Tamko Building Products, Inc.

David C Humphreys

Michael Shifferd

Kyle Wayne Davis

Chris Freeborg

Alex Alekhine

Thomas M King

Christopher Freeborg

Rodney Lewis

Steven Russell

Disclosed is an additive manufacturing process for making shingles and roof tiles. The entire shingle, including the substrate, can be manufactured on location, or a substrate can be manufactured at a manufacturing plant and then colored and textured on location to provide a wide variety of shapes and colors of shingles and roof tiles. Costs for inventory and shipping are reduced and a greater variety of shapes and colors can be provided for the shingles and roof tiles. The additive manufacturing equipment can be mounted on a truck so that the additive manufacturing techniques can be a mobile application of the additive manufacturing technology.

On demand three dimensional roof system manufacturing

A lightweight roofing shingle comprising a saturated mat having an exposed side and an unexposed side wherein a fabric reinforcing layer substantially replaces the bottom asphalt coating and the backing aggregate on the unexposed side of a conventional shingle. The lightweight shingle will have a top asphalt layer applied to the exposed side of the mat and a layer of granular material applied to the top asphalt layer opposite the mat per conventional construction, and the fabric reinforcing layer is adhered directly to the unexposed side of the saturated mat. In one embodiment, the fabric reinforcing layer covers an entire area of the unexposed side of the saturated mat. The reinforcing layer may preferably be a nonwoven fabric made from PET or polypropylene. The lightweight roofing shingle may also include a release tape layer applied to the reinforcing layer opposite the saturated mat.

Lightweight roofing shingle and method for making same

An asphalt shingle coating system that includes a coater, a mixer, a viscosity gauge, a wax supply, a wax pump and a control system. The coater applies a layer of a coating asphalt mixture on an asphalt shingle substrate. The mixer mixes the coating asphalt mixture and is positioned upstream of the coater. The viscosity gauge may be positioned between the coater and the mixer, and it measures the viscosity of said coating asphalt mixture before it is delivered to the coater. The wax supply is in fluid communication with the mixer and a wax pump may deliver a volume of wax from the wax supply to the mixer, and the control system may selectively adjust the operation of the wax pump to substantially maintain a desired viscosity of said coating asphalt mixture.

System and method for reducing viscosity variations in roofing asphalt

Disclosed is a release material that can be applied as a liquid, gel, emulsion, foam, etc. in a shingle manufacturing line. The release material can also be used in the manufacturing of roll roofing. The release material primarily constitutes an emulsion of polymers that can be cured with heat, IR light or other methods. Silicone may also be included in the emulsion which assists in releasability. The release material can be sprayed or extruded on to the surface of the shingle in an automated fashion, eliminating the necessity for operator interaction.

Applying a release material to a shingle during manufacturing

An asphalt shingle manufacturing machine that includes a curtain die for applying a liquid release layer on an asphalt coated substrate. The moisture of the liquid release layer evaporates leaving a dispersed solid particulate release layer. The curtain die includes a first body section and a second body section with a shim disposed between the body sections to define a distribution channel. The second body section may include chamber manifold defined therein to store a volume of liquid release agent. The distribution channel places the chamber manifold in fluid communication with a discharge outlet of the curtain die in order to disperse a volume of liquid release agent from a chamber manifold out of the discharge outlet. The shim may be configured to define a width of the distribution channel to determine the flow rate and discharge pattern of the liquid release agent.

Curtain die for applying a liquid release agent to a shingle substrate

Disclosed is waterproofing sheeting that uses a polyester layer that provides high lateral stability and puncture resistance. The waterproof sheeting can be used in many applications including waterproof roof underlayments waterproof sheeting for foundations, underlayment for tile and flooring and various other applications. The waterproof sheeting can be manufactured without many of the problems associated with the granular coatings of existing waterproof sheeting that create excessive wear and environmental hazards.

Peel and stick waterproofing material

An asphalt shingle having an asphalt-coated substrate sheet with a top surface and a bottom surface, wherein a liquid release layer is applied on the bottom surface of the asphalt shingle instead of conventional backing particulates. The liquid release layer may help the shingle proceed through the manufacturing machinery without sticking and may prevent the adhesion of the bottom surface of the asphalt shingle to an adjacent shingle in a stack of shingles upon experiencing a pressure up to around four pounds per square inch, a temperature of around eighty degrees Celsius or below. The liquid release agent may also prevent adhesion of adjacent shingles in a stack at various temperature and pressures for at least fourteen days.

Liquid release agent and associated methods of application

A roofing shingle comprising a base mat having a tab portion covered with granules and a headlap portion covered with a mask or film layer. An asphalt-based coating is applied to at least a top surface of the base mat. The film layer is adhered to the asphalt-based coating applied to the headlap portion and the granules are adhered to the asphalt-based coating applied to the tab portion. The film layer is adapted for preventing granules from adhering to the headlap portion of the base mat and, as such, the headlap portion may be substantially free from any granules adhered thereto. A method for manufacturing a roofing shingle is also provided wherein granules that are not adhered to the tab portion of one shingle may be collected and reapplied the tab portion of another shingle.

Shingle with headlap mask

Disclosed is waterproofing sheeting that uses a polyester layer that provides high lateral stability and puncture resistance. The waterproof sheeting can be used in many applications including waterproof roof underlayments, waterproof sheeting for foundations, underlayment for tile and flooring and various other applications. The waterproof sheeting can be manufactured without many of the problems associated with the granular coatings of existing waterproof sheeting that create excessive wear and environmental hazards.

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Joplin, MO, United States of America

David C Humphreys