A method of fabricating a polymer coated mat is disclosed to form a moisture barrier. The method includes moving a substrate mat along a processing path and heating the substrate mat to a predetermined temperature. A curtain of molten polymer is extruded through a slot die onto a surface of the heated substrate mat as the mat moves along the processing path to create a composite mat comprising a thin polymer film coating on at least one side of the substrate mat. The composite mat is then cooled in a controlled manner to cure and solidify the polymer film. The resulting composite mat may be used as a construction wrap, or it may be incorporated into other products such as an underlayment. A novel asphalt shingle may be fabricated using the composite mat in lieu of a traditional asphalt saturated mat or other substrate.

A method of fabricating a polymer coated mat is disclosed to form a moisture barrier. The method includes moving a substrate mat along a processing path and heating the substrate mat to a predetermined temperature. A curtain of molten polymer is extruded through a slot die onto a surface of the heated substrate mat as the mat moves along the processing path to create a composite mat comprising a thin polymer film coating on at least one side of the substrate mat. The composite mat is then cooled in a controlled manner to cure and solidify the polymer film. The resulting composite mat may be used as a construction wrap, or it may be incorporated into other products such as an underlayment. A novel asphalt shingle may be fabricated using the composite mat in lieu of a traditional asphalt saturated mat or other substrate.

A method is disclosed for continuously manufacturing a composite hollow structure. The method may include continuously coating fibers with a matrix, and revolving matrix-coated fibers about a non-fiber axis. The method may also include diverting the matrix-coated fibers radially outward away from the non-fiber axis, and curing the matrix-coated fibers.

A weatherstrip assembly includes a body having a carrier or core formed from a first metal for providing strength and rigidity to the body. A show surface of the weatherstrip assembly is formed of a second metal different than the first metal. The second metal acts as the show surface of the weatherstrip assembly. An isolative, electrically low conductivity layer is received only on portions of the first metal that are disposed adjacent to portions of the second metal and potentially subject to electrical contact therebetween.

The tool which contains: a support, and an arm bearing a strip extrusion member and a strip applicator roller, wherein the arm is articulated with respect to the support about a first axis parallel to a geometric axis of the roller and about a second axis tangential to a circumference of the roller, of the first and second axes at least one passing through a centre of gravity of the arm.

A process for in-line extrusion of polymeric coatings onto roofing shingles during manufacturing includes moving a web of shingle substrate material in a downstream direction and extruding a liquefied coating of polymeric material onto at least one surface of the moving web to form a thin film. The liquefied coating may be a molten polymeric material that forms a thin film on a back surface of the shingle material to prevent sticking and eliminate the need for a traditional back dusting with material such as powdered stone. The polymeric film further may be applied to the substrate material in lieu of a saturation coating of asphalt, thus reducing cost and weight while providing a comparable moisture barrier and a lighter more flexible shingle.

Disclosed are methods for forming and adhering an entrained polymer structure to a substrate. The methods include providing a substrate (114) configured to receive application of a molten entrained polymer (118). A mineral entrained polymer in molten form is applied in a predetermined shape, to a surface of the substrate, to form a solidified entrained polymer structure on the substrate. The entrained polymer includes a monolithic material formed of at least a base polymer (25) and a mineral active agent (30) to absorb excess moisture. The surface of the substrate is compatible with the molten entrained polymer so as to thermally bond with it. In this way, the entrained polymer bonds to the substrate and solidifies upon sufficient cooling of the entrained polymer. The polymer can have a channeling or foaming agent (35), eg polyglycol. To apply the polymer is provided a hot melt dispensing apparatus comprising: a feeder (102) (optionally an extruder or loader) for providing a flow of mineral entrained polymer in molten form; one or more hoses (104), each of which having an internal lumen in fluid communication with an exit (106) of the feeder to receive flow of the mineral entrained polymer in molten form, the lumen terminating at an applicator (110) to which the entrained polymer in molten form is conveyed; the applicator comprising a dispenser (112) for applying the entrained polymer in the predetermined shape to the surface of the substrate. The hose and the dispenser can be heated.

Disclosed are methods for forming and adhering an entrained polymer structure to a substrate. The methods include providing a substrate (114) configured to receive application of a molten entrained polymer (118). A mineral entrained polymer in molten form is applied in a predetermined shape, to a surface of the substrate, to form a solidified entrained polymer structure on the substrate. The entrained polymer includes a monolithic material formed of at least a base polymer (25) and a mineral active agent (30) to absorb excess moisture. The surface of the substrate is compatible with the molten entrained polymer so as to thermally bond with it. In this way, the entrained polymer bonds to the substrate and solidifies upon sufficient cooling of the entrained polymer. The polymer can have a channeling or foaming agent (35), eg polyglycol. To apply the polymer is provided a hot melt dispensing apparatus comprising: a feeder (102) (optionally an extruder or loader) for providing a flow of mineral entrained polymer in molten form; one or more hoses (104), each of which having an internal lumen in fluid communication with an exit (106) of the feeder to receive flow of the mineral entrained polymer in molten form, the lumen terminating at an applicator (110) to which the entrained polymer in molten form is conveyed; the applicator comprising a dispenser (112) for applying the entrained polymer in the predetermined shape to the surface of the substrate. The hose and the dispenser can be heated.

In a method of manufacturing an object, a filament is fed to an extrusion head. The filament has a semi-crystalline polymeric reinforcement portion and a polymeric matrix portion. The temperature of the filament is raised in the extrusion head above the melting point of the matrix portion but below the melting point of the reinforcement portion so that the matrix portion of the filament melts within the extrusion head, thereby forming a partially molten filament within the extrusion head. The reinforcement portion of the partially molten filament remains in a semi-crystalline state as it is extruded from the extrusion head. Relative movement is generated between the extrusion head and the substrate as the partially molten filament is extruded onto the substrate in order to form an extruded line on the substrate. The matrix portion of the extruded line solidifies after the extruded line has been formed on the substrate.

A method for producing a laminate, the method comprising at least a pretreatment step of pretreating a surface of a substrate made of a plastic film by reactive ion etching so that the maximum displacement of the substrate surface measured by local thermal analysis is 300 nm or more, and a lamination step of laminating a thermoplastic resin layer made of a material different from that of the substrate on the pretreated surface of the substrate; wherein the plastic film is a polyethylene terephthalate film.