In-Line Extrusion Coating for Flexible Roofing Shingle Webs
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Solution Overview
Problem
Existing methods for applying polymeric films to asphalt roofing shingles require thick, prefabricated rolls that are costly and cumbersome, leading to increased manufacturing complexity and costs, as well as potential damage during the manufacturing process due to inflexibility of traditional shingle webs.
Innovation Solution
A method involving the extrusion of molten polymeric material directly onto a moving web of shingle material, allowing it to cure and form a thin film, which can be applied across the entire width or selectively, eliminating the need for prefabricated rolls and reducing material thickness to minimize costs and enhance flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick prefabricated rolls of polymeric film are used to coat shingles, then the film provides sufficient protection during handling and application, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent replaces the mechanical system of handling and applying thick prefabricated film rolls with an extrusion-based system that deposits molten polymer directly onto the shingle web. This substitution eliminates the need for large film rolls, associated handling equipment, and manual or automated film application mechanisms, thereby reducing manufacturing complexity while maintaining protective functionality through in-line extrusion and curing
Solution Approach 2:
The patent changes the physical state and application parameters of the polymeric material from solid thick film to molten extrudable material. By extruding the polymer in a molten state and curing it in place, the system achieves both the protective function of thick film and the simplicity of direct application, eliminating the need for separate film handling and application steps
2Reliability
If thick prefabricated rolls of polymeric film are used, then adequate film thickness is achieved for protection, but material costs and storage requirements increase
Solution Approach 1:
The patent applies preliminary action by heating and preparing the polymeric material in a molten state before application, allowing it to be extruded in a controlled manner. This preliminary preparation enables precise control over the amount and thickness of material applied, ensuring adequate protection while minimizing waste and reducing the total quantity of material needed compared to handling thick prefabricated rolls
3Ease of manufacture
If traditional inflexible shingle webs are used, then manufacturing processes are simpler, but damage occurs during manufacturing due to inflexibility
Solution Approach 1:
The patent changes the physical parameters of the shingle web by incorporating a polymeric material that remains flexible at manufacturing temperatures. This parameter change allows the web to bend and flex during the manufacturing process without damage, while the subsequent curing process provides the necessary structural integrity, thus resolving the contradiction between flexibility during manufacturing and strength in the final product
4Strength
If polymeric film is applied to eliminate back dusting, then adhesive bonding between layers is improved, but the application process becomes more complex
Solution Approach 1:
The patent merges the functions of back dusting and polymeric film application into a single integrated process. The polymeric material is extruded directly onto the back surface of the shingle web in the molten state, where it serves both as a protective coating and as an adhesive bonding layer. This merging eliminates the need for separate back dusting and film application steps, reducing overall process complexity while maintaining improved adhesive bonding
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 method allows for more flexible shingle webs, improved adhesive bonding between layers, and reduced manufacturing complexity by eliminating the need for back dusting and cellophane strips, while providing a waterproof barrier and UV protection, thus enhancing the manufacturing process and product quality.
Implementation Method 1
A film extrusion die 58 is provided below the web and is configured to eject a sheet or curtain of molten polymeric material toward the web
Implementation Method 2
The extruded film material is then allowed to cure to form a thin film that is bonded to the web of shingle material
Data Source
AI summary
A process for in-line extrusion of polymeric coatings onto roofing shingles during manufacturing includes moving a web of shingle substrate material in a downstream direction and extruding a liquefied coating of polymeric material onto at least one surface of the moving web to form a thin film. The liquefied coating may be a molten polymeric material that forms a thin film on a back surface of the shingle material to prevent sticking and eliminate the need for a traditional back dusting with material such as powdered stone. The polymeric film further may be applied to the substrate material in lieu of a saturation coating of asphalt, thus reducing cost and weight while providing a comparable moisture barrier and a lighter more flexible shingle.