Patent ID: 7541059
Filing Date: 2009-06-02
Classification: D06N,E04D,Y02A,Y02B,Y10T

Abstract:
1. A continuous process of applying first and second asphalt-based coatings to a mat for manufacturing a roofing material, the process comprising: continuously moving a continuous mat along a path, the mat having a first surface and a second surface; in a first coating operation, continuously applying a first asphalt-based coating to the first surface of the mat in a manner so that the first coating saturates the mat and forms a layer on the first surface and does not form a layer on the second surface; and then in a second coating operation, continuously applying a second asphalt-based coating to the second surface of the mat in a manner so that the second coating forms a layer on the second surface and does not form a layer on the first surface; the second coating having properties which differ from the first coating in at least one of the following aspects: (a) one of the first and second coatings meets or exceeds a pliability standard described in CSA Standard A123.5-98, and the other coating does not meet the pliability standard; (b) one of the first and second coatings passes a weathering performance test as measured b at least 60 cycles-to-failure using ASTM Method D4799, and the other coating does not pass the weathering performance test; (c) one of the first and second coatings has a solar reflectance of at least 0.7 when tested by ASTM Method E903, and the other coating has a solar reflectance of less than 0.7; (d) one of the first and second coatings has viscoelastic properties effective to prevent the coating from sticking to a coating of an adjacent roofing material when the roofing materials are stacked face to face in a bundle and stored at a temperature exceeding 90° F. (32° C.), and the other coating does not have the viscoelastic properties; (e) one of the first and second coating has an increased adhesion defined by a granule loss of less than 0.8 grams when the roofing material is soaked in water for seven days and then tested by ASTM Method D4977, and the other coating does not have the increased adhesion; (f) one of the first and second coatings includes a filler of igneous or metamorphic rock particles in an amount from about 30% to about 75% by weight of the coating, and the other coating includes from 0% to about 10% of the filler of igneous or metamorphic rock particles; and (g) one of the first and second coatings has an increased toughness compared to the other coating, such that the roofing material has an increased impact resistance of at least one UL 2218 class compared to the same roofing material made without one of the coatings having the increased toughness.