Rounded ridge cap with asphaltic foam materials

Abstract

A method of making a rounded ridge cap includes providing an intermediate product comprising a plurality of sections arranged side by side and integrated as a single body of an asphaltic foam material, each of the plurality of sections comprising a rounded top surface, the plurality of sections comprising first and second sections immediately neighboring each other. The first section comprises a first side and the second section comprises a second side integrated with the first side to form a bridge portion between the first and second sections. The method further includes bending the first section with respect to the second section about the bridge portion, thereby forming a rounded ridge cap comprising a rounded exterior surface. The rounded top surfaces of the first and second sections form together the rounded exterior surface of the rounded ridge cap.

What is claimed is: 
     
         1 . A method of making a rounded ridge cap, the method comprising:
 providing an intermediate product comprising a plurality of sections arranged side by side and integrated as a single body of an asphaltic foam material, each of the plurality of sections comprising a rounded top surface, the plurality of sections comprising first and second sections immediately neighboring each other, wherein the first section comprises a first side and the second section comprises a second side integrated with the first side of the first section to form a bridge portion between the first and second sections; and   bending the first section with respect to the second section about the bridge portion, thereby forming a rounded ridge cap comprising a rounded exterior surface, wherein the rounded top surfaces of the first and second sections form together the rounded exterior surface of the rounded ridge cap.   
     
     
         2 . The method of  claim 1 , wherein providing the intermediate product comprises:
 providing a reaction mixture comprising an asphalt in an mold;   subjecting the reaction mixture to react to form the asphalt foam material; and   curing the asphaltic foam material, thereby molding the single body of the intermediate product in the mold.   
     
     
         3 . The method of  claim 2 , further comprising detaching the molded intermediate product from the mold, wherein the bending is performed immediately after detaching. 
     
     
         4 . The method of  claim 2 , wherein the bending is performed at a temperature of the molded intermediate product which is about 140° F. 
     
     
         5 . The method of  claim 2 , further comprising, subsequently to bending, additionally curing the asphaltic foam material. 
     
     
         6 . The method of  claim 2 , wherein providing the intermediate product further comprises:
 providing a conveyor belt;   applying a granule layer to said conveyor belt; and   placing the reaction mixture and the mold over the conveyer belt.   
     
     
         7 . The method of  claim 2 , wherein providing a reaction mixture comprises:
 providing the asphalt and one or more isocyanates, thereby forming a first intermediate mixture;   forming a second intermediate mixture comprising one or more polyols, a blowing agent, and a surfactant; and   mixing said first intermediate mixture with said second intermediate mixture, thereby forming the reaction mixture.   
     
     
         8 . The method of  claim 1 , wherein the rounded exterior surface comprises granules embedded therein. 
     
     
         9 . The method of  claim 1 , wherein the top surfaces of the plurality sections of the intermediate product form an undulating top surface of the intermediate product. 
     
     
         10 . The method of  claim 1 , wherein the intermediate product comprises a notch located between the first and second sections and under the bridge portion. 
     
     
         11 . The method of  claim 10 , wherein each of the first and second sections of the intermediate product comprises a wall comprising the rounded top surface, wherein the walls of the first and second sections are integrated at the bridge portion, wherein the bridge portion has a thickness smaller than that of the wall. 
     
     
         12 . The method of  claim 1 , wherein the first and second sections comprise a first and second stop surfaces, respectively, wherein the first section is bent with respect to the second section until the first and second stop surfaces contact to each other. 
     
     
         13 . The method of  claim 1 , wherein the first and second sections comprise male and female latches, respectively, wherein the first section is bent with respect to the second section until the male and female latches are engaged with each other. 
     
     
         14 . The method of  claim 1 , wherein the rounded exterior surface of the rounded ridge cap has a substantially semi-circular shape in a cross-section perpendicular to a length direction of the rounded ridge cap. 
     
     
         15 . A rounded ridge cap comprising:
 a rounded exterior surface; and   a plurality of sections arranged side by side and integrated as a single body of an asphaltic foam material, each of the plurality of sections comprising a wall with a rounded surface portion, wherein the rounded surface portions of the plurality of sections configured to form together the rounded exterior surface,   wherein the plurality of sections comprising first and second sections immediately neighboring each other, wherein the first section comprises a first side and the second section comprises a second side integrated with the first side to form a bridge portion between the first and second sections,   wherein the bridge portion has a thickness smaller than that of the wall of each of the first and second sections.   
     
     
         16 . The rounded ridge cap of  claim 15 , wherein the wall of the first section comprises a first surface and the wall of the second section comprises a second stop surface contacting the first surface and located under the bridge portion. 
     
     
         17 . The rounded ridge cap of  claim 15 , wherein the first section comprises a male latch and the second section comprises a female latch engaged with the male latch. 
     
     
         18 . The rounded ridge cap of  claim 15 , wherein the rounded exterior surface comprises granules embedded therein. 
     
     
         19 . The rounded ridge cap of  claim 15 , wherein the rounded exterior surface of the rounded ridge cap has a substantially semi-circular shape in a cross-section perpendicular to a length direction of the rounded ridge cap. 
     
     
         20 . The rounded ridge cap of  claim 15 , wherein the rounded exterior surface has a continuously rounded shape throughout the rounded exterior surface.