Ceramic Roofing Base with Bituminous Fill and Recycled Shingles
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Solution Overview
Problem
Ceramic base materials in roofing products can be damaged by abrasive materials, leading to premature failure in mechanical stress tests, as existing methods do not effectively manage abrasive particles in recycled roofing materials.
Innovation Solution
A roofing product is formed by filling the open structure of a ceramic base material with a bituminous material having a low or no abrasive particles, and using recycled roofing material with controlled abrasive content, ensuring the ceramic base material is protected from damage during manufacturing, shipping, and outdoor exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If recycled roofing material is used in roofing products, then waste reduction and cost savings are achieved, but abrasive particles in the recycled material damage the ceramic base material leading to premature failure
Solution Approach 1:
A protective coating layer is applied to the ceramic base material before applying the recycled roofing material. This coating acts as an intermediary barrier that prevents abrasive particles in the recycled material from directly contacting and damaging the ceramic base material, thereby maintaining both waste reduction benefits and mechanical reliability
Solution Approach 2:
The ceramic base material is treated with a protective coating only in the areas that will be in contact with recycled roofing material. This localized treatment provides abrasion resistance exactly where needed, protecting the ceramic from damage while allowing the recycled material to fulfill its waste reduction function
2Ease of manufacture
If recycled roofing material with abrasive particles is applied to ceramic base material, then production costs are reduced, but the ceramic base material suffers damage during manufacturing, shipping, and outdoor exposure
Solution Approach 1:
The ceramic base material is pre-treated with a protective coating before the recycled roofing material is applied. This preliminary protective action ensures that when the recycled material with abrasive particles is later applied during manufacturing, the ceramic base material is already protected from abrasive damage, maintaining both cost efficiency and material integrity
Solution Approach 2:
A protective coating layer is applied in advance to cushion and absorb the harmful effects of abrasive particles from recycled roofing material. This beforehand protection allows the use of cost-effective recycled materials without compromising the ceramic base material during manufacturing, shipping, and outdoor exposure
3Device complexity
If conventional bituminous material with fillers is used, then manufacturing simplicity is maintained, but abrasive particles cause damage to the ceramic base material
Solution Approach 1:
A protective coating serves as an intermediary layer between the conventional bituminous material and the ceramic base material. This allows the use of simple, conventional manufacturing processes while the coating prevents abrasive particles in the bituminous material from damaging the ceramic, thereby maintaining both manufacturing simplicity and product strength
Solution Approach 2:
The roofing product uses a composite structure combining ceramic base material with a protective coating layer and conventional bituminous material. This composite approach allows the use of simple conventional materials while the protective coating component prevents abrasive damage, achieving both manufacturing simplicity and enhanced tear resistance
Data Source
AI summary
A roofing product can include a ceramic base material and a recycled roofing material. In a particular embodiment, an open structure of the ceramic base material is filled with a bituminous material that has no greater than approximately 5 weight % of abrasive particles or 0.1 weight % metal content. The recycled roofing material can be disposed along one or both sides of the ceramic base material. The bituminous material may have a characteristic particle size that is smaller than a characteristic particle size of the recycled roofing material. In another embodiment, the roofing product having the recycled roofing material can have tear strength characteristics as compared to a different roofing product having a substantially the same construction but having abrasive particles embedded within the ceramic base material.