US1927824A - Process of producing thick butt shingles with sealed edges - Google Patents

Description

C. R. ECKERT Sept. 26, 1933.

PROCESS OF PRODUCING THICK BUTT 'SHINGLES WITH SEALED EDGES Original Filed Aug. 14. 1926 w M F. H

m m NQ NK ATTOR f Patented Sept, 26 1933 UNITED STATES PROCESS OF PRODUCING THICK BUTT ,SHINGLES WITH SEALED EDGES Clarence It. Eckert, Englewood, N. 3., assignor to The Barrett Company, New York, N. Y., a corporation of New Jersey Qriginal application August 14, 1926, Serial No.

129,132. Divided and this application OctoberQ it, 1931. Serial No. 568,495?

l eClaims.

This invention relates to a process of making shingle elements, and more particularly to the manufacture of thick buttstrip shingles having tabs disposed along one longitudinal edge 85 of the body portion thereof, the cut edges of the strip shingles being sealed by means of a suitable water-proof coating. This application is a division of application Serial No. 129,132, filed August 14, i926, claiming a continuous process for making thick butt shingles.

'l'hick butt shingle elements have heretofore been made chiefly by hand-dipping a granular surfaced coated felt base into a bath of molten asphalt or other bituminous material, the element allowed to drain and then surfaced with granular material. This is an expensive and unsatisfactory manner of producing thick butt shingles since it involves time-consuming hand labor and 0 waste of asphalt occasioned by the dipping opera- 5 tion.

In applicant's prior application, Serial No. 129,132, hereinabove referred to, a continuous process of making thick butt shingles is disclosed and claimed. This application is directed to the :5 novel procedure disclosed in the prior application permitting the sealing of all coated edges of the strip shingles with water-proofing material during the production thereof from a web of a width sufficient to produce a plurality of 39 strips which are subsequently cut into shingles, and this without transverse flexing or bending of the fibrous base with consequent disrupting and weakening oi? the-base.

According to my prior application, a fibrous foundation preferably the usual roofing felt, is first saturated with asphalt or other bituminous material, dried, and while moving in a horizontal direction, coated with asphalt on both sides. The top coating is then surfaced with granular niaterial and mica dust applied to the base coating wrender it non-cementitious. Thereafter the surfaced web is cut longitudinally into a plurality of strips, four in the embodiment of the r invention disclosed. Each strip is cut so as to 9 provide tabs along one longitudinal edge thereof The face of the spaced tabs and the out edges are then coated with asphalt or other waterproofing material and granular material is apr plied to the coating to form a thick butt shingle,

" the tab portions of which have a double coating and surfacing on the felt foundation whereas the body portion'has but a single coating and surfacing on the felt foundation.

, To permit the effective sealing of the forward tab edges of the strip with coating material in continuous processes of manufacturing the elements such as briefly described above, it is necessary to separate the contiguous strips formed in the longitudinal slitting of the starting web. If the strips are not separated the coating 9 material applied to the surfaces of contiguous strips adheres to the faces thereof and does not effectively seal the longitudinal out edges. Separating the strips by causing them to move apart from each other after the web is cut, involving $55 transverse movement of the cut strips with respect to the portions of the web from which they are cut, it has been found, weakens and tends to disrupt the felt base, seriously impairing the final product. l

in accordance with this invention the strips formed by the longitudinal slitting operation are separated by passing alternate strips about guides so that-they travel in the same longitudinal direction as the portions of the web from which they are-cut but in a difierent horizontal plane from the plane of movement of the remaining strips formed in the cutting operation. Thus, if tour strips are out from a web and the strips be numbered 1 to 4 from right to left, viewing Fig. 3 of the drawing, strips 1 and 3, while traveling in the same longitudinal direction as the portions of the web or fabric from which they are cut, are caused to travel in a different horizontal plane and are consequently separated a distance equal to the width of the intervening strip. Separation of the strips in this manner gives ready and complete access to the cut edges of the strip in the succeeding coating and sealing operation. w Strips 2 and 4 may travel in the same horizontal plane as the starting web or may be elevated'or depressed to travel in a difierent plane from that in which strips l and 3 travel. Thus, it will be noted that the individual strips are separated while continuously moving in the same longitudinal direction as the portions of the starting web from which they are out without moving the strips transversely of the longitudinal direction of movement of the corresponding portions or the oo starting web. Hence, the felt base is not subject to strains and weakening influences occasioned by movement of a portion of the strip transversely, to the longitudinal direction of movement of the remaining portion of the'strip.

In the accompanying drawing illustrating one embodiment of this invention in which like ref= erence characters refer to like parts- Fig. 1 is a diagrammatic side elevation, vpar-- no tially in section, of the type of apparatus which asphalt or tar.

invention;

Fig. 2 is a diagrammatic plan view of the web as it travels through the apparatus;

Fig. 3 is a diagrammatic perspective view showing the cut web as it leaves the longitudinal cutters and indicating the path of movement of the cut strips resulting in the separation thereof;

Fig. 4 is a vertical section partly in elevation of apparatus which may be employed for the application of the butt thickening coating to the strips;

Fig; 5 is a plan view of the apparatus of Fig. 4. showing the coating mechanism for two strips; and

Fig. 6 is a section, taken through one of the tabs, of the thick butt shingle of my invention.

Referring now to the drawing, a web A of roof ing felt of the desired width is led through the saturating tank 5, where it may be impregnated with a suitable water-proofing compound, such as The saturated web passes between the squeeze rolls 6 for removing excess saturant after which the web may 'pass over dry- ;ing racks 7 for allowing the saturated web to cool somewhat. The web is then fed through the coating rolls 8 and 9, by means of which a relatively thin coat of weather-proofing compound, such as tar or asphalt (usually of a higher melting point than that of the saturant) is aphere.

plied to the impregnated sheet. While the coating is still soft, the web passes under the hoppers l1 and 12 and around the rolls 13 and 14.

The hoppers 11 and 12 are of usual design, hopper 11 containing crushed slate, or other wearresistant granular material, of any suitable color or mixture of colors which may be showered upon the face of the coated web, thus surfacing the web. Hopper 12 contains mica dust which is fed to the rear surface of the web as it passes about roller 13, thus rendering the rear surface of the web non-cementitious.

The web now passes over the cooling rolls 15 and 16 and over the idler roll 17 and between the platen roll 18 and the cutting roll 19. By the installation of the desired cutting roll the finished shingle element may be made to take the form of a strip having rectangular tabs, or hexagonal tabs, or octagonal tabs or other desired shape. Such cutting practice is, in general, known to those skilled in the art, and it is thought, need not be dealt with more specifically After passing the cutting roll, the web A will appear as a plurality of strips 1, 2, 3, and t (Figs. 2 and 3) These strips pass through the tab knocker 20 and splitter assembly 21 which; in the case of the type of shingle strip shown,

removes the cut outs and splits the almost severed web into strips having shinge simulating tabs. (The specific details of this assembly are described and claimed in U. 8. Patent No. 1,744,-

are) Obviously, if octagonal or hexagonal shingles are being produced certain portions of the tab knocker and stripper assembly, such as the tab knocker itself, would be omitted.

The cut web, shown to the extreme leithof Fig. 3, now passes on to conveyor bands 22 and 23. Strips 1 and 3 are carried by bands 22 in a downward direction while strips 2 and 4 are naeaeaa 4 also travel in the same longitudinal direction I as the direction of movement of the portions of web A from which they are cut and pass over idler roll 65 while strips 1 and 3 pass over idler roll 64 to the tab or butt-thickening apparatus 1 hereinafter described. Thus, the strips are saparated without distortion to give ready access to the cut edges permitting effective sealing of the cut edges.

The strips 1, 2, 3 and 4 are now ready to have i applied thereto the tab or butt-thickening coating of weather-resisting compound such as asphalt, tar, or other bituminous material. This is accomplished by means of an apparatus as shown in Figs. 4 and 5, and indicated generally in Fig. 1 by the reference numerals 24 and 25.

The coating apparatus of Figs. 4 and 5 involves a coating material tank 33 arranged to feed the coating material to a coating roll 34 having an enlarged portion 35 thereon. The flow of coating material from tank 33'upon the enlarged portion 35 of roll 34 is controlled by means of a gate 36. Enlarged portion 35 of roll 34 applies the coating 30 to the upper side of the tabs and to the edges thereof, while the strips are supported on plates 66, the coating material being supplied to the portion 35 of roll 34 slightly in excess of that needed to coat the upper surface of the tabs so that sufiicient coating material will run over the edges of the tabs to coat '1! them. Thus, the face of the tabs and the cut edges thereof are completely covered and sealed with bituminous coating material. If desired additional coating material may be applied to the cut edges by means of a pipe or hose arranged 1 to discharge coating material onto the edges.

While thecoating material is still soft and plastic the strips 1 and 3, and 2 and 4 pass under crushed slate hoppers 36, one for each strip, which shower crushed slate or other wear-resist- 11 ing material upon the coated portion of each. strip. As shown in Fig. 1, the strips also pass over the rolls 41 which press the crushed slate into the plastic coating. The strips are then conducted over the cooling rolls 42 andover the 11 timing rolls 43, projections upon the periphery of which engage in the notches between the tabs upon the strips. The cutters 44 are so synchronized with the timing rolls 43 that the strips are out along a line of severance between the tabs 11 to form the finished shingle strips or elements 50, a section of which is shown in Fig. 6.

From Fig. 6 it will be noted that the element involves a felted fibrous foundation 51 which may be and preferably is the usual roofing felt. This felt, as hereinabove described, is saturated with bituminous material and then the upper surface is completely coated with bituminous material as indicated at 52. If desired, the base of the felted foundation may be rendered non-cementitious by dusting it with mica, indicated by the reference numeral 53. A layerof granular material 54 is partially embedded over the complete face of the bituminous coating 52. A second coating 55 of bituminous material extending about the cut 14 edges of the tab, thus sealing the edges, and over the tab portion only of the element, is then ap-= plied to thegranular surfacing 54. Granular material 56 is then partially embedded in the bituminous coating 55. By the expression moving alternate strips in the same longitudinaldirection as the portions of the base from which they are cut, used in the claims, is meant that the direction of movement of the strips after contiguous strips have manage been separated either by depressing or elevating alternate strips is in the samelongitudinal direction as the direction of movement of the web from which the strips were cut.

While the embodiment of the invention hereinabove described pertains to the manufacture of thick butt strip shingles, it will be understood that the invention is not confined thereto and is applicable to the treatment of fibrous and other bases which are weakened or disrupted by moving a portion thereof transversely to the remaining portion.

I claim:

1. In the method of treating the edges of a plurality of strips produced from a single web which is weakened when a portion thereof is moved in the same plane transversely to the remaining portion, the improvement which involves cutting the web into a plurality of contiguous strips, and moving alternate strips in a diiierent plane from that in which the remaining cut strips move, thus separating the contiguous edges of the cut strips a distance equal to the width of the intervening strips cut from the web.

2. The method of sealing the edges of contiguous strips of felt cut from a felt base which comprises moving a felt base, cutting said base into a plurality of contiguous strips, moving alternate strips in the same longitudinal direction as the portions of the base from which they are cut and in a difierent plane from that in which the remaining strips travel, thus separating the cut edge of the strips 2. distance equal to the width of the strips between alternate strips when out and treating the cut edges of the strips with waterproofing material.

3. The method of sealing the edges of contiguous strips of felt cut from a felt base which comprises moving a felt base in a horizontal plane, cutting said base into a plurality of contiguous strips, moving alternate strips in the same longitudinal direction as the portions of the base from which they are cut in a plane at an angle to the plane of movement of the felt base and then in a plane substantially parallel to the plane of movement of said base and the plane of movement of the remaining strips, thus separating the cut edges of the strips a distance equal to the width of the strips between alternate strips when out and coating the cut edges of the strips with waterproofing material.

4. The method of making thick butt shingles having tabs disposed along one longitudinal edge which comprises continuously moving a felt web through a saturating bath, continuously coating with waterproofing material the upper surface of said web, continuously surfacing with granular material the coated face of said web, continuously cutting said web into strips each having tabs disposed along one longitudinal edge thereof, continuously separating saidstrips by moving alternate strips in the same longitudinal direction as the portions of the base from which they are cut and in a plane different from the'plane of movement of the remaining strips, thus separating the cut edges of the strips a distance equal to the width of the strips intervening alternate strips when cut, coating the tab portions and the cut edges of each strip with waterproofing material, applying granular material to the coated portions and severing each strip transversely into strip shingles.

CLARENCE R. ECIERT.

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