CONSTRUCTION MATERIAL WITH IMPROVED LAP INTEGRITY

Abstract

Disclosed is a hybrid composite construction material and a process for creating it. The substrate used to create the new hybrid material has the same compound applied on at least the side lap area on the top side of the substrate and at least a portion of the back side of the substrate. The substrate can be pre-saturated with a selected compound prior to applying the same compound on at least the side lap area on the top side of the substrate and at least a portion of the back side of the substrate. The processes to create the product and other embodiments is also disclosed.

Claims

1. A hybrid composite construction material comprising: a substrate with a top side and a back side; a first compound applied on the top side of the substrate; a portion of the first compound subsequently removed from a side lap area on the top of the substrate; and a second compound applied on at least a portion of the back side of the substrate and applied on the side lap area on the top side of the substrate.

2. A hybrid composite construction material according to claim 1 in which the first compound was applied on at least a portion of the back side of the substrate and the first compound at least partially removed from the back side of the substrate prior to having the second compound applied to at least the portion on the back side of the substrate.

3. A hybrid composite construction material according to claim 2 in which the substrate is saturated with the first compound.

4. A hybrid composite construction material according to claim 2 in which the substrate is pre-saturated with asphalt or bitumen before the first compound is applied to the substrate.

5. A hybrid composite construction material according to claim 2 in which the substrate is pre-saturated with a modified bitumen compound.

6. The hybrid composite construction material according to claim 2 wherein the first compound is a plastomeric modified bitumen compound.

7. The hybrid composite construction material according to claim 2 wherein the first compound is an elastomeric modified bitumen compound.

8. The hybrid composite construction material according to claim 2 wherein the first compound is asphalt or bitumen.

9. The hybrid composite construction material according to claim 6 wherein the second compound is self-adhered modified bitumen compound.

10. The hybrid composite construction material according to claim 6 wherein the second compound is an elastomeric modified bitumen compound.

11. The hybrid composite construction material according to claim 6 wherein the second compound is asphalt and or bitumen.

12. The hybrid composite construction material according to claim 7 wherein the second compound is self-adhered modified bitumen compound.

13. The hybrid composite construction material according to claim 7 wherein the second compound is a plastomeric modified bitumen compound.

14. The hybrid composite construction material according to claim 7 wherein the second compound is asphalt and or bitumen.

15. The hybrid composite construction material according to claim 8 wherein the second compound is self-adhered modified bitumen compound.

16. The hybrid composite construction material according to claim 8 wherein the second compound is an elastomeric modified bitumen compound.

17. The hybrid composite construction material according to claim 8 wherein the second compound is a plastomeric modified bitumen compound.

18. The hybrid composite construction material according to claim 2 wherein a thickness of the second compound on the side lap area on the top side of the substrate is between 0.1 and 2.0 mm.

19. The hybrid composite construction material according to claim 2 wherein a thickness of the second compound on the bottom of the substrate is between 0.1 and 3.0 mm.

20. A process for creating a hybrid material comprising: selecting a substrate with a top side and a back side; loading one end of the substrate onto a production line; proceeding with the substrate into a first vat wherein the substrate is coated with a first compound on the top of the substrate and on a back side of the substrate; passing through at least one adjustable roller wherein the first compound is squeezed into the substrate; proceeding with the substrate though a subsequent coating station wherein the substrate is coated with the first compound on the top side of the substrate and on a back side of the substrate and passes through at least one thickness roller to ensure a selected thickness of a first coating on the top side of the substrate and on the back side of the substrate; passing through adjustable scrapers to remove a selected amount of the first compound from a lap area on the top side of the substrate and from at least a portion of the back side of the substrate; and passing through a second vat wherein the substrate is coated with a second compound onto at least a portion of the back side of the substrate, and onto a selected portion of the top side of the substrate.

21. The process for creating a hybrid material according to claim 20 in which a temperature of the first compound is between 100 and 250 degrees Celsius.

22. The process for creating a hybrid material according to claim 20 in which a temperature of the second compound is between 100 and 250 degrees Celsius.

23. The hybrid composite construction material according to claim 20 wherein the first compound is plastomeric modified bitumen compound.

24. The hybrid composite construction material according to claim 20 wherein the second compound is self-adhered modified bitumen compound.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0031] FIG. 1 shows the substrate material as it moves through the production line creating the hybrid composite material.

[0032] FIG. 2 shows a section of the production line

PARTS LIST

[0033] 1 First compound [0034] 2 Second compound [0035] 3 Thickness rolls [0036] 4 Calender rolls [0037] 5 First coating station [0038] 6 Second coating station [0039] 7 Coated substrate [0040] 8 Squeeze rolls [0041] 9 Substrate [0042] 10 Not used [0043] 11 Not used [0044] 12 Not used [0045] 13 Saturated substrate [0046] 14 Side lap area [0047] 15 Not used [0048] 16 Top side lap area scraper [0049] 17 Back side scraper [0050] 18 Mechanical stop [0051] 19 Second compound applicator for side lap area [0052] 20 Second compound applicator for bottom/back side [0053] 21 Surfacing [0054] 22 Weathering area [0055] 23 First compound vat [0056] 24 Second compound vat [0057] 25 Hybrid composite material [0058] 26 Dry end looper [0059] 27 Production line

DETAILED DESCRIPTION

[0060] An innovative technique has been discovered that partially or completely replaces the compound in the side lap area of hybrid composite materials with the same compound that is used and or applied on the back or bottom of the hybrid composite material. The disclosed hybrid composite material and process eliminates the need to apply the expensive specially formulated glue/adhesive on the top of the existing side lap compound. This reduces costs and improves long and short term compatibility. The compound used in the overlapping side lap area will now be bonded to the same compound used on the back and or bottom of the material ensuring that the hybrid composite material will perform as intended.

[0061] The disclosed hybrid composite material and process also eliminates the dependency of the manufacturing process to apply the expensive adhesive/glue in sufficient quantity and amount to facilitate the bonding of dissimilar compounds in hybrid composite materials. The disclosed hybrid composite material has many applications such as for roofing, siding, building, or construction material. The disclosed also eliminates the need to have the entire material made entirely of a softer, less functional pressure sensitive or self-adhering adhesive compound and opens the door to different multiple compound hybrid composite construction materials.

[0062] In one embodiment, the disclosed hybrid composite material includes plastomeric modified bitumen compound used in the weathering area on the top/upper side of a substrate, and elastomeric compound used on both the back/bottom side of the substrate and in the side lap area located on the top or upper side of the substrate. The disclosed hybrid composite material is an all plastomeric material converted during the manufacturing process to a material that is a hybrid composite utilizing both a plastomeric compound in the weathering area on the top side of a substrate and an elastomeric self-adhered compound used on both the back side of the substrate and in the side lap area adjacent to the plastomeric compound on the top of the material.

[0063] The disclosed hybrid composite material and process includes altering the manufacturing process of materials particularly modified and unmodified bitumen membranes and the like that use a substrate or multiple substrates. Examples of the materials used for the substrates are: glass mat, glass scrims and the like; polyester mats either woven or nonwoven; polyester scrims either woven or nonwoven; glass mat, glass scrims, glass filaments and the like in combination with polyester mats that are woven or nonwoven and the like. Other types of substrates include: mats, or reinforcement carrier support sheets made of materials that are known and are commonly used as substrates in the manufacturing of roofing materials, siding materials, building materials, construction materials and the like

[0064] A preferred manufacturing process used for the creation of the disclosed hybrid composite material is disclosed below and is not intended to be the only way to manufacture the material.

[0065] There are several different ways to saturate the substrate and add top/upper compound and bottom/back compound that can consist of plastomeric modified bitumen, elastomeric modified bitumen compound or even unmodified bitumen and the like well-known in the industry today. Once the disclosed hybrid composite material and process is understood, it will become apparent to one versed in the production of material used for roofing, siding, construction and or building materials and the like, how to alter and modify this process to adapt other production methods well-known in the industry to achieve the same desired result.

[0066] In one embodiment, the disclosed hybrid composite material 25 comprises a substrate that is about 1 meter (about 39.4 inches) wide and that is about 1 mm (about 0.04 inches) thick. In another embodiment, the disclosed hybrid composite material 25 comprises a substrate that is about 0.9 meters (about 36 inches) wide and about 0.6 mm (about 0.024 inches) thick. But the substrate used can be of any thickness and of any width for the disclosed hybrid material.

[0067] Substrate 9 typically come in large master rolls and are unwound during the manufacturing process usually into dry end looper 26 that contain rolls that move up and down individually or as a unit or both. When substrate 9 is almost completely used up on the first master roll another master roll of substrate 9 can be put in place and the end of the second master roll of substrate 9 is spliced onto the first master roll of substrate 9 using tape, adhesive and the like well-known in the industry today. Dry end looper 26 holds excess substrate 9 so that production line 27 does not have to stop and or slow down during the splicing together of the two master rolls of substrate 9. Subsequent rolls of substrate 9 on production line 27 are consumed and used in this manner for a continuous production process for the disclosed hybrid composite material 25.

[0068] In one embodiment of the disclosed process, substrate 9 leaves optional dry end looper 26 and enters first compound vat 23 on production line 27 where it is coated at first coating station 5 with first compound 1. Coated substrate 7 then passes through a set of adjustable squeeze rolls 8 located inside or above the first compound vat 23 to squeeze first compound 1 into substrate 9 and or substrate 9 passes over and or under rollers and or scrapers located inside first compound vat 23 to ensure that substrate 9 is completely saturated with first compound 1. Excess first compound 1 falls back into first compound vat 23 to be used again.

[0069] Saturated substrate 13 is then coated with first compound 1 at second coating station 6 in first compound vat 23 so that there is first compound 1 on both sides of saturated substrate 13. Coated substrate 7 then enters a set of thickness/calender rolls 3 where a predefined thickness of first compound 1 will remain across the entire upper/top surface and across the entire bottom/back surface of coated substrate 7 after exiting thickness rolls 3 located in or above first compound vat 23 so that excess first compound 1 falls back into first compound vat 23 to be used again.

[0070] After coated substrate 7 passes through a set of thickness rolls 3 to achieve a predefined top and bottom thickness, the back side of coated substrate 7 passes over adjustable back side scraper 17 that is typically wider than the width of coated substrate 7 and can be adjusted so that all, most, or a portion of first compound Located on the backside of the coated substrate 7 can be removed from coated substrate 7 as desired.

[0071] Adjustable back side scraper 17 is located above or in first compound vat 23 so that the desired amount of first compound 1 that is removed from the back side of coated substrate 7 falls back into first compound vat 23 to be used again.

[0072] In a preferred embodiment, first compound 1 is removed from the back side of coated substrate 7, so that some of the fibers from which the substrate is made, become visible on the back side of coated substrate 7. These exposed fibers help to mechanically attach and bond second compound 2 that is applied with applicator 20 to the back side of scraped coated substrate 7. Back side scraper 17 is wider than the width of the coated substrate 7 for ease of production.

[0073] At or about the same time that first compound 1 is being removed by back side scraper 17, a small adjustable side lap scraper 16 located on the top side of coated substrate 7 in first compound vat 23, scrapes the top side first compound 1 longitudinally along coated substrate 7 in side lap area 14. Top side lap scraper 16 is wider than the desired side lap area 14 width and can be adjusted so that all or a portion of first compound 1 is removed from and along the side lap area 14. First compound 1 that is removed from the top side lap area 14 falls back into first compound vat 23 to be used again.

[0074] The top and back side scraped coated substrate 7 from the disclosed process, exits first compound vat 23 and enters second compound vat 24 on production line 27 that contains second compound applicator 19 for the side lap area and second applicator 20 for the back side located in or above second compound vat 24 on production line 27. Second compound 2 will be used and applied to the desired thickness across the entire back side of scraped and coated substrate 7 and in the scraped side lap area 14 adjacent to first compound 1 that remained on the top or upper side of coated substrate 7.

[0075] Second compound 2 for the disclosed process is applied on and in the side lap area by means of a transfer pump and a supply line that meters on second compound 2 to a thickness of about 0.1-2.0 mm in side lap area 14 using second compound applicator 19 located above second compound vat 24. Mechanical stop 18 prevents second compound 2 applied in the side lap area 14 from intermingling with the previously applied first compound 1 along side lap area 14 where the two compounds meet. Mechanical stop 18 also allows excess second compound 2 to fall back into second compound vat 24 without being contaminated so that second compound 2 can be used again.

[0076] Second compound applicator 20 applies second compound 2 to the back side of coated substrate 7 by means of a transfer, inking or kiss coat roll, extruder, or the like. For the disclosed process, inking roll 20 is used to apply second compound 2 to the back side of the coated substrate 7. Hybrid composite material 25 then passes through a set of calender rolls 4 where typically only the bottom heated calendar roll 4 is usually rotating opposite the direction of production line 27 is used in this disclosed process to achieve the desired back side compound thickness. Excess second compound 2 falls back into second compound vat 24 so it can be used again.

[0077] Hybrid composite material 25 will have superior bonding and compatibility between rolls, pieces, sections and the like where they are overlapped in the field since the same compound, second compound 2 in the disclosed process, is used in side lap area 14 and on the back side of hybrid composite material 25 that are being overlapped and bonded together. If one desires, a different compound formula can be used to saturate substrate 9.

[0078] In another embodiment of the disclosed process, saturated substrate 13 is coated with first compound 1 at second coating station 6 only on the top side of saturated substrate 13 in first compound vat 23. Top coated substrate 7 then passes through a set of adjustable thickness rolls 3 located inside and or above first compound vat 23 to obtain the desired top side first compound 1 thickness. Excess first compound 1 falls back into first compound vat 23 to be used again.

[0079] Since there is no back side first compound 1 to scrape off only small adjustable side lap scraper 16 located on the top side of coated substrate 7 in first compound vat 23, is used to scrape the top side first compound 1 longitudinally along coated substrate 7 in side lap area 14. Top side lap scraper 16 is wider than the desired side lap area 14 width and can be adjusted so that all or a portion of first compound 1 is removed from and along the side lap area 14. First compound 1 that is removed from the top side lap area 14 falls back into first compound vat 23 to be used again.

[0080] Top scraped coated substrate 7 from the disclosed process, exits first compound vat 23 and enters second compound vat 24 on production line 27 that contains second compound applicator 19 for the side lap area and second applicator 20 for the back side located in or above second compound vat 24 on production line 27. Second compound 2 will be used and applied to the desired thickness across the entire back side of coated substrate 7 and in the scraped side lap area 14 adjacent to first compound 1 that remained on the top or upper side of coated substrate 7.

[0081] Second compound 2 for the disclosed process is applied on and in the side lap area by means of a transfer pump and a supply line that meters on second compound 2 to a thickness of about 0.1-2.0 mm in side lap area 14 using second compound applicator 19 located above second compound vat 24. Mechanical stop 18 prevents second compound 2 applied in the side lap area 14 from intermingling with the previously applied first compound 1 along side lap area 14 where the two compounds meet. Mechanical stop 18 also allows excess second compound 2 to fall back into second compound vat 24 without being contaminated so that second compound 2 can be used again.

[0082] Hybrid composite material 25 then passes through a set of calender rolls 4 where typically only the bottom heated calendar roll 4 is usually rotating opposite the direction of production line 27 is used in this disclosed process to achieve the desired back side compound thickness. Excess second compound 2 falls back into second compound vat 24 so it can be used again.

[0083] Hybrid composite material 25 will have superior bonding and compatibility between rolls, pieces, sections and the like where they are overlapped in the field since the same compound, second compound 2 in the disclosed process, is used in side lap area 14 and on the back side of hybrid composite material 25 that are being overlapped and bonded together. If one desires, a different compound formula can be used to saturate substrate 9.

[0084] In yet another embodiment of the disclosed process, substrate 9 leaves optional dry end looper 26 and enters first compound vat 23 on production line 27 where it bypasses first coating station 5 and is only coated with first compound 1 on the top side at second coating station 6. Top-coated substrate 7 enters a set of thickness rolls 3 where a predefined thickness of first compound 1 will remain across the entire upper or top surface of coated substrate 7 and coated substrate 7 in partially saturated with first compound 1. Excess first compound 1 falls back into first compound vat 23 to be used again.

[0085] Since there is no back side first compound 1 to scrape off only small adjustable side lap scraper 16 located on the top side of coated substrate 7 in first compound vat 23, is used to scrape the top side first compound 1 longitudinally along coated substrate 7 in side lap area 14. Top side lap scraper 16 is wider than the desired side lap area 14 width and can be adjusted so that all or a portion of first compound 1 is removed from and along the side lap area 14. First compound 1 that is removed from the top side lap area 14 falls back into first compound vat 23 to be used again.

[0086] Top scraped coated substrate 7 from the disclosed process, exits first compound vat 23 and enters second compound vat 24 on production line 27 that contains second compound applicator 19 for the side lap area and second applicator 20 for the back side located in or above second compound vat 24 on production line 27. Second compound 2 will be used and applied to the desired thickness across the entire back side of coated substrate 7 and in the scraped side lap area 14 adjacent to first compound 1 that remained on the top or upper side of coated substrate 7.

[0087] Second compound 2 for the disclosed process is applied on and in the side lap area by means of a transfer pump and a supply line that meters on second compound 2 to a thickness of about 0.1-2.0 mm in side lap area 14 using second compound applicator 19 located above second compound vat 24. Mechanical stop 18 prevents second compound 2 applied in the side lap area 14 from intermingling with the previously applied first compound 1 along side lap area 14 where the two compounds meet. Mechanical stop 18 also allows excess second compound 2 to fall back into second compound vat 24 without being contaminated so that second compound 2 can be used again.

[0088] Second compound applicator 20 applies second compound 2 to the back side of coated substrate 7 by means of a transfer, inking or kiss coat roll, extruder, or the like. For the disclosed process, inking roll 20 is used to apply second compound 2 to the back side of the coated substrate 7. Hybrid composite material 25 then passes through a set of calender rolls 4 where typically only the bottom heated calendar roll 4 is usually rotating opposite the direction of production line 27 is used in this disclosed process to achieve the desired back side compound thickness. Excess second compound 2 falls back into second compound vat 24 so it can be used again.

[0089] Hybrid composite material 25 will have superior bonding and compatibility between rolls, pieces, sections and the like where they are overlapped in the field since the same compound, second compound 2 in the disclosed process, is used in side lap area 14 and on the back side of hybrid composite material 25 that are being overlapped and bonded together. If one desires, a different compound formula can be used to saturate substrate 9.

[0090] Generally for the disclosed processes, the thickness of the upper or top compound portion of hybrid composite material 25 above coated substrate 7 as it exits thickness rolls 3 and calender rolls 4 typically ranges from about 0.1 to about 4.0 mm and the thickness of the bottom compound portion of the material below the substrate as it exits calender rolls 4 will typically have a thickness that ranges between about 0.1 to about 4.0 mm in thickness.

[0091] A preferred top/upper thickness for hybrid composite material 25 above coated substrate 7 will range from about 0.1 to about 2.0 mm. The preferred back side thickness for hybrid composite material 25 located below coated substrate 7 will range from about 0.1 to about 3.0 mm. The preferred total thickness of finished hybrid composite material 25 will range from about 0.6 mm to about 5.5 mm. The preferred thickness range will vary depending on the original thickness of the substrate being used.

[0092] The importance of this disclosed process and embodiments is that compatible or similar compounds are used in side lap area 14 and the back side of hybrid composite material 25 that differ from the top or upper compound used above coated substrate 7 to make hybrid composite material 25.

[0093] FIG. 1 shows a section of the production line moving right to left with substrate 9 being coated with molten first compound 1 in first coating station 5 located in vat 23. Substrate 9 is saturated with molten first compound 1 using adjustable squeeze rolls 8 to achieve saturated substrate 13 so that excess molten first compound 1 falls back into vat 23 to be used again.

[0094] Saturated substrate 13 is coated with molten first compound 1 at second coating station 6 located above vat 23 so that excess first compound 1 falls back into vat 23 to be used again. Coated substrate 7 passes through a set of thickness rollers 3 located above vat 23 to achieve the desired top and bottom compound thickness so that molten first compound 1 is recovered in vat 23 to be used again.

[0095] Back side scraper 17 is engaged in vat 23 to remove molten first compound 1 from the entire bottom width of coated substrate 7 to the desired thickness so that first compound 1 is captured back into vat 23 to be used again.

[0096] Top scraper 16 is engaged and adjusted to scrape molten first compound 1 longitudinally along one top edge of coated substrate 7 to the desired side lap width and depth in side lap area 14 as shown in FIG. 2 so that first compound 1 is recovered into vat 23 as shown in FIG. 1 to be used again.

[0097] Scraped coated substrate 7 moves along the production line from vat 23 to vat 24 as shown in FIG. 1. Molten second compound 2 is pumped and applied onto the substrate using applicator 19 in and on scraped side lap area 14 as shown in FIG. 2. Mechanical stop 18 prevents second compound 2 from intermingling with first compound 1 along the side lap area 14 as shown in FIG. 2 so that excess second compound 2 falls back into vat 24 to be used again as shown in FIG. 1.

[0098] Second compound 1 is applied to the back of coated substrate 7 in vat 24 using inking roll 20 as shown in FIG. 1 and FIG. 2. Excess second compound 2 is recovered in vat 24 to be used again as shown in FIG. 1. Hybrid composite material 25 passes through calender rolls 4 located above vat 24 to obtain the desired thickness of second compound 2 that was applied on the back of coated substrate 7 as shown in FIG. 1. Excess second compound 2 falls back into vat 24 to be used again as shown in FIG. 1.

[0099] FIG. 2 shows a section of the production line moving from right to left. Saturated substrate 13 has been coated on the top and bottom surfaces with molten first compound 1. Top scraper 16 removes molten first compound 1 to the desired thickness inside lap area 14. Back side scraper 17 removes molten first compound 1 to the desired thickness from entire bottom width of saturated substrate 13. Applicator 19 applies molten second compound 2 in scraped side lap area 14 to the desired thickness while mechanical stop 18 prevents molten second compound 2 from intermingling with molten first compound 1 inside lap area 14. Applicator 20 applies molten second compound 2 to the desired thickness on the back of scraped saturated substrate 13. Optional surfacing 21 are applied in weathering area 22.

[0100] Table 1 below shows the improvement in shear and peel test results when using elastomeric self-adhered compound replacing the specially formulated glue/adhesive in the side lap area of a plastomeric/elastomeric hybrid composite material.

TABLE-US-00002 TABLE 1 Lap Joint (Shear) Maximum Load Failure CGSB* 37-GP-56-M (lbf) Mode Prior Art** glue in side lap 94.4 +/ 4.1 Adhesive New Elastomeric Self-Adhered 113.9 +/ 2.4 Adhesive Compound in side lap*** Percent Improvement 20.7% T-Peel Adhesion Avg Load/width Failure ASTM**** D1876-08 (2015) (lbf/ft) Mode Prior Art** glue in side lap 63.7 +/ 7.6 Adhesive New Elastomeric Self-Adhered 97.5 +/ 3.8 Adhesive Compound in side lap*** Percent Improvement 53.1% *Canadian General Standards Board **Plastomeric Top Compound with 4.5 grams/linear meter of Special Glue on top of Plastomeric Compound in the side lap area bonded to the Elastomeric Self-Adhered Bottom Compound ***Plastomeric Top Compound with 0.35 mm of Elastomeric Self-Adhered Compound thickness applied in the side lap area bonded to the same Elastomeric Self-Adhered Bottom Compound ****American Society for Testing and Materials

[0101] A 20.7% improvement in shear testing was recorded when tested by CGSB Lap Strength test method and a 53.1% improvement in peel strength was recorded when tested by ASTM D1876 T-Peel test method.

[0102] An embodiment for the disclosed process is: [0103] 1. Coat substrate 9 with first compound 1 at a temperature between 100 and 250 C. in first coating station 5 located in first compound vat 23. [0104] 2. Saturate substrate 9 with same first compound 1 using adjustable squeeze rolls 8 or rolls in an S-wrap or similar configuration to achieve saturated substrate 13 so that excess first compound falls back into first compound vat 23 to be used again. [0105] 3. Recoat saturated substrate 13 with a temperature between 100-250 C. first compound 1 at second coating station 6 located in and or above first compound vat 23 so that excess first compound 1 falls back into first compound vat 23 to be used again. [0106] 4. Coated substrate 7 passes through a set of thickness rolls 3 located above first compound vat 23 to achieve the desired top and bottom compound thickness so that first compound 1 is recovered in first compound vat 23 to be used again. [0107] 5. Back side scraper 17 is engaged in first compound vat 23 to remove molten first compound 1 from the entire bottom width of coated substrate 7 to the desired thickness so that first compound 1 is captured back into first compound vat 23 to be used again. [0108] 6. Top side lap scraper 16 is engaged and adjusted to scrape molten first compound 1 longitudinally along one top edge of the coated substrate 7 to the desired side lap 14 width and depth so that first compound 1 is recovered into first compound vat 23 to be used again. [0109] 7. Scraped coated substrate 7 moves from first compound vat 23 to second compound vat 24 along production line 27. [0110] 8. 100-250 C. molten second compound 2 is pumped and applied onto the coated substrate 7 in and on scraped side lap area 14. [0111] 9. Mechanical stop 18 prevents second compound 2 from intermingling with first compound 1 along the side lap area 14 in second compound vat 24 so that excess second compound 2 falls back into second compound vat 24 to be used again. [0112] 10. 100-250 C. molten second compound 2 is applied to the back side of coated substrate 7 in second compound vat 24 using inking roll applicator 20. Excess second compound 2 is recovered in second compound vat 24 to be used again. [0113] 11. Hybrid composite material 25 passes through calender rolls 4 located above second compound vat 24 to obtain the desired thickness. Excess second compound 2 falls back into second compound vat 24 to be used again. [0114] 12. Hybrid composite material 25 is cooled, finished with release liner and or film and or granules, sand, etc. can be applied to the weathering area 22 if desired as is known in the industry today, cut into sections and or rolls and packaged.

[0115] It should be noted that there are many ways to achieve the desired hybrid composite material configuration using alternate manufacturing processes known in the industry. Also methods known in the industry can be used to saturate or pre-saturate the substrate with elastomeric and or plastomeric compound, asphalt, bitumen and or a different modified bitumen compound and the like in one or more steps to prevent water infiltration into the substrate to improve the durability of the material and at times lower the overall costs of the material if desired. Examples of First Compound 1 that can be used for the disclosed hybrid composite material include: [0116] 1. Plastomeric (APP) modified bitumen compounds [0117] 2. Elastomeric (SBS) modified bitumen compounds [0118] 3. Self-Adhered or pressure sensitive adhesive (PSA) modified bitumen compounds [0119] 4. Asphalt or bitumen compounds

[0120] Examples of Second Compound 2 that can be used for the disclosed hybrid composite material include: [0121] 1. Elastomeric (SBS) modified bitumen compounds [0122] 2. Self-Adhered or pressure sensitive adhesive (PSA) modified bitumen compounds [0123] 3. Asphalt or bitumen compounds [0124] 4. Plastomeric (APP) modified bitumen compounds

[0125] Examples of hybrid composite materials that this invention includes but are not limited to are materials that have: [0126] 1. Plastomeric (APP) First Compound 1 used on the top side of a substrate with elastomeric self-adhered or pressure sensitive Second Compound 2 utilized on the top side lap area and on the back side of the substrate, [0127] 2. Plastomeric (APP) First Compound 1 used on the top side of a substrate utilizing elastomeric (SBS) Second Compound 2 on the top side lap area and on the back side of the substrate, [0128] 3. Plastomeric (APP) First Compound 1 used on the top side of a substrate utilizing asphaltic or bitumen Second Compound 2 on the top side lap area and on the back side of the substrate, [0129] 4. Elastomeric (SBS) First Compound 1 used on the top side of a substrate utilizing elastomeric self-adhered or pressure sensitive Second Compound 2 on the top side lap area and on the back side of the substrate, [0130] 5. Elastomeric (SBS) First Compound 1 used on the top side of a substrate utilizing plastomeric (APP) Second Compound 2 on the top side lap area and on the back side of the substrate, [0131] 6. Elastomeric (SBS) First Compound 1 used on the top side of a substrate utilizing asphalt or bitumen Second Compound 2 on the top side lap area and on the back side of the substrate, [0132] 7. A material with a First Compound 1 used on the top side of a substrate utilizing Second Compound 2 on the top side lap area and on the back side of the substrate, [0133] 8. A material with a First Component 1 used on the top side of a substrate utilizing Second Component 2 on the top side lap area and on the back side of the substrate.

[0134] Disclosed is a hybrid composite construction material created from a substrate with a top side and a back side; a first compound applied on the top side of the substrate; a portion of the first compound subsequently removed from a side lap area on the top of the substrate; and a second compound applied on at least a portion of the back side of the substrate and applied on the side lap area on the top side of the substrate.

[0135] In another embodiment the hybrid composite construction material the substrate has a first compound applied on at least a portion of the back side of the substrate and then the first compound is at least partially removed from the back side of the substrate prior to having the second compound applied to at least a portion on the back side of the substrate.

[0136] In one embodiment the substrate is pre-saturated with asphalt or bitumen before first compound is applied to substrate. And in another embodiment the substrate is pre-saturated with a modified bitumen compound.

[0137] One process disclosed to create the hybrid composite construction material includes: selecting a substrate with a top side and a back side; loading one end of the substrate onto a production line; proceeding with the substrate into a first vat wherein the substrate is coated with a first compound on the top of the substrate and on a back side of the substrate; passing through at least one adjustable roller wherein the first compound is squeezed into the substrate; proceeding with the saturated substrate though a subsequent coating station wherein the substrate is coated with a first compound on the top side of the substrate and on a back side of the substrate and passes through at least one thickness roller to ensure a selected thickness of the first coating on the top side of the substrate and on the back side of the substrate; passing through adjustable scrapers to remove a selected amount of the first compound from the side lap area on the top side of the substrate and from at least a portion of the back side of the substrate; and passing through a second vat wherein the substrate is coated with a second compound onto at least a portion of the back side of the substrate, and onto a selected portion of the top side of the substrate.

[0138] The disclosed hybrid composite material and process demonstrates one way to accomplish the invention and those schooled in the manufacturing of these types of materials will understand that this is not the only way to construct the material and alternate manufacturing techniques are captured in the spirit of this invention.

[0139] Having described preferred embodiments which serve to illustrate various concepts, structures and techniques which are the subject of this patent, it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts, structures, and techniques may be used. Accordingly, it is submitted that the scope of the patent should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the following claims.