Composite Roofing Panel with Asphalt Layer and Polymeric Base
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Solution Overview
Problem
Existing building materials for roofing and siding lack a cost-effective solution that combines weather protection, aesthetic appeal, and weight efficiency while maintaining structural integrity and functionality, particularly in simulating large shingle or tile appearances with efficient airflow and potential photovoltaic integration.
Innovation Solution
A panel comprising a molded synthetic polymeric base layer with an asphalt-based layer on top, featuring a configuration that mimics individual shingles or tiles, allowing for large panel sizes, reduced weight, and incorporating features like airflow zones, insulation, and photovoltaic energy transmission, with optional temperature sensors and varied aesthetic designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional asphalt-based shingles are used for roofing, then weather protection is achieved, but weight is excessive and material costs are high
Solution Approach 1:
The patent employs a composite structure combining a lightweight polymeric foam core with an asphalt-based shingle layer. The polymeric base layer provides structural support and insulation while the asphalt layer delivers weather protection. This composite approach reduces overall weight compared to traditional full-asphalt shingles while maintaining protective functionality.
Solution Approach 2:
The roofing panel is segmented into distinct functional layers: a polymeric base layer for structural support and weight reduction, and an asphalt-based weather-resistant layer. This segmentation allows each layer to optimize its specific function while collectively achieving both weight reduction and weather protection.
2Productivity
If large panel sizes are used to simulate shingles, then installation efficiency and aesthetic appearance improve, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates pre-formed shingle-like patterns and features directly into the molded polymeric panel during manufacturing. The panel is pre-configured with simulated shingle edges, grooves, and aesthetic details, eliminating the need for post-manufacturing assembly or complex field installation procedures. This preliminary formation of aesthetic features simplifies both manufacturing and installation.
Solution Approach 2:
The polymeric panel is molded to replicate the appearance of traditional individual shingles, including edge profiles, surface textures, and dimensional variations. This copying of aesthetic features at the panel level allows large-area coverage with simplified installation while maintaining the visual complexity and charm of traditional shingle roofing.
3Use of energy by moving object
If integrated photovoltaic features are added to the panel, then energy harvesting capability is provided, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent integrates multiple functions into the single panel structure: the polymeric base layer provides structural support and insulation, the asphalt layer provides weather protection, and integrated photovoltaic elements provide energy harvesting. This multi-functional integration allows the panel to serve as structural support, weather barrier, and energy-generating surface simultaneously, reducing the need for separate components and simplifying overall system complexity.
Data Source
AI summary
A building panel of the roofing or siding type is disclosed, as well as a building structure having such roofing or siding panels, in which the panels are comprised of two different types of building materials. The composite panel includes at least one layer of synthetic polymeric building material, having adhesively secured thereto at least one layer of asphalt based building material, with outer, upper surfaces of the panel, that would be weather-exposed in the installed condition on a building structure being comprised of the asphalt based building material, and with the synthetic polymeric layer(s) of polymeric building material being weather-protected in the installed condition on a building structure.