Environmental Reprocessing, Inc.

Recycled Asphalt Shingle Technology, LLC

Other

Owens Corning Intellectual Capital, LLC

Gaf Buildinhg Materials Corp.

Thomas J Zickell

Robert Zickell

Charles Diman

Mat Bockh

Steven C Bettoli

James A Karlis

Stephen Mahoney

An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. In one heavyweight underlayment, an oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer. In a lightweight underlayment, a split release sheet or facer segmented to provide a releasable selvedge edge and incorporating a high traction polymer on its surface is applied to the rubberized asphalt.

Rubberized roof underlayment

A system () for recycling asphalt shingle scrap. There is a cold process, hot process, and a separation process. In the hot process, all of the components are ground except for the course surface granules. In the cold process, a type of grind is formed that is the same as the hot process except it is a dry powder. A horizontal mixer () can be used either hot or cold. The hot process and cold process can be run in combination with one another or independently. The component separation process uses a screen or the like () to separate the cold process material into surface granules, filled asphalt coating, and saturated felt component, while a magnet () may be used to help separate nails and other metal objects from the mixture.

Horizontal mixer

An asphalt roofing material recycling system and method is used to recycle new and used (post consumer) asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material, which may be in bundles, is broken up and separated and then provided to a cooled recycling vessel. Dry ice is added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of high speed shippers having tulip hear chipping teeth as well as one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be separated by screening and stored as power or compressed into bricks or briquettes.

Asphalt material recycling system and method

An asphalt roofing material recycling system and method is used to recycle new and used asphalt materials. The asphalt material is broken up and separated. Dry ice may be added to the recycler and/or a jacket coolant used to cool the recycling vessel. The recycle vessel includes a number of high speed choppers having a blunt end as well as a horizontal mixer element with paddles. The recycled asphalt material is provided to a screener that may feature a plurality of sloping levels, each level including a tray below a screen and balls located within the tray that bounce due to vibration to prevent clogging of the screener. A second processing trip involving gravity feeding the material to be further recycled into a cutter with knife edges to further break down the size of the asphalt material is used for large particles that do not pass through the screener.

Asphalt material recycling system and method with ball screener and impact and cutting choppers

The method of depositing granules in a frame pattern includes moving an asphalt-coated web and depositing successive granule blend drops on the web. The first blend drop has a first color and forms a first blend drop pattern defining an inner region. The second blend drop has a second color and forms a second blend drop pattern sized to fit within the inner region of the first blend drop such that the first blend drop frames the second blend drop. A third blend drop having a different third color or the same as the first color is deposited such that the third blend drop adheres to an intermediate region between the first and second blend drops. The system includes a mechanism for moving the web and an asphalt coater for coating the web with asphalt. First and second media applicators are used to deposit the first and second blend drops in the respective first and second blend drop patterns. A third media applicator deposits the third blend drop as a curtain of granules over the first and second blend drop patterns.

System and method for depositing granules in a frame pattern

An asphalt based material recycling system and method is used to recycle asphalt materials, such as asphalt shingles and tar paper that include granules, fibers or other particles. The asphalt material is simultaneously heated and milled in a heated milling apparatus, such as a heated ball mill, to reduce the asphalt material including granules to a fine mesh in suspension in liquid asphalt. Excess moisture is removed from the asphalt material being recycled by continuously venting the heated milling apparatus. The heated milling apparatus preferably includes a rotatable milling vessel rotated at an acute angle with respect to the horizontal plane and having an opening that provides continuous venting. The shape of the milling vessel allows the liquid level inside the milling vessel to have a liquid head above the outlet region of the milling vessel, for facilitating milling. The rotatable milling vessel includes a plurality of mixing members, such as rods or paddles, extending from an interior surface to enhance milling and to pull the asphalt material being recycled under and into the liquid slurry. The asphalt material recycling system further includes a filter apparatus for filtering reduced asphalt and removing foreign objects therefrom.

Method for recycling asphalt material

A recycled asphalt roofing material for use on sloped roofs, which provides the required elevated melt point without using prior art methods of oxidizing the asphalt prior to incorporation into the roofing material is provided. The recycled asphalt roofing material is made up of approximately 30% flux asphalt and approximately 70% reclaimed asphalt roofing material. The fibrous backing in the reclaimed material modifies the asphalt in such a way as to provide the required elevated melt point. The manufacturing process for recycled fiberglass mat-based roll and shingle roofing, in its preferred embodiment, consists of impregnating a roofing material backbone, such as a fiberglass or polyester mat with recycled asphalt material to form inner and outer layers of recycled material and then applying optional second inner and outer layers of standard asphalt coating to the inner and outer layers of the recycled material. The second coating encapsulates and seals the recycled material and thus ensures that the recycled roofing material will have the same longevity as prior art asphalt roofing materials.

Recycled roofing material and method of manufacturing same

Method of manufacturing roofing materials utilizing reclaimed

A system and method for depositing a pattern of media on a moving surface includes a media depositing apparatus that deposits media in a predefined pattern on the moving surface. A media applicator roll having a media receiving region, such as engraved or raised portions, receives the media from a media feeder as the media applicator roll rotates. A media retaining member maintains the media in contact with the media receiving region until the media reach a bottom region of the media applicator roll and are released from the media applicator roll in the predefined pattern onto the moving surface. The media depositing system also includes a multiple compartment media feeder that selects and selectively feeds one or more of multiple types of media or granules to the receiving region of the media applicator roll. The method for depositing a pattern of media includes synchronizing the speed of rotation of the media applicator roll with the speed of the moving sheet of material so that the media are precisely deposited as they are released from the media receiving region. The method also includes minimizing the distance that the media must drop from the applicator roll receiving region to the moving surface.

Media depositing system and method

An asphalt roofing material recycling system and method is used to recycle asphalt materials, such as asphalt shingles and tar paper that include granules, fibers or other particles. The asphalt material is simultaneously heated and milled in a heated milling apparatus, such as a heated ball mill, to reduce the asphalt material granules to a fine mesh in suspension in liquid asphalt. Excess moisture is removed from the asphalt material being recycled, either during heating and milling by continuously venting the heated milling apparatus, or before the heating and milling in a drying apparatus. The heated milling apparatus preferably includes a rotatable milling vessel rotated at an acute angle with respect to the horizontal plane and having an opening that provides continuous venting. The rotatable milling vessel includes a plurality of mixing members, such as rods or paddles, extending from an interior surface and preferably arranged in a helical pattern to force the asphalt material away from the opening. The asphalt material recycling system further includes a storage apparatus for storing reduced asphalt material and a filter apparatus for filtering reduced asphalt and removing foreign objects therefrom.

A system and method for depositing a pattern of media on a moving surface includes a media depositing apparatus that deposits media in a predefined pattern on the moving surface. A media applicator roll having a media receiving region, such as engraved or raised portions, receives the media from a media feeder as the media applicator roll rotates. A media retaining member maintains the media in contact with the media receiving region until the media reach a bottom region of the media applicator roll and are released from the media applicator roll in the predefined pattern onto the moving surface. The method for depositing a pattern of media includes synchronizing the speed of rotation of the media applicator roll with the speed of the moving sheet of material so that the media are precisely deposited as they are released from the media receiving region. The method also includes minimizing the distance that the media must drop from the applicator roll receiving region to the moving surface.

System and method for depositing media in a pattern on a moving sheet

A bituminous roofing membrane, and method of manufacture, is disclosed having a reinforcing mat sandwiched between top and bottom layers of a tacky polymer modified bitumen. The leading edge portion of the top layer is provided with a layer of roofing granules. A track of adhesive is provided on the roofing granules. The trailing edge portion of the top layer is provided with a layer of non-slip plastic film. A release sheet is applied to the bottom layer of the membrane to prevent engagement of the top and bottom layers with one another when the membrane is rolled for storage or shipment. In use, upon removal of the release sheet, the membrane is secured to the roof with the leading edge portion constituting a starter strip for receiving thereon the first row of roofing shingles, and the trailing edge portion constituting an underlayment for receiving thereon successive rows of roofing shingles.

Growing community of inventors

New Castle, NH, United States of America

Thomas J Zickell