US1890017A - Method of and machine for making thick butt roofing - Google Patents

Description

Dec. 6., 1932. c. R. MKODONALD METHOD OF AND MACHINE FOR MAKING THICK BUTT ROOFING Original Filed March 1 192 Patented Dec. 6, 1932 UNITED STATES PATENT OFFICE CHESTER R. MACDONALD, OF MONROE, MICHIGAN, ASSIGNOR, IBY MESNE ASSIGNMENTS,

TO THE PATENT AND LICENSING CORPORATION, OF BOSTON,

CORPORATION OF MASSACHUSETTS v MASSACHUSETTS, A

METHOD OF AND MACHINE FOR, MAKING THICK BUTT ROOFING- Application filed March 1, 1926, Serial No. 91,385. Renewed March 8, 1932.

This invention relates to a method of and mechanism for coating the marginal portions of a continuous sheet of material in such a way as to permit the coating material to drain in some measure toward the edges of the sheet so as to give a certain amount of taper to the thickness of the coats adhering to the sheet so that the coated marginal portions of the sheet will be thickest at the edges and taper inwardly toward the uncoated middle portion of the sheet.

In carrying out the invention, it is preferable to use a coating fluid which is not too fluid, and which quickly becomes non-fluid after application. The thickness -'and taper of the coating desired will govern the choice of the coating fluid employed.

An object of the invention is to provide means for the rapid and economical production of manufactured roofing with thickened tapering butts. Another object of the invention is to provide means for making thick butt roofing units having slots or notches cut into their lower edges and enveloping the cut edges of the slots with the coating material.

An embodiment of the invention will be found illustrated on the drawing, on which,

Fig. 1 represents diagrammatically a side elevation, partly in section, of apparatus for slotting and dipping the edges of a continuous sheet of material;

Fig. 1a represents apparatus for applying grit to a surface of the dipped portions of the sheet;

Fig. 1?) represents apparatus for cooling and cutting the sheet; the apparatus shown in Figs. 1, 1a and 1?) being sections of a single machine for carrying out'the successive steps of manufacture of roofing units from a. continuous sheet;

Fig. 2 is a section on the line 2-2 of Fig. 1;

Fig. 3 is a section on the line 33 of Fig. 1;

Fig. 4 is a section on the line {1-4 of Fig. 1;

Fig. 5 shows a modified form of apparatus for applying coating material to the sheet;

Fig. 6 is a side view of the roll 26 indicating the belts that pass thcreover.

Referring to the drawing in detail, 10 represents a roll of sheet material such as roofing felt, or any other material suitable for use as a roofing base as for example, asphalt-coated or asphalt-coated and grit-surfaced roofing felt. This roll may be supported as by a frame 11. The sheet 12 from the roll'lO is led horizontally over a container 13 which may be of any desired shape and is preferablyA adapted to hold a supply of liquid 14, suc for example, as heated asphalt, or similar thermoplastic, or any other equivalent coating material. Steam pipes 15 may be provided to maintain the asphalt or other thermoplastic material in liquefied form. Before being passed over the container 13, the sheet 12 may be run between a pair of rolls 16 carrying cutters for cutting slots in the marginal edges of the sheet, which may serve to define shingle simulating tabs in the finished units. The cutting elements on the roll 16 may be arranged to trim or shape the edges of the sheet in accordance with any desired design in addition to or instead of cutting any preferred shape of slot. The sheet is then passed between a pair of guide rolls 17 a belt 18 being also'passed over the middle of the lower roll 17. Instead of a continuous sheet 12 of indeterminate length, a succession of individual sheets may be fed between the rolls 17. The belt 18 is preferably narrower than the sheet and is intended to support the central portion .only thereof. The sheet 12 with the belt 18 under its middle portion is then passed over the rim 19 of the container 13, whereupon one or both of themarginal portions of the sheet are bent are supported preferably on the sides of the container 13 as on bosses 21, and are positioned to engage the marginal portions of the sheet 12 in such a way as to bend them down into the liquid 14, the central portion of the sheet being supported above the liquid by the belt 18, and the sheet assuming a channellike form. While the marginal portions of the sheet 12 are immersed in the liquid, both surfaces of each portion are thoroughly coated with the liquid, as are also the edges of the sheet and the edges of the slots, if any. By means of a guide wheel 21 supported as by bosses 22, the sheet as a whole is led updownwardly. as by vertical wheels 20, which wardly in order to leave the container with its marginal portions in their downwardly bent condition. The downwardlybent condition of the marginal portions is maintained as by guide rolls 23, 24, the roll 23 supporting the central portion of the sheet 12, while the rolls 24 are shaped to bear on the marginal portions, as may be seen in Fig. 4. The travel of the sheet in its bent condition from the rolls 20 to the rolls 23, 24, permits the sheet to emerge from the coating liquid while the marginal portions are still extending downwardly, so that the coating material on said marginal portions is permitted to drain by gravity toward the edges of the sheet and the excess coating is permitted to drip therefrom. Although I have shown positive means for efiecting the bending of the marginal portions of the sheet, it will be appreciated by those skilled in the art that the limp and flexible character of roofing material of this type would permit the same, especially when w warm, to bend of its own weight, in which case the rollers 20 and 24 may be dispensed with as the marginal portions of the sheet will, by virtue of their naturally flexible character and under the action of gravity, bend downwardly when the support of the sheet is confined to the central portions thereof. A suitable wiping device 25, which is preferably heated, as, for example, a steam pipe, ispositioned inside the rim of the container so as to engage the edges ofthe sheet and to wipe therefrom drippings of coating material. The container 13, as shown in Fig. 1, is open, but it will be understood that a cover may, if desired, be provided thereover having suitably shaped apertures to permit the sheet to enter and leave the container. After passing the rolls 23, 24, the sheet is preferably passed over a guide roll 26, from which the endless belt 18 may be returned to the roll 17.

In order to prevent the central portion of the sheet 12 from buckling or bulging upwardly when the marginal ortions are bentdownwardly, a second belt 2 equal in width 4 to the belt 18, may be led over the upper roll a 17 to engage the upper surface of the central portion of the sheet 12 as it passes between the rolls 17. If it is desired to pass sheet sections through the machine instead of a 'con tinuous sheet 12, the belts 18 and 27 will engage the sections and carry them through. Suitable guide rolls 28, 29 and 30 may be provided for the belt 27, and, if desired, a fixed table or guide 31 may be secured to the ends of the tank, as at 32, 33,and also to suitable standards 34 extending upwardly from the bottomof the tank to support the belts 18 and 27 and the'sheet 12 during their over or through the container 13.

Between the rolls 23, 24 and the roll 26 the drooping marginal portions of the sheet are picked up from beneath by a pair of endpassage less belts 40, 40, on which may be deposited from a suitable feeding device 54 comminuted or powdered material, as desired, to surface the under face of the sheet. The materials so deposited on the belts 40, 40 may be crushed slate, mica, coke, or talc, ground cork, sawdust, or any mixture or equivalent of these. If the units to be cut from the sheet are eventually to be electroplated, the material on the belts 40, 40 may beelectrically conductive grit or powder. The belts 40, 40 after being led over a roll underneath the sheet 12 converge with the sheet towards the roll 26, the belts and the sheet traveling at the, same speed. As shown in Fig. 1, the edges of the sheet are picked up by the belts 40 and the sheet is straightened out so that it passes over the roll 26 with its edges rounded off and surfaced by contact with the belts, and the coated under faces of the sheet in contact with surfacing material. From the roll 26 the sheet may be led beneath a device gen- -erally indicated as 35, for depositing bands of vari-colored grit particles or the like on the upper coated portions of the sheet. The hoppers act intermittently as the sheet passes beneath so that each color is deposited in a transverse band registering with one of the. tabs formed by the slots or notches in the edges of the sheet. The finished shingle strip will thus present tabs having different colored surfacing on successive tabs, an arrangement which is capable of artistic mottled effects on .minuted material which may fall from the surface of the sheet as it is led around the lower roller 38.

The sheet may then be led by suitable guide rolls through any convenient cooling device, such as is shown in Fig. 1?), wherein is illustrated conventionally an air blast or suction device 42. After being sufficiently cooled, the sheet may be slit as by slitters 43 on its median line, that is, midway between the coated portions. The slit strips may then be cut into units, as by suitable cutters 44, the units being conveyed to any desired assembling or packing device, as by a conveyor 45.

In Fig. 5 a modified device for coating the marginal portions of the sheet is illustrated.

- Instead of immersing the marginal portions beneath the surface of coating liquid in a container, the coating material may be led through pipes 46 to suitable spouts 47,.

through which the coating material maybe allowed to flow on to the upper surface of the marginal portions of the sheet. [he under surface of the marginal portions may be similarly coated with material ledthrough pipes 48 to suitable spouts 49, from which a coating material flows over the portions of the under surface of the sheet which are to be coated. After receiving the coating material from the spouts 4'7, -19, the marginal portions of the sheet 12 are maintained in their downwardly extending position for a predetermined interval of travel, while the excess coating is allowed to drain down to the edge and to drip into the container 50, where it is kept liquid as by steam pipes'51 and allowed to recirculate through a drain 52 and a suitable pump, not shown, back to the spouts 47,

It will be apparent that the interval of travel during which the marginal portions of the sheet are kept in a downwardly bent pofor applying the coating material thereto will permit a certain amount of the coating material to collect toward the edges of the ing a complete. sealing coat over the exposed surfaces and edges wh ch will effectually pro tect the sheet material which is employed as a base from moisture. Since most material used as a roofing baseis fibrous, roofing units made therefrom are liable to expand, wrinkle and curl as a result of "moisture entering the fibres through out ends exposed when the unit is cutto shape. It is therefore very important tosee that all exposed edges are properly sealed against moisture-since otherwise the unit is liable to rapid deterioration in appearance and efiectiveness when laid on a roof and exposed to the weather. By cutting. the units from the sheet with cuts registeringv with one of the slots which extend inwardly from the outeredges ofthe sheet,the sealing of. the butt portion of the shingle strip is not broken and when laid} the strip presents a completely sealed surface to the weather, all the cutedges of which are also fully protected."

Having thus described ,an embodiment of this invention, it should be evident to those skilled in the art that various changesand modifications may bei'made therein without depart-mg from its spiritor scope as defined by the appended claims.

mined interval. sition after being removed from the means I claim: I 1. In a device of the class described, means for feeding a sheet in a flat condition, means for bending said sheet longitudinally, means bent, thereby permitting excess liquid to f I drain from the coated portion. I

3. In a device of the class described, means for progressively bending the marginal portions of a horizontal moving sheet downwardly,'means for applying coating material to part of said downwardlyextending portions, and means for retaining-said marginal portions bent downwardly fora predeterl. In a device of the class described, means for continuously bending the. marginal por tions of a horizontal moving sheet downwardly, means for applyingcoating material to part of said downwardly extending portions, and means for keeping the coated areas extending downward while they are being removed from the coating means. I

5. In a device of the class described, means for feeding a continuous sheet horizontally, means for bending the marginal portions of said sheet downwardly, means for applying a liquid coating to both sides of said marginal portions while so bent, thereby permitting excess coating to drain from the sheet.

6. In a device of the class described, means for feeding a continuous sheet horizontally.

means for bending the marginal portions of said sheet downwardly, meansfor applying a liquid coating to both sides of said marg1 nal portions, and'means for wlplng excess coating from t,he s heet.-

7. ,In a device ofthe class described, means for feeding a sheet horizontally, means for cutti'ngslots in the edges of said sheet, means .forbending the marginal portions of said sheet downwardly means for coating both 7 sides of said mar inal portions andthe edges, 1 5 means for keepmg said marginal portions extendingcdownward during their removal from the coating means, means, for removing thevdrippings from the margin al edges of said sheet. and means for restoring the mar-i gmal portions to horizontal position. 1

8. In a device of the class described, an x.

open containenfor coating material, means for feeding a continuoussheet horizontally '.over said container, means for bending a marginal portion of said sheet downwardly when over said cont-aineiy-so as to dip into said eoatingjmaterial, means for keepingsaid marginal portion bent while over said container, andmeans for wiping the drippings ,130

from said sheet as it container. V

9. In a device of the class described, a conpasses from over said tainer for thermoplastic coating material,

means for liquefying said material, means for feeding a sheet horizontally over said coating material, means for bending a mar-- 7 for bending a marginal portion of said sheet downwardly, means for flowing a coating liquid on said downwardly bent portion,

thereby permitting excess coating to drain fromthe coated area, and means for removing excess coating from the edge of said coated area." g 11. In a device of the class described,

means for fecdingva sheet, means for supporting said sheet fora part of its length with a Widthwise portion thereof extending downwardly, and means for applying liquid coating to said downwardly extending portion.

12. In a device of the class described, means for feeding a sheet, means for supporting said sheet-for a part of its length in a bent condition, a widthwise portion of the sheet being disposed downwardly while an adjacent Widthwise portion is carried by said supporting means more nearly horizontal,

. and means for applying liquid coating material to the downwardly extending portion.

13. In a device of the class described,

means for feeding a semi-"flexible sheet, means widthwise extent, the rest of said portion befor supporting a longitudinal portion of'the fed sheet horizontally for a part only of its ing disposed downwardly, and means for applyingliquid coating material to said downwardly extending part.

14. In a device of .the class described,

means for feeding 'a semi-fiexible sheet horizontally, means for supporting-adongitudinal portion ofqthe fedsheet along its central area only the marginal areas of the sheet'being disposed downwardly, and means for applying liquid coating to said downwardly extending areas. i

15. The method of taper coating a semiflexible sheet of indeterminate length, which comprises feeding the sheet, supporting the central portion of a longitudinal section of the sheet substantially horizontally disposing the marginalportions of the part of the sheet so supported in a downward direction, and applying liquid coating to the down wardly extending portions. 1

16. The method of taper-coating a marginal portion of a continuous sheet which comprises feeding the sheet with said mar- 17. The method of taper-coating amar ginal portion of a continuous sheet'which comprises feeding thesheet'with said marginal portion thereof extending downwardly,

applying a liquid coating to said downwardly extending portion, and permitting excess liquid to drain from the, coated portion.

18. The method of taper-coating both mar- ,ginal portions of a continuous sheet which comprises bending said marginal portions downwardly, applying a liquid coating thereto, and permitting excess liquid to drain from the coated portions. 1

19. The method of taper-coating a marginal portion of a continuous sheet which comprises feeding the sheet with said marginal portion extending downwardly, applying a liquid coating to said downwardly extendingportion, and permitting some of the coating material to drain toward the edge of the coated portion of the sheet. I

20. The method of making roofing units which comprises feeding a continuous sheet of roofing base in a fiat conditiombending the sheet longitudinally, applying coating material to a portion of said sheet while so bent, restoring the sheetto a fiat condition and cutting units therefrom.

21. The methodof making roofing units which comprises feeding a continuous sheet of roofing base in a horizontal flat condition, bending a marginal portion of said sheet downwardly, applying coating material to said downwardly bent portion, applying grit toa surface and the edges of the coated portion, and cuttingunits from the sheet. I

22..The method of making roofingunits which comprises feeding a continuous sheet of roofing base with its marginal portions extending downwardly, applying a liquefied thermoplastic compound to said downwardly extending portions, permittingpart of said compound to drain toward the edges of the sheet, removing the drippings from said edges, applying grit to the coated .portions of the sheet, cooling the sheet, .slitting the.

ing both marginal portions of the sheet down wardly, applying liquefied thermoplastic material to said downwardly bent portions so, vas to cover both sides of, said marginal portions and all the edges, keeping said marginal portions bent downwardly for a predetermined interval, wipingthe drippingsfroni the lower edges of the sheet, restoring said marginal portions to hor zontal position, de-

positing grit on the surfaces of the coated areas, cooling said sheet, slitting the sheet midway between the coated portions, and cutting units from the slit strips.

24. The method of making roofing units which comprises feeding a continuous sheet of roofing material in the direction of its length, cutting a series of tab-defining slots in an edge of said sheet, applying liquefied coating material to the marginal portion of the sheet including said tabs, and permitting excess coating to drain from the coated areas.

25. An apparatus for the purpose specified, having in combination, means for longitudinally moving a piece of strip stock, means for bending down both edges of said strip stock, while so moving, and means for guiding the said turned down edges through a coating bath for the purpose of forming a ribbon-like coating along the edges of said strip stock.

26. The process of making prepared roofing strips which comprises supporting a strip with a notched edge so that the portion of the strip adjacent to the notched edge extends downwardly thereto and the notched edge is free, applying weatherproofing composition to the face of said downwardly sloping portion of the strip so that the composition flows by gravity towards and extends over the free notched edge.

27. The process of making prepared roofing strips which comprises feeding longitudinally a strip with a notched edge so that the portion of the strip adjacent to said notched edge extends downwardly thereto and the notched edge is free, applying weatherproofing composition to a face of the downwardly extending portion of the traveling strip so that the composition flows towards and extends oVer the free notched edge, then shaping the composition to form a coating on said face which is of gradually increasing thickness toward said notched edge.

28. In the process of making prepared roofing elements, the step of pouring adhesive waterproofing compound on a portion of a face of the roofing base which is to be exposed to the weather when laid, causing the coating to flow over said face portion and its marginal edge by gravity only by maintaining the said marginal edge at a point below the adjacent edge of the roofing element being treated, and applying comminuted surfacing material to the said portion of said coating.

29. The method of making roofing units which comprises causing a portion of a continuous strip of roofing base to travel lengthwise and substantially vertically on edge, applying coating material to said portion along a line substantially above the lower edge of the strip.

30. The method of making roofing units which comprises causing a portion of a continuous strip of roofing base to travel lengthwise and substantially vertically on edge, projecting liquid coating compound against a face of said portion in its vertical position, and applying comminuted surfacing material to the coated area.

31. In a machine of the class described, means for supporting a length of a continuous traveling strip of roofing base substantially vertically on edge, and means for applying liquid coating material to a face of said Vertically supported length along a line substantially above the lower edge of the strip.

32. In a machine of the class described, means for supporting a length of a continuous traveling strip of roofing base substan tially vertically on edge, means for applying liquid coating material to said length along a line substantially above the lower edge of the strip, and means for applying grit to cover the coated areas. 33. Steps in the process of making prepared roofing strips, which comprise feeding longitudinally a strip having a notched edge with the said edge in a lower plane than the opposite edge and free, flowing liquid weatherproofing material on to a face of the strip while thus fed so that said material flows by gravity towards the lower edge of the strip and extends thereover.

34. A method of making prepared roofing strips which consists in continuously advancing a strip, in flowing liquid material on the face of the strip while it is advanced and when one edge of the strip is in a substantially lower plane than the opposite edge thereof whereby said waterproofing material flows by gravity towards the lower edge of the strip.

35. In the art of preparing roofing elements, the steps which comprise supporting a portion of a continuous strip of rooting material, of loosely matted, porous character, substantially vertically on edge, advancing the strip through a coating zone, maintaining the strip with one edge lower than the other whereby to permit drainage of the asphaltic coating material and finally subdividing the thus treated roofing strip into shingles of the desired length.

- 36. The method of making roofing elements, which comprises causing a portion of a continuous strip of roofing material to travel lengthwise and substantially vertically on edge, and progressively applying liquefied coating material to the substantially vertically supported portion of the strip along a line substantially above the lower edge of the strip, and maintaining the coated portion of the strip in a non-horizontal position fora sufiicient interval after the application of the coating to permit the coating to flow toward the lower butt edge of the strip and to set in a coating of tapering thickness.

In testimony whereof I have afiixed my signature.

CHESTER R. MACDONALD.

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