Hip Ridge Shingle Manufacturing With Segmented Adhesion

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Solution Overview

Problem

Existing shingle manufacturing processes struggle to produce hip, ridge, or rake shingles that match the aesthetic appearance of laminated shingles covering the rest of the roof, and these shingles often require cutting, which complicates the bending process over roof intersections.

Innovation Solution

A process involving laminated shingles with a thickened edge and optional shadow lines, where shingle layers are adhered to allow relative movement, facilitating smooth bending and aesthetic consistency by applying bituminous materials and granules in specific patterns to create a high-profile, visually appealing design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If shingle layers are adhered together rigidly, then structural strength is improved, but bending ability deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidbending ability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The shingle is divided into multiple layers with different adhesion characteristics. The lower layers are fully adhered for strength, while the upper layer is partially unadhered to allow bending. This segmentation of adhesion zones enables the shingle to maintain both structural integrity and flexibility during installation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the shingle layers have different adhesion properties. Specifically, portions of the upper shingle layer are intentionally left unadhered to the lower layer, creating local zones of flexibility while maintaining overall structural strength through adhered regions. This local variation in adhesion quality resolves the contradiction between strength and bendability.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If traditional cutting methods are used to create hip/ridge shingles, then customization is improved, but installation complexity deteriorates

Engineering Contradiction:

ImprovecustomizationVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The shingles are pre-manufactured with specific thickness variations, unadhered portions, and design features during the factory production process. This preliminary preparation of customization features eliminates the need for on-site cutting and complex installation procedures, reducing installation complexity while maintaining design flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual cutting and shaping process is replaced by a controlled manufacturing process that uses adhesive application patterns and layer construction to achieve the desired hip/ridge shingle geometry. This substitution of mechanical post-production modification with controlled manufacturing processes simplifies installation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If uniform thickness is used throughout the shingle, then manufacturing simplicity is improved, but aesthetic appeal deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidaesthetic appeal

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The shingle incorporates local variations in thickness, with certain areas made thicker than others to create visual depth and aesthetic appeal. These thickness variations are integrated into the manufacturing process through controlled adhesive application and layer construction, maintaining manufacturing simplicity while achieving enhanced aesthetic qualities.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8266861B2Process of producing hip, ridge or rake shingles, and high profile shingles produced thereby

Publication Date: 2012.09.18 CERTAINTEED CORP

AI summary

A hip, ridge or rake shingle is provided, having a high profile, by using various shingle layers to form a built-up wedge-shaped headlap portion, comprised of a plurality of layers of different dimensions in the headlap portion of the shingle, and the process for manufacturing the same from a single sheet of shingle material is provided.