US2661303A

US2661303A - Method of coating roofing material

Info

Publication number: US2661303A
Application number: US154528A
Authority: US
Inventors: George A Fasold; Howard E Callahan
Original assignee: Philip Carey Manufacturing Co
Current assignee: Philip Carey Manufacturing Co
Priority date: 1950-04-07
Filing date: 1950-04-07
Publication date: 1953-12-01
Anticipated expiration: 1970-12-01

Description

1953 e. A. FASOLD EIAL METHOD OF COATING ROOFING MATERIAL 2 Sheets-Sheet 1 Filed April 7, 1950 I l l l l I ll Illll l ATTORNEYS.

D 1, 1953 a. A. FASOLD ET'AL METHOD OF COATING ROOFING MATERIAL 2 Shets-Sheet 2 Filed April 7, 1950 Z/swr Fae:

INVENTORS. GEOQGE A l-TasaLa f/awmm 1 0441.404,

ATTORNE YS Patented Dec. 1, 1953 UNITED STATS GFFICE METHOD OF COATING ROOFING MATERIAL Application April 7, 1950, Serial No. 154,528

3 Claims. 1

Our invention relates to plastic coated and plastic formed building material which may be briefiy described as prepared roofing for use in making roofs or other parts of buildings.

Our invention relates to a prepared roofing construction and a method and machine for making such construction in which mineral surfacing granules of varying hue, chroma and color value are embedded like mosaics in the exposure surfaces of roofing units. It is our object to so arrange the areas of distribution of the granules on the roofing units that when they are laid on a roof or wall, illusory shadow effects are produced. These optically accentuate relief effects so that higher relief is simulated than that physically present.

In our method of manufacture and in the prepared roofing manufactured thereby, it is our object to so control the three color variables that an aesthetically pleasing eiiect is produced.

The first variable of colored mineral granules is hue by which the light waves reflected from the surface are dominated by and may be measured in terms of hue like red, blue, yellow or mixtures thereof. The second variable is chroma by which the various hues are more or less intense or pure, and are measured in terms of admixture with whites, grays, and blacks. Finally the color value is the visual effect of hue and chroma measured in terms only of dark and light. Thus all colored surfaces have hue, chroma and color value. A black and white surface has only color value.

It is an object of our invention to embed mineral granules in batches of predetermined variance of hue, chroma, and value on the areas of the exposure surface of prepared roofing, such as shingles, with adjacent areas blended together so that, when the shingle units are laid on a roof, an optical effect of deep shadows below the butts of the shingle units is produced simulating shingles of greater than actual thickness, the blending of adjacent areas on which the batches of predetermined hue, chroma and color value are embedded, being such that banding effects are minimized and irrespective of the hue and chroma, the color value of each exposed shingle unit gradually deepens or darkens from butt to overlap. As a variant of this arrangement we may, by reversing the control, cause the shingle unit to gradually become lighter in color from butt to overlap.

Another object of our invention is to employ granules having different hues and chroma wherein the color value is such that banding efiects are avoided. For example, in a strip shingle predominantly blue in color, reddish brown granules may be used to give an interesting contrast in hue, the color value being such that there is no abrupt change in color value and the optical illusory shadow effect is produced even though the hue and chroma of the granules vary widely. Copyrighted Roof Designs as are made possible with our new method and machine, are depicted in Copyrights Cl. G, form G, 12,907, 12,908, 12,909 and 12,910, registered June 19, 1949. The specific example illustrated in the drawing explains the detailed technique of making the roof design 12,908 Green Shadow Blend Roof Design. Of course, other colors may be used to make designs of varying hues and chroma while maintaining the principle of the shadow blend color value effect.

It is an object of our invention to apply to the roofing sheet batches of granules of various hues and chroma on the principle described of blending color value by dropping the granules by gravity in bands on a web of asphalt coated roofing material as it is conveyed through the roofing machine and controlling the areas of distribution of the granules by various means which will he described.

In the drawings:

Figure l is a plan view, partly diagrammatic, of a preferred type of granule distributing machine.

Figure 2 is a side elevation, also partly diagrammatic, of the mechanism as shown in Figure '1.

Figure 3 is a plan view of a web as roofing material after the granules have been applied, the cross hatching and shading indicating areas of different hues, chroma and color value.

Figure 4 is a plan view on an enlarged scale, of a shingle unit such as may be cut from the web shown in Figure 3.

The mechanism involved is an adaptation and modification of the mechanism of What is known in the industry as the Norwood Blender, various modifications of which appear in the expired patents to Robert Maclean No. 1,574,835, 1,774,988, 1,794,719 and 1,857,463 to which reference is hereby made. The broad purpose of such machines has been to distribute mineral granules of diiierent hues over the surface of a web of asphaltic coated roofing material so as to provide a series of diiferently colored areas having a somewhat regular defined pattern and with fairly sharp division lines between such areas. So far as we are aware, the arrangement of granule distribution on a web 01 shingle material so that when the web is cut into shingles, irrespective of the hue and intensity of the granule colors in the various areas, an efiect of shadow blending in the exposure portions of the shingles i achieved, is new in the art, although in his Patent 2,036,329 Giles suggests this achievement by spraying applications of paint in a prescribed pattern to a shingle web surface.

Referring to the drawings, the web of shingle material impregnated and coated with an asphaltic surfacing material to which mineral granules will adhere and become partially embedded is indicated at l in Figure 2, the travel being in the direction of the arrow. The travel of the web is up over a surfacing roll 2 which compresses the granules distributed on the web into embedment with the web coating. The excess of granules over and above those embedded into the web by the surfacing roll 2 is collected off the roll by the deflector plate 3 and falls into bin IS. The web passes up over the roller 4 and from thence to the cooling looper which forms no part of this invention.

The bins in which the granules of different hue, chroma and value are distributed are indicated at 5, 6, l, and 8 and in order to explain specifically how the web, which in the drawings is indicated as four feet in width, has the granules distributed on it, we may assume that bin #5 is filled with a mixture of 3 parts dark (bluish) green granules and 1 part light (bluish) green granules. Bin #ii is filled with medium (yellowish) green granules. Bin #1 is filled with a mixture of 3 parts dark (bluish) green granules- Bin #8 and one part shiny jet black granules. is filled with dark (bluish) green granules. The granules in the difierent bins are of different hue and chroma, but they have substantially the same color value.

The discharge of granules from the bins is controlled by cam and clutch mechanisms (not shown) which cause intermittently timed rotation of the feed rollers 5A, 6A, 1A and 8A during certain predetermined intervals. Under normal conditions each roller operates for a period when the rotation of the other rollers is inhibited thereby depositing a band of granules, the areas of which vary in hues and chromas but. not in color values.

In Figure l the rectangular areas at thebottom of the bins indicate

blocks

5B, 6B, 1B and 8B which block ofi the delivery of granules excepting through the slots 5C, 60, 1C and 8C. These slots remain open and direct the flow of granules onto the conveyor belt 9 when the

respective feed rollers

5A, 6A, 7A and 8A are in operation.

The granules bounce on the belt and bafile in a heterogeneously dispersed pattern due to their irregular shape. This causes the adjacent bands to blend into one another. The granules from the bins in hands on the conveyor belt 9 are discharged onto the inclined plate Ill which is at such an angle that the granules do not pile up but discharge at the bottom of theincline at about the same rate as they are received from the conveyor belt 9.

Before reaching the asphaltic web the granules in bands of varying hue and chroma have mixed at their edges on each side, granules of sharply contrasting color value. Thus the bin I l is subdivided into set of short bins. These are indicated by the double horizontal lines in Figure l. The bins marked I 2 of which there are four, have discharge slots HA. The bins marked l3 4 have discharge slots ISA. The compartments, blocked off at the bottoms by the blocks MA contain no granules.

We fill the bins I2 with shiny jet black granules and the bins I3 with light color value granules. The feed roller 15 is normally in constant operation and continuously feeds black. granules from the bins 12 into four bands staggered with relation to the bands on which the granules from bins 5 to 8 are deposited. The feed roller 15 also feeds the granules of light color value in a band staggered between the bands from the bins 5 to 8.

Fromthe bin II the black granules from comertments l2 and the light granules from the compartments l3 fall onto the inclined plate 10 and blend at the edges of the bands, this blending being accomplished by the heterogeneous bouncing of the granules on the baffle plate producing a dispersion of the granules into adjacent color bands thus forming a combination of color areas having no sharp edge delineations.

In bin marked IS the spill-over granules from surfacing roll 2 are constantly distributed over the entire surface of the web through the feed slot 11. The granules from the bin it drop onto the inclined plate l8 from which they are deposited over the entire surface of the web of shingle material.

Referring now to Figure 3, the entire width of the web of shingle material is shown with the various bands for making strip type shingles which when laid on a roof produce the Green Shadow Blend Roof design registered in CODY- right Class G. No. 12,908 June 10, 1949. It will be noted that the distribution of mixed hues and chroma occupy the bands marked Blend. Between the bands marked Blend are the bands marked Light Edge and outside the bands marked Blend are the bands marked Dark Shadow.

The hopper ll spills only light edge and dark shadow granules. The spaces marked I4 are the blocks to confine granules to, the spaces. [2.

and 13. Bin it which is spilling; constantly, covers the entire sheet also covers the area outside the bands with the mixture. These areas are marked Mixture and it will be understood-that when strip shingles are out from the web the reasmarkecl Mixture will bethe upper portion of each strip shingle which when. laid will be covered over by overlapping shingles. It is the exposure areas of the shingles in which the shad ow blend effect is produced.

When the web is cut into two pairs of op posed. edge shingles along thev lines I9I9' of Figure 3, an individual strip shingle like that illustrated in Figure 4 will be produced. The upper end of the slots 20 mark the upper area of the exposure portions of each shingle. The lower or butt end of each shingle will be light and intermediate the light butt area and the dark upper exposure edgev there will appear a constantly variable group of different huecl: granules having different chroma but all having.

substantially the same color value. In order to control the areas of distribution of the granules from the hoppers 5 to 8, it is arranged so that.

distribution fromv these hoppers does not match up with the width of the strip shin les. Thus in Figure 3 the width of a strip shingle is indicated by the lines 2-2, while the repeat pattern of distribution from. the hoppers 5 to. 8 is indicated by the lines 11-12. In order to show this more clearly the areas of the Blend bands in Figure 3 carry the numbers of the bins from which the granules in the different bins are derived. Thus there is a constant repeat of the

area patterns

5, 6, l and 3 in regular sequence on a band the length of which is about one-half longer than the width of the individual strip shingles.

Thus it Will be observed that no one shingle is similar in the arrangement of color areas on it to any other shingle. At the same time the shadow effect at the covered area of each shingle is dark and the butt edge is light, the intermediate area being a constantly changing blend of granules of different hue and chroma. The color value is similar to the Guild Building Roof as set forth in application for design patent Ser. D. 3,640 filed June 30, 1949.

For producing different arrangements, as for example shingles with dark butts and light overlap areas, all that is necessary is to change the granules in the compartments I2, l3, putting the dark granules in the compartments l3 and the light granules in the compartments it. While the simulation of deep shadows caused by an arrangement of shingles on the roof with light butts contrasted. against dark underlying portions is more effective, much the same efiect is produced with dark butts against light underlying shingles. In each case the apparent thickness of the shingles is accentuated.

While the machine described and the method of distributing granules is broadly explained as depositing certain types of granules in what are called bands and areas, it should be clearly understood that the method of spilling the granules on a conveyor and spilling the granules from the conveyor so that they bounce on the inclined deflector plates, causes an intermingling of the granules both widthwise of the web and lengthwise which completely obliterates sharp edge delineations. A roof having the strip shingles laid entirely haphazard has a constant variation in hue, chroma and value to a sufficient extent to obliterate any visual effect of what is called banding.

The individual shingle units or tabs of a strip shingle may have granules applied which vary not only in hue and chroma but also in value between adjoining shingles or tabs of the strip in a course on the roof. The granules may be applied so as to exhibit this variation in color value on the individual tabs. The range and variation in color value may also be exhibited lengthwise of the strip. Such variation is shown in the copyrighted roof designs previously referred to.

Having thus described our invention, what We claim as new and desire to secure by Letters Patent is:

1. A method of distributing mineral granules on a web of roofing material to provide at least two rows of shadow blend strip shingles in opposed butt edge relationship which consists in feeding along an asphaltic coated web in tacky condition, depositing on the tacky web, in a series of bands spaced to form the middle exposure portions of the strip shingles in each row, batches of granules of predetermined uniform color value in heterogeneously mixed areas having blended end edges, the granules in said areas having distinctly diflerent chromatic values with substantially the same color value, depositing in bands adjacent to opposed side edges of the first referred to bands, and which will form the overlapping areas of the opposed strip shingles in each row, granules of darker color value than.

the granules of the first noted band while controlling the deposition to produce edge blending with the side edges of the first referred to bands, depositing in double width bands adjacent to the opposite side edge of the first referred to bands and which will form the butts of the opposed strip shingles in each row granules of lighter color value than the granules of the first noted band while controlling the deposition to produce edge blending with the opposed side edges of said first referred to bands, pressing the deposited granules into the coated web and then cutting the web forming rows of oppositely arranged strip shingles medially of said doublewidth bands to provide strip shingles which when laid on a roof will produce an optical effect of deep shadow below the butts of the shingle units of each strip without an optical effect of handing.

2. A method of distributing mineral granules on a Web of roofing material to provide at least two rows of shadow blend strip shingles in opposed butt edge relationship which consists in feeding along an asphaltic coated web in tacky condition, depositing on the tacky web, in a series of bands spaced to form the middle exposure portions of the strip shingles in each row, batches of granules of predetermined uniform color value in heterogeneously mixed areas having blended end edges, the granules in said areas having distinctly different chromatic values with substantially the same color value, depositing in bands adjacent to opposed side edges of the first referrcd to bands, and which will form the overlapping areas of the opposed strip shingles in each row, granules of darker color value than the granules of the first noted band while controlling the deposition to produce edge blending with the side edges of the first referred to bands, depositing in double width bands adjacent to the opposite side edge of the first referred to bands and which will form the butts of the opposed strip shingles in each row granules of lighter color value than the granules of the first noted band while controlling the deposition to produce edge blending with the opposed side edges of said first referred to bands, pressing the deposited granules into the coated web, collecting such granules as are non-adherent to the coated web and distributing them uniformly over the entire surface of the web, and then cutting the web forming rows of oppositely arranged strip shingles medially of said double width bands to provide strip shingles which when laid on a roof will produce an optical eifect of deep shadow below the butts of the shingle units of each strip without an optical effect of banding,

3. A method of distributing mineral granules on a web of roofing material to provide at least two rows of strip shingles, having changing color value depthwise of the exposure areas of the shingle units, in opposed butt-edge relationship, which consists in feeding along an asphaltic coated Web in tacky condition, depositing on the tacky web, in a series of bands spaced to form the middle exposure portions of the strip shingles in each row, batches of granules of pre-determined uniform color value in heterogeneously mixed areas having blended end edges, the granules in said areas having distinctly different chromatic values with substantially the same color value, depositing in bands adjacent to opposed side edges of the first referred to bands, and which will form the overlapping areas of the opposed strip shingles in each row, granules of a color value different in one direction from and contrasting with the color value of the granules of the first noted band, while controlling the deposition to produce edge blending with the side edges of the first referred to bands, depositing in double width bands adjacent to the opposite side edge :of the first referred to bands and which will form the butts of the opposed strip shingles in each row granules of a color value different in the other direction from and contrasting with the color value of the granules of the first noted band, while controlling the deposition to produce edge blending with the opposed side edges of said first referred to bands, pressing the deposited. granules into the coated web and then cutting the web forming rows of oppositely arranged strip shingles medially of said double width bands to provide strip shingles which when laid on a roof will produce an optical effect of enhanced shingle thickness below the butts of the shingle units of each strip without an optical effect of handing.

GEORGE A. FASO-LD. HOWARD E. CALLAHAN.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date Becker Apr. 30, 1912 Becker Apr. 30, 1912 Wright June 22, 1915 Overbury Sept. 21, 1915 McKay Dec. 12, 1916 Elvidge May 2, 1922 Elvidge Oct. 31, 1922 Overbury May 6, 1930 Cumfer June 27, 1933 Wettlaufer Sept. 26, 1933 Levin May 29, 1934 Freegard Apr. 16, 1935 Harshberger May 7 .1935 Penley Mar. 16, .1937 Penley Oct. 18, 1938 Howell Jan. 14, 1941

Claims

1. A METHOD OF DISTRIBUTING MINERAL GRANULES ON A WEB OF ROOFING MATERIAL TO PROVIDE AT LEAST TWO ROWS OF SHADOW BLEND STRIP SHINGLES IN OPPOSED BUTT EDGE RELATIONSHIP WHICH CONSISTS IN FEEDING ALONG AN ALIPHATIC COATED WEB IN TACKY CONDITION, DEPOSITING OF THE TACKY WEB, IN A SERIES OF BANDS SPACED TO FORM THE MIDDLE EXPOSURE PORTIONS OF THE STRIP SHINGLES IN EACH ROW, BATCHES OF GRANULES OF PREDETERMINED UNIFORM COLOR VALUE IN HETEROGENEOUSLY MIXED AREAS HAVING BLENDED END EDGES, THE GRANULES IN SAID AREAS HAVING DISTINCTLY DIFFERENT CHROMATIC VALUES WITH SUBSTANTIALLY THE SAME COLOR VALUE, DEPOSITING IN BANDS ADJACENT TO OPPOSED SIDE EDGES OF THE FIRST REFERRED TO BANDS, AND WHICH WILL FORM THE OVERLAPPING AREAS OF THE OPPOSED STRIP SHINGLES IN EACH ROW, GRANULES OF DARKER COLOR VALUE THAN THE GRANULES OF THE FIRST NOTED BAND WHILE CONTROLLING THE DEPOSITION TO PRODUCE EDGE BLENDING WITH THE SIDE EDGES OF THE FIRST REFERRED TO BANDS, DEPOSITING IN DOUBLE WIDTH BANDS ADJACENT TO THE OPPOSITE SIDE EDGE OF THE FIRST REFERRED TO BANDS AND WHICH WILL FORM THE BUTTS OF THE OPPOSED STRIP SHINGLES IN EACH ROW GRANULES OF LIGHTER COLOR SHINGLES IN EACH ROW GRANULES OF THE FIRST NOTED BAND WHILE CONTROLLING THE DEPOSITION TO PRODUCE EDGE BLENDING WITH THE OPPOSED SIDE EDGE OF SAID FIRST REFERRED TO BANDS, PRESSING THE DEPOSITED GRANULES INTO THE COATED WEB AND THEN CUTTING THE WEB FORMING ROWS OF OPPOSITELY ARRANGED STRIP SHINGLES MEDIALLY OF SAID DOUBLE WIDTH BAND TO PROVIDE STRIP SHINGLES WHICH WHEN LAID ON A ROOF WILL PRODUCE AN OPTICAL EFFECT OF DEEP SHADOW BELOW THE BUTTS OF THE SHINGLE UNITS OF EACH STRIP WITHOUT AN OPTICAL EFFECT OF BANDING.