EPDM Roof Shingle Composite Structure for Wind and UV Resistance
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Solution Overview
Problem
Existing asphalt shingles suffer from limited durability, susceptibility to UV degradation, thermal expansion issues leading to shingle shifting and wind uplift, and are non-recyclable, contributing to landfill waste and environmental concerns.
Innovation Solution
Development of EPDM roofing shingles with a reinforcement core, such as galvanized steel, that provide structural integrity, recyclability, and ease of installation, allowing for nail-affixment and offering improved resistance to weathering and wear, suitable for both low-slope and steep-slope roofs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If asphalt shingles are used for roofing, then installation is simple and cost is low, but durability is limited and UV resistance is poor
Solution Approach 1:
The patent uses a composite structure combining EPDM rubber material with a reinforcement core (metal or plastic). The EPDM layer provides UV resistance and weatherability, while the reinforcement core provides structural strength and dimensional stability. This composite approach resolves the contradiction by integrating materials with complementary properties to achieve both durability and structural integrity.
2Strength
If asphalt shingles are used, then initial cost is low, but resistance to wind uplift and thermal expansion is poor
Solution Approach 1:
The reinforcement core (metal or plastic) provides high strength and rigidity to resist wind uplift forces, while the EPDM outer layer provides flexibility and weather resistance. This composite structure resolves the contradiction by combining rigid and flexible materials to achieve both strength and environmental resistance.
Solution Approach 2:
The patent changes the material parameters from traditional asphalt to EPDM rubber with specific physical properties (elongation, tensile strength, UV resistance). This material substitution resolves the contradiction by selecting materials with optimized parameters for both strength and environmental durability.
3Ease of manufacture
If asphalt shingles are used, then installation is straightforward, but recyclability is poor and environmental impact is high
Solution Approach 1:
The patent addresses recyclability by using materials that can be recovered and recycled at the end of their service life. The EPDM and reinforcement core materials can be separated and reused, resolving the contradiction by enabling material recovery while maintaining ease of installation during the product's useful life.
4Duration of action of stationary object
If traditional asphalt shingles are used, then cost is low, but lifespan is limited to 10-20 years
Solution Approach 1:
The composite structure of EPDM with reinforcement core provides extended lifespan by combining UV-resistant elastomer with structurally stable core material. This resolves the contradiction by using material synergies to achieve long-term durability while maintaining a relatively simple two-layer structure.
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
The EPDM roofing shingles exhibit high resistance to UV radiation, thermal cycling, wind uplift, and hail impact, with a long lifespan, recyclability, and ease of installation, while maintaining a familiar appearance and safety for roofers.
Implementation Method 1
UV absorption by the asphalt leads over the years to brittleness and, eventually, to failure of shingle material
Implementation Method 2
Nails, wood and asphalt have significantly different coefficients of expansion. Thus, daytime heating and precipitous cooling of the roof, as often accompany summer thunderstorms, may shift shingles' positions relative to each other and relative to the underlying wood
Implementation Method 3
Roofs also absorb sunshine's infra-red ('IR') radiation. IR heating may lead to daytime roof temperatures running ̃10°- ̃25° C. ( ̃50°- ̃75° F.) higher than ambient air temperatures
Data Source
AI summary
Roof shingles and methods of production thereof are provided. The roof shingles may include ethylene-propylene-diene terpolymer (“EPDM”). The EPDM may include an outward-facing surface and a substrate-facing surface. The outward-facing surface may include a reveal and a conceal. The reveal may be visible when the roof shingle is installed and the conceal may be covered by an upslope adjacent roof shingle when the roof shingle is installed. The roof shingle may include a reinforcement core. The reinforcement core may include galvanized steel. The reinforcement core may be embedded within the EPDM. The roof shingles may include adhesive sealant. The adhesive sealant may be applied to the substrate-facing surface for binding the roof shingle to a downslope adjacent roof shingle or a substrate. The roof shingles may include a plurality of EPDM granules being located on at least a portion of the surface of the reveal.