Abstract:
A method of making shingles that have an overlay portion and an underlay portion includes establishing a continuous shingle overlay sheet having a repeated pattern of tabs and cutouts. A continuous shingle underlay sheet having a repeated pattern of granule patches is also established. The presence of the pattern of tabs and cutouts on the continuous shingle overlay sheet is sensed and the presence of the pattern of granule patches on the continuous shingle underlay sheet is also sensed. The position of the continuous shingle overlay sheet relative to the continuous shingle underlay sheet is synchronized in response to the sensed presence of the repeated pattern of tabs and cutouts and the sensed presence of the repeated pattern of granule patches. Each granule patch in the pattern of granule patches is then aligned with one of the tabs in the pattern of tabs and cutouts. The continuous shingle overlay sheet is laminated to the continuous shingle underlay sheet to define a laminated sheet, and the laminated sheet is cut into a plurality of shingles.

Description:
BACKGROUND 
       [0001]    This invention relates to asphalt-based roofing materials. More particularly, this invention relates to methods for controlling the deposition of granules from a granule applicator onto an asphalt-coated sheet. 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, and to give the roof an aesthetically pleasing look. 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. 
         [0002]    A common method for the manufacture of asphalt shingles is the production of a continuous sheet of asphalt material followed by a shingle cutting operation which cuts the material into individual shingles. In the production of asphalt sheet material, either a glass fiber mat or an organic felt mat is passed through a coater containing hot liquid asphalt to form a tacky, asphalt-coated sheet. Subsequently, the hot asphalt-coated sheet is passed beneath one or more granule applicators which discharge protective and decorative surface granules onto portions of the asphalt sheet material. 
         [0003]    In the manufacture of colored shingles, two types of granules are typically employed. Headlap granules are granules of relatively low cost used for the portion of the shingle which will be covered up on the roof. Colored granules or prime granules are of relatively higher cost and are applied to the portion of the shingle that will be exposed on the roof. 
         [0004]    To provide a visible color pattern of pleasing appearance, the colored portion of the shingles may be provided with areas of different colors. Usually the shingles have a background color and a series of granule deposits of different colors or different shades of the background color. A common method for manufacturing the shingles is to discharge blend drops onto spaced areas of the tacky, asphalt-coated sheet. Background granules are then discharged onto the sheet and adhere to the tacky, asphalt-coated areas of the sheet between the granule deposits formed by the blend drops. The term “blend drop,” as used herein, refers to the flow of granules of different colors or different shades of color (with respect to the background color) that is discharged from a granule blend drop applicator onto the asphalt-coated sheet. The patch or assemblage of the blend drop granules on the asphalt-coated sheet is also referred to as the “blend drop.” 
         [0005]    One of the problems with conventional granule application methods for manufacturing laminated shingles is that the underlay will be covered by relatively more expensive prime granules. In such conventional methods for manufacturing laminated shingles, even the portions of the underlay that will be covered by the tabs of the overlay are covered with prime granules. 
         [0006]    A known granule depositing method is shown in U.S. Pat. No. 5,795,389 issued to Koschitzky, which is hereby incorporated by reference in its entirety. The Koschitzky reference discloses a method of depositing a pattern of sharply demarked granule patches on the visible surface of a shingle. The Koschitzky reference further discloses an auxiliary belt onto which a series of patches of granules is deposited. The auxiliary belt is positioned above the asphalt-coated sheet, and includes an upper flight and a lower flight, with the upper flight travelling in a direction opposite that of the asphalt-coated sheet. At the upstream end of the auxiliary belt (i.e., upstream with respect to the movement of the asphalt-coated sheet) the upper flight of the auxiliary belt turns around a belt roller to form the lower flight. A retaining conveyor is wrapped around the upstream end of the auxiliary conveyor to keep the granules from flying about as the granules are turned into a downward direction. The granules of each of the patches are dropped vertically straight down onto the asphalt-coated sheet to form blend drops. After the blend drops are applied to the asphalt-coated sheet the background granules are applied to form a granule-coated sheet, which is then cooled and cut into individual granule-coated shingles. 
         [0007]    U.S. Pat. No. 5,814,369 to Bockh et al. discloses another blend drop granule applicator having an applicator roll positioned to rotate directly above a moving asphalt-coated sheet. The applicator deposits a pattern of granule patches or blend drops on the visible surface of a shingle. The Bockh et al. reference is hereby incorporated by reference in its entirety. Granules corresponding to a desired blend drop are deposited onto the applicator roll at the top of the rotation, and when the applicator roll rotates approximately 162 degrees the blend drop falls off onto the asphalt-coated sheet when the blend drop reaches the bottom of the rotation. A media retaining belt engages the applicator roll, contacting and wrapping around the applicator roll to hold the blend drop granules on the surface of the applicator roll until the applicator roll rotates about 162 degrees. At the point where the media retaining belt stops contacting or becomes disengaged from the applicator roll, the blend drop granules are released to drop onto the moving asphalt-coated sheet to form the blend drop. The Bockh et al. patent states that the distance that the granules fall from the applicator roll to the asphalt-coated sheet should be minimized. The Bockh et al. patent further states that the linear velocity of the applicator roll should be synchronized with that of the moving asphalt-coated sheet so that the granules can be dropped precisely in the desired pattern. 
         [0008]    The concurrently filed U.S. patent application entitled “Apparatus and Method for Depositing Particles” (U.S. patent application Ser. No. ______) to David P. Aschenbeck discloses a method and a granule applicator for applying granules onto an asphalt-coated sheet. The granule applicator includes a rotating member having a body defining an interior space and an axis of rotation. A granule outlet opening is formed in the body and connects the interior space and an exterior of the rotating member. The granule outlet opening further defines a granule bin in the body of the rotating member. A granule dispenser is mounted within the interior space of the body of the rotating member and is connected to a source of granules. A belt engages a first portion of an outer circumferential surface of the body of the rotating member. As the rotating member rotates about its axis of rotation, the granule outlet opening moves between a closed position wherein the granule outlet opening is closed by the belt, and an open position wherein the granule outlet opening is uncovered. U.S. patent application Ser. No. ______ is commonly assigned, has the same inventor as the present application, and is incorporated herein by reference. 
         [0009]    The above notwithstanding, there remains a need in the art for an improved method of making shingles having an overlay portion and an underlay portion. 
       SUMMARY OF THE INVENTION 
       [0010]    The present application describes various embodiments of a method of making shingles. In one embodiment, the method of making shingles that have an overlay portion and an underlay portion includes establishing a continuous shingle overlay sheet having a repeated pattern of tabs and cutouts. A continuous shingle underlay sheet having a repeated pattern of granule patches is also established. The presence of the pattern of tabs and cutouts on the continuous shingle overlay sheet is sensed and the presence of the pattern of granule patches on the continuous shingle underlay sheet is also sensed. The position of the continuous shingle overlay sheet relative to the continuous shingle underlay sheet is synchronized in response to the sensed presence of the repeated pattern of tabs and cutouts and the sensed presence of the repeated pattern of granule patches. Each granule patch in the pattern of granule patches is then aligned with one of the tabs in the pattern of tabs and cutouts. The continuous shingle overlay sheet is laminated to the continuous shingle underlay sheet to define a laminated sheet, and the laminated sheet is cut into a plurality of shingles. 
         [0011]    In another embodiment, a method of making shingles that have an overlay portion and an underlay portion includes establishing a continuous asphalt-coated sheet having a continuous underlay sheet portion and a continuous underlay sheet portion. A repeated pattern of granule patches is applied to the continuous underlay sheet portion. A repeated pattern of tabs and cutouts is formed in the continuous overlay sheet portion. The continuous underlay sheet portion is separated from the continuous overlay sheet portion to define a continuous shingle underlay sheet and a continuous shingle overlay sheet. The presence of the pattern of tabs and cutouts on the continuous shingle overlay sheet is sensed. The presence of the pattern of granule patches on the continuous shingle underlay sheet is sensed. The position of the continuous shingle overlay sheet is synchronized relative to the continuous shingle underlay sheet in response to the sensed presence of the repeated pattern of tabs and cutouts and the sensed presence of the repeated pattern of granule patches. Each granule patch in the pattern of granule patches is then aligned with one of the tabs in the pattern of tabs and cutouts. The continuous shingle overlay sheet is laminated to the continuous shingle underlay sheet to define a laminated sheet, and the laminated sheet is cut into a plurality of shingles. 
         [0012]    Other advantages of the method of making shingles will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    A complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
           [0014]      FIG. 1  is a schematic view in elevation of an apparatus for manufacturing an asphalt-based roofing material according to the invention. 
           [0015]      FIG. 2  is a plan view of a portion of the apparatus illustrated in  FIG. 1 , showing the laminating of the continuous underlay sheet beneath the continuous overlay sheet to make shingle overlay to form a continuous laminated sheet. 
           [0016]      FIG. 3A  is an exploded schematic perspective view of a laminated shingle manufactured in the apparatus illustrated in  FIG. 1 . 
           [0017]      FIG. 3B  is a schematic plan view of the laminated shingle illustrated in  FIG. 3A . 
           [0018]      FIG. 4  is an enlarged schematic view in elevation of the first granule applicator illustrated in  FIG. 1 . 
           [0019]      FIG. 5  is a plan view of a portion of the continuous belt illustrated in  FIG. 1 , showing the pattern of holes. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The present invention will now be described with occasional reference to the illustrated embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein, nor in any order of preference. Rather, these embodiments are provided so that this disclosure will be more thorough, and will convey the scope of the invention to those skilled in the art. 
         [0021]    Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. 
         [0022]    Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements. 
         [0023]    As used in the description and the appended claims, the phrase “asphalt coating” is defined as any type of bituminous material suitable for use on a roofing material, such as asphalts, tars, pitches, or mixtures thereof. The asphalt may be either manufactured asphalt produced by refining petroleum or naturally occurring asphalt. The asphalt coating may include various additives and/or modifiers, such as inorganic fillers or mineral stabilizers, organic materials such as polymers, recycled streams, or ground tire rubber. Preferably, the asphalt coating contains asphalt and an inorganic filler or mineral stabilizer. 
         [0024]    As used in the description of the invention and the appended claims, the term “period” is defined as the completion of a cycle. 
         [0025]    Laminated composite shingles, such as asphalt shingles, are a commonly used roofing product. Asphalt shingle production generally includes feeding a base material from an upstream roll and coating it first with a roofing asphalt material, then a layer of granules. The base material is typically made from a fiberglass mat provided in a continuous shingle membrane or sheet. It should be understood that the base material can be any suitable support material. 
         [0026]    Referring now to the drawings, there is shown in  FIG. 1  an apparatus  10  for manufacturing an asphalt-based roofing material, and more particularly for applying granules onto an asphalt-coated sheet. The illustrated manufacturing process involves passing a continuous sheet of substrate or shingle mat  12  in a machine direction  13  through a series of manufacturing operations. The sheet usually moves at a speed of at least about 200 feet/minute (61 meters/minute), and typically at a speed within the range of between about 450 feet/minute (137 meters/minute) and about 620 feet/minute (244 meters/minute). However, other speeds may be used. 
         [0027]    In a first step of the manufacturing process, the continuous sheet of shingle mat  12  is payed out from a roll  14 . The shingle mat  12  may be any type known for use in reinforcing asphalt-based roofing materials, such as a nonwoven web of glass fibers. Alternatively, the substrate may be a scrim or felt of fibrous materials such as mineral fibers, cellulose fibers, rag fibers, mixtures of mineral and synthetic fibers, or the like. 
         [0028]    The sheet of shingle mat  12  is passed from the roll  14  through an accumulator  16 . The accumulator  16  allows time for splicing one roll  14  of substrate to another, during which time the shingle mat  12  within the accumulator  16  is fed to the manufacturing process so that the splicing does not interrupt manufacturing. 
         [0029]    Next, the shingle mat  12  is passed through a coater  18  where a coating of hot, melted asphalt  19  is applied to the shingle mat  12  to form an asphalt-coated sheet  20 . The asphalt coating  19  may be applied in any suitable manner. In the illustrated embodiment, the shingle mat  12  contacts a roller  17 , which is in contact with the supply of hot, melted asphalt  19 . The roller  17  completely covers the shingle mat  12  with a tacky coating of asphalt  19 . However, in other embodiments, the asphalt coating  19  could be sprayed on, rolled on, or applied to the shingle mat  12  by other means. Typically the asphalt coating is highly filled with a ground mineral filler material, amounting to at least about 42 percent by weight of the asphalt/filler combination. In one embodiment, the asphalt coating  19  is in a range from about 350° F. to about 400° F. In another embodiment, the asphalt coating  19  may be more than 400° F. or less than 350° F. The shingle mat  12  exits the coater  18  as an asphalt-coated sheet  20 . The asphalt coating  19  on the asphalt-coated sheet  20  remains hot. The asphalt-coated sheet  20  includes a continuous underlay sheet portion  70  and a continuous overlay sheet portion  72 , as best shown in  FIG. 2  and described in detail below. 
         [0030]    The asphalt-coated sheet  20  is passed beneath a first granule applicator, shown schematically at  22 , where a repeated pattern of granule patches  74  is applied to the continuous underlay sheet portion  70  of the asphalt-coated sheet  20 . The patches  74  of the repeated pattern of granule patches  74  correspond to the shapes and sizes of the repeated pattern of tabs  86  of a finished laminated shingle  52 , as shown in  FIGS. 3A and 3B . The patches  74  will be underneath the tabs  86 , and will not be visible in the finished laminated shingle  52 . Advantageously, relatively less expensive first or headlap granules  75  may be used to form the repeated pattern of granule patches  74 . A shadow strip  78  is formed along an edge  92  (the upper edge when viewing  FIG. 2 ) of the continuous underlay sheet portion  70 , and will be described in detail below. The portion of the continuous underlay sheet portion  70  not covered by the patches  74  and the shadow strip  78  defines a prime region  76 . The prime region  76  will be visible through the cutouts  88  of the finished laminated shingle  52 . 
         [0031]    The asphalt-coated sheet  20  is then passed beneath a second granule applicator. In the illustrated embodiment, the second granule applicator is a blend drop applicator, shown schematically at  24 . The blend droop applicator  24  applies second or blend drop granules  77  to the continuous overlay sheet portion  72  of the asphalt-coated sheet  20  to define blend drops  80 . Although only one blend drop applicator  24  is shown, it will be understood that several blend drop applicators  24  may be used. Alternatively, the blend drop applicator  24  may be adapted to supply several streams of blend drops, or blend drops of different colors, shading, or size to the continuous overlay sheet portion  72 . The blend drop applicator  24  also applies blend drop granules to the prime region  76  of the continuous underlay sheet portion  70  of the asphalt-coated sheet  20 . 
         [0032]    The asphalt-coated sheet  20  is then passed beneath a third granule applicator. In the illustrated embodiment, the third granule applicator is a backfall granule applicator  26 , for applying additional granules, such as shadow granules to the shadow strip  78 , background granules, and headlap granules onto the asphalt-coated sheet  20 . 
         [0033]    The shadow granules are deposited along the edge  92  (the upper edge when viewing  FIG. 2 ) of the continuous underlay sheet portion  70  and define the shadow strip  78 . A portion of the shadow strip  78  will be visible adjacent an upper edge  90  of the cutout  88  of the laminated shingle  52 . The background granules are applied to the continuous overlay sheet portion  72  and adhere to a remainder portion  82 ; i.e., the portion of the continuous overlay sheet portion  72  of the asphalt-coated sheet  20  that is not already covered by the blend drops  80 . Similarly, the headlap granules are applied to a headlap region  60  of the continuous overlay sheet portion  72 . 
         [0034]    The background granules are applied to the extent that the asphalt-coated sheet  20  becomes completely covered with granules, thereby defining a continuous granule-coated sheet  28 . The granule-coated sheet  28  is then turned around a slate drum  30  to press the granules into the asphalt coating and to temporarily invert the sheet  28 . Such inverting of the granule-coated sheet  28  causes any excess granules to drop off the granule-coated sheet  28  on the backside of the slate drum  30 . The excess granules are collected by a hopper  32  of the backfall granule applicator  26  and may be reused. As described below, the hopper  32  is positioned on the backside of the slate drum  30 . 
         [0035]    The continuous granule-coated sheet  28  is fed through pull rolls  34  that regulate the speed of the sheet  28  as it moves downstream. In one embodiment, at least one of the pull rolls  34  is driven by a motor (not shown). 
         [0036]    The granule-coated sheet  28  is subsequently fed through a rotary pattern cutter  36  which includes a bladed cutting cylinder  38 , a backup roll  40 , and a motor  42 , as shown in  FIG. 2 . The pattern cutter  36  cuts a repeated pattern of tabs  86  and cutouts  88 . It will be understood that the tabs  62  may have any desired combination of color blend drops. 
         [0037]    The pattern cutter  36  also cuts the granule-coated sheet  28  into the continuous underlay sheet  46  and the continuous overlay sheet  48 . As shown in  FIG. 2 , the continuous underlay sheet  46  is directed to be aligned beneath the continuous overlay sheet  48 , and the two sheets  46 ,  48  are laminated together to form a continuous laminated sheet  50 . As shown in  FIG. 1 , the continuous underlay sheet  46  is routed on a longer path than the path of the continuous overlay sheet  48 . Further downstream, the continuous laminated sheet  50  is passed into contact with a rotary length cutter  44  that cuts the laminated sheet  50  into individual laminated shingles  52 . 
         [0038]    To facilitate synchronization of the cutting and laminating steps, various sensors and controls can be employed, as disclosed in U.S. Pat. No. 6,635,140 to Phillips et al., the disclosure of which is incorporated herein by reference. For example, a timing mark as known in the art and indicating the period of the repeated pattern of granule patches  74  may be applied to an appropriate part of the granule-coated sheet  28 . 
         [0039]    In one embodiment, the timing mark may be applied within a patch  74 , as shown at  54 . In another embodiment, the timing mark may be applied within the shadow strip  78 , as shown at  56 . In another embodiment, the timing mark may be applied on a back side of the continuous underlay sheet portion  70 , as shown by the dashed line  58 . Any of the illustrated embodiments of the timing mark  54 ,  56 ,  58  may be used for synchronization in a known manner. The timing mark  54 ,  56 ,  58  may be applied by any means, and may be a relatively thin blend drop of granules applied by a blender  24  or a timing mark blender (not shown). The timing mark  54 ,  56 ,  58  may comprise white colored granules. Alternatively, the timing mark  54 ,  56 ,  58  may also be any suitable light-colored material, such as paint, chalk, or the like. The timing may be sensed by a sensor, such as a photoeye  60 , for synchronization with the rotating rotary pattern cutter  36 . 
         [0040]    Additionally, sensors, such as photoeyes  62  and  64  may be used to synchronize the pattern of granule patches  74  of the continuous shingle underlay sheet  46  with the tabs  86  of the continuous shingle overlay sheet  48 . Such synchronization ensures that each granule patch  64  of the continuous shingle underlay sheet  46  is aligned with one of the tabs  86  of the continuous shingle overlay sheet  48 . As used herein and the appended claims, the phase “aligned with” is defined as the shapes and sizes of the granule patches  74  in the repeated pattern of granule patches  74  corresponding to the shapes and sizes of the repeated pattern of tabs  86 , such that the granule patches  74  are covered by the tabs  86  and only the prime granules of the prime region  76  are visible through the cutouts  88 . Advantageously, by synchronizing and aligning each granule patch  64  of the continuous shingle underlay sheet  46  with one of the tabs  86  of the continuous shingle overlay sheet  48 , the relatively more expensive prime granules are needed only for the prime region  76  of the continuous shingle underlay sheet  46  that will be visible through the cutouts  88  of the laminated shingle  52 . The relatively less expensive headlap granules may be used to form the pattern of granule patches  74  of the continuous underlay sheet  46 . The cost of the shingle is therefore reduced. 
         [0041]    As shown in  FIGS. 3A and 3B , a laminated shingle  52  formed by the process illustrated in  FIGS. 1 and 2  may include an overlay sheet  100  and an underlay sheet  102 . The overlay sheet  100  includes an upper or headlap portion  104 , and a lower prime or butt portion  106 . The butt portion  106  includes a repeated pattern of the tabs  86  and cutouts  88 . A rear surface of the overlay sheet  100  and a front surface of the underlay sheet  102  are fixedly attached to each other to form the laminated shingle  52 . Such attachment can be accomplished by using adhesive materials applied to the rear surface of the overlay sheet  100  and the front surface of the underlay sheet  102 . In the illustrated embodiment, a butt edge  108  of the butt portion  106  of the overlay sheet  100  and a lower edge  110  of the underlay sheet  102  are vertically aligned to define a lower edge  112  of the shingle  52 . If desired, a bead of adhesive (not shown) may be applied to a bottom surface of the underlay sheet  102 . Although  FIGS. 3A and 3B  illustrate a laminated shingle, it will be understood that the method and apparatus of the invention may be used with single layer shingles, such as three-tab shingles. 
         [0042]    The granules deposited on the composite material shield the roofing asphalt material from direct sunlight, offer resistance to fire, and provide texture and color to the shingle. The headlap portions  104  may be ultimately covered by adjacent shingles  52  when installed upon a roof. When installed upon a roof, the granule patches  74  of the underlay sheet  102  will be covered by the tabs  86 , and the prime regions  76  of the underlay sheet  102  will be visible through the cutouts  88 . Prime granules are therefore used on the prime regions  76  of the underlay sheet  102  so that the underlay sheet  102  visible through the cutouts  88  always contains prime granules. 
         [0043]    Referring now to  FIGS. 4 and 5 , a first embodiment of the first granule applicator is shown generally at  22 . The first granule applicator  22  includes a patch pattern belt assembly  120  and a granule patch conveyor  122 . 
         [0044]    As shown schematically in  FIG. 4 , the patch pattern belt assembly  120  includes a continuous belt  124  having an upper flight  126 , a lower flight  128 , and defining an interior space  130 . The belt  124  travels around a first or forward large roller  132 , an upper rear roller  134 , and a lower rear roller  136 . The patch pattern belt assembly  120  is operated by a motor (not shown) which causes the continuous belt  124  to travel at near machine speed, or the speed of the moving asphalt-coated sheet  20 . In the illustrated embodiment, the upper rear roller  134  is mounted upwardly and forwardly (to the right when viewing  FIG. 4 ) of the lower rear roller  136 . 
         [0045]    The continuous belt  124  includes a plurality of holes  138  forming a pattern of holes  138 . The repeating pattern of holes  138  corresponds to the desired pattern of granule patches  74 . Each hole  138  has a length L, measured in the machine direction  13 , and a height H, equal to the length and height, respectively, of the granule patch  74  to be applied to the asphalt-coated sheet  20 . The illustrated holes  138  have a rectangular shape. It will be understood however, that the holes  138  may have any other desired shape corresponding to a desired shape of the granule patches  74 . 
         [0046]    In the illustrated embodiment, the length of the continuous belt  124  is equal to the circumference of the pattern cutter  36 . Alternatively, the continuous belt  124  may have other lengths, such as a length smaller than the circumference of the pattern cutter  36 , or a length larger than the circumference of the pattern cutter  36 . 
         [0047]    As also shown schematically in  FIG. 4 , the granule patch conveyor  122  includes a continuous belt  140  having an upper flight  142  and a lower flight  144 . The belt  140  travels around a first or forward roller  146  and a second or rear roller  148 . The upper flight  142  of the granule patch conveyor  122  engages the lower flight  128  of the patch pattern belt assembly  120 . In the illustrated embodiment, the upper flight  142  and the lower flight  128  are oriented at an acute angle A from a plane defined by the asphalt-coated sheet  20 . In the illustrated embodiment, the angle A is about 5 degrees. Alternatively, the angle A is an angle within the range of from about 5 degrees to about 45 degrees. In another embodiment, the angle A is an angle within the range of from about 0 degrees to about 90 degrees. 
         [0048]    The granule patch conveyor  122  is operated by a motor (not shown) which causes the continuous belt  140  to travel at near machine speed, or the speed of the moving asphalt-coated sheet  20 . 
         [0049]    The first granule applicator  22  includes means for supplying granules  150  to the interior space  130  of the patch pattern belt assembly  120 . As shown schematically in  FIG. 4 , the first granule applicator  22  may include an auger  152  for moving granules  150  from a source of granules (not shown) to a hopper  154  within the interior space  130 . Alternatively, granules  150  may be moved into the hopper  154  in the interior space  130  by other suitable means. For example, the granules  150  may be moved into the hopper  154  through a gravity-feed device, such as a chute or tube (not shown). 
         [0050]    The granules  150  may then be fed from the hopper  154  by a fluted roll  156  from which upon rotation, the granules  150  are discharged into contact with a chute  158 . The illustrated chute  158  is elongated and substantially flat, although the chute may have other shapes, such as a substantially curved cross-sectional shape. The chute  158  extends outwardly and in a down-stream direction. The chute  158  guides the granules  150  radially outwardly and downwardly from the fluted roll  156  and into each of the holes  138  in the continuous belt  124 . 
         [0051]    If desired, side guides or rails, schematically illustrated at  160  in  FIG. 5 , may be mounted within the interior space  130  to maintain the granules  150  within a granule patch lane GL, the width of which is defined by the height H of the holes  138 . 
         [0052]    It will be understood that the first granule applicator  22  described above is not required, and that other granule applicators may be provided. Examples of other suitable granule applicators include the embodiments of the blend drop application station disclosed in the concurrently filed U.S. patent application entitled “Apparatus and Method for Depositing Particles” (U.S. patent application Ser. No. ______) to David P. Aschenbeck. U.S. patent application Ser. No. ______ is commonly assigned, has the same inventor as the present application, and is incorporated herein by reference. 
         [0053]    It will be further understood that the hopper  154  and fluted roll  156  described above are not required, and that any other desired granule dispenser may be provided within the interior space  130 . Examples of other suitable granule dispensers include a hopper having a slide gate, and a vibratory feeder. 
         [0054]    In operation, continuous belt  124  of the patch pattern belt assembly  120  is caused to move in a counter-clockwise direction and the continuous belt  140  of the granule patch conveyor  122  is caused to move in a clockwise direction when viewing  FIG. 4 . 
         [0055]    The granules  150  may be selectively dispensed or discharged into the interior space  130 . As used herein, the phrase “selectively dispensed or discharged” is defined as controlling the rate of flow of the granules  150  into the interior space  130  and/or controlling the axial position of the discharged granules  150  to ensure the granules  150  are discharged substantially onto the upper flight  142  of the granule patch conveyor  122  within each of the holes  138 . For example, the rate of flow out of the granule dispenser  22  may be pre-calibrated and programmed to provide a desired pre-determined rate that may vary depending on the line-speed and/or the specific pattern of holes  138  formed in the continuous belt  124 . The granules  150  that have been discharged onto the upper flight  142  of the granule patch conveyor and within the holes  138  therefore define the granule patches  74  to be applied to the asphalt-coated sheet  20 . 
         [0056]    Each granule patch  74  continues to travel on the upper flight  142 . As the belt  140  turns around the forward roller  146 , each granule patch  74  is released from contact with the belt  140 . The granule patch  74  then moves forwardly and downwardly at near-sheet speed to the asphalt-coated sheet  20  along a path generally shown by the line P. 
         [0057]    The present invention should not be considered limited to the specific examples described herein, but rather should be understood to cover all aspects of the invention. Various modifications, equivalent processes, as well as numerous structures and devices to which the present invention may be applicable will be readily apparent to those of skill in the art. Those skilled in the art will understand that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.