be in sheet form, they may also be in the form of a board. Typical stretch-foam board laminates are four feet by eight feet by one inch. Again, stud tabs may be provided as described hereinabove, appropriately spaced apart to focus on the bolts.

When the boards are placed in this way, then the fact that an installer targets the nail tabs using a nail gun will also target the bolts. Boards can be made with integrally formed nail tabs by appropriately placing the nozzles in rows formed at appropriate intervals and then feeding the boards through the area 18 of Figure 1 in a manner similar to the feeding of sheet material wound in the process. previously described. Therefore, although a particular embodiment of the invention has been shown, it will be understood that the invention is not limited thereto. Many modifications can be made and will be evident to the technicians in the matter. For example, if nails are to be made on the reverse side of the embossing material as well as on the upper side, the material with nail tabs on a first side is merely run through a second set of nozzles after passing the first on an inverter roller.

Claims (20)

1. CLAIMS 1. An enclosing material of the type generally applied to roofs prior to the application of roofing tiles, comprising a saturated lower layer material, and a plurality of tabs for tenacious and flexible nails made of a thermoplastic or thermosetting material formed at separate intervals depositing said tabs on the surface of said saturated lower layer material in a liquid state, which subsequently solidifies and bonds to said saturated lower layer material.
2. 2. A creping material according to claim 1, wherein said thermoplastic or thermosetting material includes reinforcing particles.
3. 3. A creping material according to claim 2, wherein said reinforcing particles are glass fibers.
4. 4. An embossing material according to claim 1, wherein said saturated lower layer material is felt material saturated with asphalt.
5. 5. An embossing material according to claim 1, wherein said tabs are made of a thermoplastic material that is primarily low density polyethylene.
6. 6. An embossing material according to claim 5, wherein said thermoplastic material includes a contrasting color pigment with said saturated bottom layer material.
7. 7. An embossing material according to claim 1, wherein said tabs are made of a thermofixing material.
8. 8. A method of making a composite creping material, which comprises treating an extended length of dry felt material with asphalt to make a saturated felt material, depositing a plurality of nail tongues made of a thermoplastic or thermoset material on the surface of the felt-saturated material in a liquid state in a plurality of places, the liquid deposits solidifying and bonding on the surface of said saturated felt material to form the nail tabs.
9. 9. A method of making an enclosing material according to claim 8, wherein said nail tabs are made of thermoplastic material that is primarily low density polyethylene.
10. A method of making an enclosing material according to claim 8, wherein said liquid reservoirs are made from nozzles, the design of said respective nozzles determining the width of said tabs in line with each of said respective nozzles.
11. 11. A method of making an enclosing material according to claim 10, wherein said deposits are each made from a nozzle, its opening being in the form of a plurality of closely spaced holes.
12. 12. A method of making an enclosing material according to claim 8, wherein said deposits are each made from a nozzle, its opening being in the form of an elongated slit.
13. A method of making an embossing material according to claim 10, and including synchronizing the "activation" time and the "deactivation" time of each of said nozzles to form a preselected pattern of said nails for nails, the "activation" time for each nozzle by determining the length of said tongues therefrom and the "deactivation" time for each nozzle by determining the spacing between tongues for the row of tongues in line therewith.
14. A method of making an embossing material according to claim 11, and including moving said saturated felt material at a controlled rate of speed, using controlled on / off nozzles to deposit said nail tabs in a liquid state at a plurality of places, the tabs for nails deposited from each of said nozzles forming a separate row of tabs in line with the movement of the separated felt material, and timing the conditions of activation / deactivation of said nozzles so as to stack the positions of the tabs transverse to the movement of the saturated felt material.
15. 15. A method of making an enclosing material according to claim 14, and wherein said movement of the saturated felt material and the timing of the activation / deactivation conditions of said nozzles are coordinated in a common manner.
16. 16. A method of making an enclosing material according to claim 15, wherein the length of each tab is determined by t = 1 / S, where t is equal to the time that the nozzle is active from which it is made the tongue, 1 is equal to the length of the tongue, and S is equal to the movement speed of the saturated felt material.
17. A method of making an enclosing material according to claim 15, wherein the separation of the anterior edges of two adjacent tabs formed from the same nozzle is determined by T = L / S, where T is equal to length of time that said nozzle is active for the first of said two adjacent tabs and is active for the second of said two adjacent tabs, L is equal to the distance between the anterior edges "of said two adjacent tabs, and S equals the speed of movement of the saturated felt material
18. 18. A roofing construction material of the type generally applied before the application of a finishing covering, comprising a flat sheet or board of covering material for covering separate bolts at regular intervals predetermined, And a plurality of tabs for tenacious and flexible nails made of a thermoplastic or thermosetting material, formed at separate intervals by depositing said tabs on the surface of said cover material in a liquid state, which subsequently solidifies and binds to said liquid. cover material.
19. 19. A method of making a roof composite construction material, which comprises horizontally moving a sheet or deck of the deck building material at a controlled rate of speed, And use controlled activation / deactivation nozzles, separated at predetermined intervals to deposit from each of the nozzles a thermoplastic or thermosetting material on the surface of the shell construction material in a liquid state in a plurality of places, the deposits Liquids solidifying and bonding on the surface of the roof construction material to form the nail tabs. A method of making a composite roof construction material according to claim 19, and timing the on / off conditions of the nozzles so as to stack the positions of the tabs transverse to the movement of the roof construction material.