Asphaltic Core Laminate with Metallic Facing for Exterior Cladding
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Solution Overview
Problem
Current exterior cladding materials, such as asphalt shingles and metal tiles, face issues with durability, UV resistance, cost, installation complexity, and safety concerns related to snow and ice sliding, while combinations like stone-coated metal still rely on material thickness for strength and are expensive.
Innovation Solution
A laminate construction featuring an asphaltic core body with a thin metallic facing and a granular coating providing a stone appearance, which enhances durability, UV resistance, and safety while allowing for thinner, lighter materials and easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stone is used for exterior cladding, then durability and UV resistance are improved, but weight and rigidity increase significantly
Solution Approach 1:
The patent applies composite materials by combining asphalt (providing flexibility and waterproofing), metal granules (providing durability and UV resistance), and stone-coating granules (providing aesthetic appearance and additional protection) to create a multi-layered composite shingle that achieves the durability of stone without its full weight burden
Solution Approach 2:
The patent applies local quality by concentrating the heavy, durable stone-coating granules only on the exposed exterior surfaces where UV resistance and durability are needed, while the interior and bonding layers use lighter materials like asphalt and metal granules, achieving localized protection without overall weight increase
2Weight of moving object
If metal is used for exterior cladding, then weight is reduced and shape flexibility is improved, but susceptibility to condensation leaks and specialized installation requirements worsen
Solution Approach 1:
The patent combines metal granules (providing lightweight structure and flexibility) with asphalt (providing waterproofing and condensation resistance) and stone-coating granules (providing protective exterior layer) to create a composite material that achieves the weight reduction and shape flexibility of metal while eliminating its susceptibility to condensation leaks through the waterproof asphalt and protective coating layers
Solution Approach 2:
The patent applies nested doll by embedding metal granules within the asphalt matrix, which is then coated with stone-coating granules, creating a nested structure where each layer protects and enhances the properties of the inner layers, with the asphalt providing waterproofing to protect the metal from condensation
3Weight of moving object
If tar is used for exterior cladding, then weight is reduced and waterproofing is improved, but UV resistance and structural integrity worsen
Solution Approach 1:
The patent applies composite materials by combining asphalt (providing lightweight structure and waterproofing) with metal granules (providing structural reinforcement and UV reflection) and stone-coating granules (providing UV resistance and aesthetic appearance) to create a composite shingle that achieves the weight reduction and waterproofing of tar while eliminating its poor UV resistance through the protective granular coatings
Solution Approach 2:
The patent applies local quality by concentrating UV-resistant stone-coating granules on the exterior surfaces exposed to sunlight, while the interior and bonding portions use the waterproofing asphalt material, achieving localized UV protection where needed most without compromising overall waterproofing or adding unnecessary weight throughout the entire structure
4Ease of operation
If asphalt shingles are used, then ease of installation is improved, but durability and UV resistance worsen due to granule shedding and material degradation
Solution Approach 1:
The patent applies composite materials by combining asphalt (providing ease of installation and waterproofing) with metal granules (providing structural strength and UV resistance) and stone-coating granules (providing enhanced durability and UV protection) to create a composite shingle that maintains the ease of installation of asphalt while dramatically improving durability and UV resistance through the reinforced granular structure
Solution Approach 2:
The patent applies nested doll by embedding metal granules within the asphalt matrix and then coating with stone-coating granules, creating a nested structure where each layer enhances the durability of the previous layer, with the stone-coating granules providing the outermost protective layer that prevents granule shedding and material degradation while maintaining ease of installation
5Object-affected harmful factors
If metal thickness is increased to prevent snow and ice sliding, then safety is improved, but cost and installation complexity increase
Solution Approach 1:
The patent applies composite materials by combining asphalt (providing adhesive properties) with metal granules (providing structural strength and friction) and stone-coating granules (providing enhanced surface friction and weight distribution) to create a composite shingle that achieves snow and ice sliding prevention through increased surface friction and structural integrity without requiring thick metal panels, thereby simplifying installation
Solution Approach 2:
The patent applies local quality by concentrating the friction-enhancing stone-coating granules and metal granules on the exterior surfaces where snow and ice contact occurs, providing localized anti-sliding properties where needed most without requiring overall thickness increase throughout the entire shingle structure, thereby maintaining simple installation procedures
Data Source
AI summary
An exterior cladding that combines the benefits of stone, metal and tar in a laminate form that makes the most with the least expensive forms of each of these three base materials. A construction laminate having an asphaltic core body covered with a metallic facing on a top side and part of a bottom side. A granular coating is applied to the metallic facing on the top side and front edge. The laminate is useful as exterior cladding such as a roofing shingle, siding etc. . . . and is durable and easy to install.