Controlled Particle Deposition for Roofing Shingles

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Solution Overview

Problem

Current roofing shingle manufacturing methods lack precision in depositing particles, particularly in the nail zone, which affects aesthetics, solar reflectance, and wind uplift resistance, and do not allow for controlled particle distribution for improved adhesion and UV resistance.

Innovation Solution

A method involving the controlled deposition of particles onto an asphalt-coated glass mat using electrostatic, electromagnetic, or piezoelectric generators, allowing for precise placement and distribution of particles within specific areas of the roofing shingle, such as the nail zone, to achieve desired aesthetic and performance characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional gravity-based particle deposition is used, then the manufacturing process is simple, but the particle location control precision is poor

Engineering Contradiction:

Improveparticle location controlVSAvoiddeposition device

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the conventional gravity-based mechanical deposition system with an electrostatic field-based system. The electrostatic generator creates electric fields that precisely control particle deposition locations without complex mechanical positioning mechanisms, resolving the contradiction between precision and device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical parameter of particle deposition from gravity-driven to electrostatic field-driven. By controlling voltage and electric field strength, the system achieves precise particle location control while maintaining relatively simple device architecture, addressing both precision and complexity concerns.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If particles are uniformly distributed across the entire shingle surface, then the manufacturing process is simple, but the aesthetic quality and performance in specific zones are compromised

Engineering Contradiction:

Improveparticle distribution controlVSAvoiddeposition process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies local quality by enabling different particle distributions in different zones of the shingle. The electrostatic generator can create zone-specific electric field patterns that deposit particles with controlled density and location in nail zones versus non-nail zones, achieving superior aesthetics and performance while maintaining manufacturing simplicity through field control rather than mechanical complexity.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If multiple coating layers are applied to achieve desired particle distribution, then the particle placement precision improves, but the manufacturing time and process complexity increase

Engineering Contradiction:

Improveparticle placementVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-charging particles with electrostatic charge before deposition. This preliminary electrostatic conditioning enables single-pass precise particle placement without requiring multiple coating layers, thereby maintaining high manufacturing speed while achieving excellent particle placement precision through the electrostatic field-guided deposition process.

Inventive Principle:

Principle #10Preliminary 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 method enhances the aesthetics of roofing shingles, improves solar reflectance, and increases wind uplift resistance by ensuring precise particle placement, thereby improving the overall performance and durability of the shingles.

Implementation Method 1

the depositing includes controlling a location of the plurality of particles on the first side of the asphalt coated substrate using an electrostatic generator

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Implementation Method 2

the depositing includes controlling a location of the plurality of particles on the first side of the asphalt coated substrate using an electromagnetic generator

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 3

the depositing includes controlling a location of the plurality of particles on the first side of the asphalt coated substrate using a piezoelectric depositor

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 4

the plurality of particles is deposited via gravity on a top surface of the top side of the glass mat

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20230331628A1Controlled particle deposition for a roofing shingle

Publication Date: 2023.10.19 BMIC LLC

AI summary

A method includes obtaining a glass mat having a first side and a second side opposite the first side. The method includes coating the first side of the glass mat with a molten asphalt. The method includes obtaining a plurality of particles. The method further includes depositing the particles on the first side of the asphalt coated substrate. The depositing includes controlling a location of the plurality of particles on the first side of the asphalt coated substrate using an electrostatic generator, an electromagnetic generator, or a piezoelectric depositor. The method further includes forming a roofing shingle from the asphalt coated substrate having the plurality of particles as deposited.