Asphalt Roofing Shingle Infrared Reflectivity via Selective Granule Application

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Solution Overview

Problem

Conventional asphalt-based roofing materials absorb solar heat due to exposed black asphalt, and existing granule application methods inefficiently use more expensive reflectivity-increasing granules, covering both visible and non-visible portions of shingles.

Innovation Solution

The method involves selectively applying reflectivity-increasing granules or asphalt to specific portions of laminated shingles, such as tabs and prime areas, to maximize infrared reflectivity while minimizing the use of expensive granules, using a manufacturing process that includes granule applicators and asphalt coating techniques to ensure even coverage and reduced heat absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional granule application methods are used to cover the entire shingle surface, then the infrared reflectivity is improved, but the cost increases due to excessive use of expensive reflectivity-increasing granules

Engineering Contradiction:

Improveinfrared reflectivityVSAvoidcost

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The patent applies reflectivity-increasing granules selectively only to the prime portion (exposed area) of the shingle, while using conventional granules on the headlap portion (covered area). This local differentiation optimizes infrared reflectivity where needed while reducing granule consumption and cost on areas that will be covered by overlapping shingles.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The shingle surface is divided into two distinct zones: the prime portion that requires infrared reflectivity and the headlap portion that does not. This segmentation allows for differentiated granule application strategies, applying expensive reflectivity-increasing granules only where they provide functional value and using cheaper conventional granules elsewhere.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If traditional black asphalt is used for the entire shingle, then the manufacturing cost is reduced, but the heat absorption increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidheat absorption

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The patent combines traditional black asphalt on the headlap portion with reflectivity-increasing asphalt on the prime portion. This local quality differentiation allows the shingle to maintain cost-effectiveness where appearance is hidden while achieving reduced heat absorption in the visible, sun-exposed prime area.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the optical and thermal parameters of the asphalt material specifically in the prime portion by using reflectivity-increasing asphalt, while maintaining traditional black asphalt parameters in the headlap portion. This parameter change reduces solar heat absorption in the exposed area without unnecessarily increasing costs in the covered area.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If reflectivity-increasing granules are applied to the entire shingle surface including covered areas, then the infrared reflectivity is maximized, but the material waste increases

Engineering Contradiction:

Improveinfrared reflectivityVSAvoidmaterial waste

Core Design Contradiction:

TemperatureVSLoss of substance

Solution Approach 1:

The patent applies reflectivity-increasing granules only to the prime portion where they are visible and functional, while using conventional granules on the headlap portion that will be covered. This prevents material waste by avoiding application of expensive reflectivity-increasing granules to areas where they provide no functional benefit.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of applying reflectivity-increasing granules to the entire shingle surface (excessive action), the patent applies them only to the necessary prime portion (partial action). This partial application is sufficient to achieve the desired infrared reflectivity effect while avoiding unnecessary material consumption and waste.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances the infrared reflectivity of asphalt-based roofing materials, reducing heat absorption and optimizing the use of costly granules by strategically applying them only to exposed areas, thereby improving energy efficiency and cost-effectiveness.

Implementation Method 1

asphalt-based roofing materials having increased infrared reflectivity

Methodology Applied

Scientific EffectInfrared reflection: Reflection

Data Source

PatentUS10584494B2Asphalt based roofing material with increased infrared reflectivity

Publication Date: 2020.03.10 OWENS CORNING INTELLECTUAL CAPITAL LLC

AI summary

A laminated roofing shingle has an overlay sheet having top surface and bottom surface opposite the top surface. The overlay sheet includes a headlap portion and a butt portion. The butt portion defines a series of tabs and cutouts. An underlay substrate has a top surface attached to the bottom surface of the butt portion of the overlay sheet. The underlay sheet includes a covered portion positioned beneath the tabs of the overlay sheet and a prime portion positioned beneath the cutouts. A layer of reflectivity-increasing granules and/or a layer reflectivity-increasing asphalt, is positioned on only one or both of the tabs of the overlay sheet and the prime portion of the underlay sheet.