Two-Layer Asphalt Shingle Segmentation for Wind Resistance
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Solution Overview
Problem
Conventional asphalt shingles lack the aesthetic appeal and structural rigidity of thicker slate or wood shingles, making them susceptible to wind failure, especially in cold weather, and require more material for manufacturing.
Innovation Solution
A two-layer asphalt roofing shingle design featuring a posterior layer with partial slots and connecting segments that simulate traditional tabs, providing rigidity and an aesthetic appearance of thickness without additional weight, and eliminating alignment notches on the anterior headlap to allow a narrower backer strip for reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional asphalt shingles are used, then cost is reduced and manufacturing is simplified, but aesthetic appearance and structural rigidity deteriorate compared to slate or wood shingles
Solution Approach 1:
The shingle is divided into multiple layers (antecedent layer and posterior layer) with the posterior layer segmented into tab portions and connecting segments. This segmentation allows the thin asphalt shingle to simulate the appearance and rigidity of thicker materials while maintaining ease of manufacture through standardized layering processes.
Solution Approach 2:
The posterior layer is designed to copy the appearance characteristics of slate or wood shingles through its tab portions that extend beyond the antecedent layer edges. This creates a visual and structural imitation of thicker materials without requiring actual slate or wood, maintaining manufacturing simplicity while improving aesthetic appearance and rigidity.
2Quantity of substance
If conventional single-layer asphalt shingles are used, then material usage is reduced and cost is lowered, but wind resistance and structural rigidity deteriorate
Solution Approach 1:
The shingle combines multiple material layers (antecedent layer and posterior layer) with different structural functions. The posterior layer acts as a reinforcement composite that provides wind resistance and rigidity without requiring a proportional increase in total material quantity, as it is strategically positioned to maximize structural efficiency.
Solution Approach 2:
The posterior layer extends in the vertical dimension beyond the antecedent layer to create tab portions, adding structural rigidity and wind resistance in the vertical dimension without significantly increasing horizontal material usage. This dimensional approach provides enhanced reliability while maintaining material efficiency.
3Ease of operation
If alignment notches are included on the anterior headlap to facilitate installation, then ease of installation is improved, but material usage and manufacturing complexity increase
Solution Approach 1:
The invention removes the alignment notches feature from the anterior headlap, extracting this installation aid function. Instead of modifying the shingle structure with notches, the design relies on the natural overlapping geometry of the layered construction, thereby reducing manufacturing complexity and material usage while maintaining adequate installation ease through the inherent layer alignment capability.
4Shape
If thicker slate or wood shingles are used to achieve pleasing aesthetic appearance, then aesthetic appearance is improved, but weight and material cost increase
Solution Approach 1:
The posterior layer copies the visual appearance characteristics of thick slate or wood shingles through its tab portions that extend beyond the antecedent layer. This creates the aesthetic illusion of thickness and texture without the actual weight and material cost of slate or wood, achieving pleasing appearance while maintaining lightweight properties.
Solution Approach 2:
The invention uses thin film asphalt layers to create the visual effect of thick materials. The posterior layer acts as a flexible thin film that simulates the appearance of rigid thick shingles, providing aesthetic appeal without the weight penalty of actual thick materials.
Data Source
AI summary
A two-layer laminated roofing shingle is disclosed comprising a posterior layer having an upper portion and a buttlap including a plurality of simulated tabs extending from the posterior upper portion, each simulated tab is connected to at least one adjacent simulated tab by a connecting segment, and an anterior layer having a headlap and a buttlap including one or more anterior tabs extending from the anterior headlap. Also disclosed is a single layer roofing shingle comprising a headlap and a buttlap including a plurality of simulated tabs extending from said headlap, the simulated tabs spaced apart by a plurality of partial slots, and each simulated tab is connected to at least one adjacent simulated tab by a connecting segment. Also disclosed is a roofing system comprising a plurality of courses of the inventive shingles.