Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Coated or impregnated woven – knit – or nonwoven fabric which... – Coating or impregnation provides wear or abrasion resistance
Reexamination Certificate
1998-12-30
2001-05-08
Morris, Terrel (Department: 1771)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Coated or impregnated woven, knit, or nonwoven fabric which...
Coating or impregnation provides wear or abrasion resistance
C442S104000, C442S167000, C442S170000, C442S171000, C442S381000, C442S389000, C442S390000
Reexamination Certificate
active
06228785
ABSTRACT:
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
This invention relates to asphalt-based roofing materials, and in particular to an asphalt-based roofing material including a web that is positioned and bonded in such a manner as to provide the roofing material with improved impact resistance.
BACKGROUND OF THE INVENTION
Asphalt-based roofing materials, such as roofing shingles, roll roofing and commercial roofing, are installed on the roofs of buildings to provide protection from the elements. Typically, the roofing material is constructed of a substrate such as a glass fiber mat or an organic felt, an asphalt coating on the substrate, and a surface layer of granules embedded in the asphalt coating.
The typical roofing material construction is suitable under most circumstances. However, sometimes a roofing material is subjected to forceful impacts, such as impacts from hailstones during storms, which may cause significant damage to the roofing material. For instance, the force of the impact may cause a puncture or tear in the roofing material. Accordingly, there is a need for a roofing material having improved impact resistance.
Several patents disclose asphalt roofing materials constructed with multiple substrates. For example, U.S. Pat. No. 5,326,797 to Zimmerman et al. discloses an asphalt-coated roofing shingle including a top mat of glass fibers and a bottom mat of polyester. The patent is related to a fire-resistant shingle, and there is no mention of improved impact resistance. Also, there is no suggestion of improved bonding between the polyester mat and the asphalt coating.
U.S. Pat. No. 5,571,596 to Johnson discloses an asphalt-coated roofing shingle including an upper layer of directional fiber such as Kevlar fabric, a middle layer of fibrous mat material such as glass fiber mat, and a lower layer of directional fiber such as E-glass fabric. The upper fiber layer is described as being important to shield the shingle from hail impact damage. The lower layer of E-glass fabric is not effective for improving impact resistance of the shingle.
U.S. Pat. No. 5,822,943 to Frankoski et al. discloses an asphalt-coated roofing shingle including a scrim and a mat. The scrim is bonded to the mat with adhesive; there is no suggestion of improved bonding between the scrim and the asphalt coating. A scrim is not very effective for improving impact resistance of a shingle.
A journal article, “Ballistic Impact Resistance of SMA and Spectra Hybrid Graphite Composites”, Journal of Reinforced Plastics and Composites, Vol. 17, 2/1998, by Ellis et al., discloses placing energy absorbing fibers on the back surface of a graphite composite. The fibers were found to provide only a slight improvement in the impact strength of the composite. The journal article is not related to roofing materials.
Thus, the previous literature does not suggest the specific positioning and bonding of a web, and the selection of the right material for the web, to effectively dissipate the energy of impacts on the roofing material.
It is known to manufacture roofing materials with rubber-modified asphalt to provide some improvement in impact resistance. Unfortunately, roofing materials made with rubber-modified asphalt are more difficult to manufacture, handle, store and install, and are more expensive, than roofing materials made with conventional roofing asphalt. Also, the rubber-modified asphalt shingles are not very effective in resisting impacts. Accordingly, there is still a need for a roofing material having improved impact resistance.
SUMMARY OF THE INVENTION
The above objects as well as others not specifically enumerated are achieved by an asphalt-based roofing material according to the present invention. The roofing material includes a substrate coated with an asphalt coating. The asphalt coating includes a lower region that is positioned below the substrate when the roofing material is installed on a roof. A web is fused to the lower region of the asphalt coating. A portion of the web and of the asphalt coating have been intermingled by melting, thereby fusing the web and the asphalt coating.
The present invention also relates to a method of manufacturing the asphalt-based roofing material. The method includes the steps of coating a substrate with an asphalt coating, and applying a web to the lower region of the asphalt coating. A portion of the web and of the asphalt coating are intermingled by melting, thereby fusing the web to the lower region of the asphalt coating. Another embodiment of the method includes the steps of applying a web to a substrate, coating the substrate and the web with an asphalt coating, where the web is in contact with the lower region of the asphalt coating, and intermingling a portion of the web and of the asphalt coating by melting, thereby fusing the web to the lower region of the asphalt coating.
Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
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Ellis, Roger L., et al., “Ballistic Impact Resistance of SMA and Spectra Hybrid Graphite Composities.”Journal of Reinforced Plastics and Composites, vol. 17, No. 2, (1998), pp. 147-164.
Miller Carla A.
Miller David George
Dottavio James J.
Eckert Inger H.
Morris Terrel
Owens Corning Fiberglas Technology Inc.
Torres Norca L.
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