Laminated Roofing Shingle with Varying Tab Breadths
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Solution Overview
Problem
Existing roofing shingles struggle to replicate the aesthetic thickness and weather resistance of slate or wood shingles while being susceptible to wind failure, especially in cold weather, and inefficient in material usage during manufacturing.
Innovation Solution
A two-layer laminated shingle design featuring a posterior layer with partial slots and an anterior layer with tabs of varying breadths, where each posterior simulated tab is partially covered by an anterior tab, providing additional rigidity and a visual pattern that mimics the appearance of thicker materials, while minimizing material waste during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If composite shingles are made thinner to reduce material usage, then material cost decreases, but aesthetic appearance and weather resistance deteriorate
Solution Approach 1:
The shingle is divided into multiple layers (antecedent layer, intermediate layer, consequent layer) with specific tab configurations. The antecedent layer has tabs that extend beyond the consequent layer tabs, creating a multi-level appearance that simulates thicker materials while using efficient material quantities in each layer.
Solution Approach 2:
The invention creates visual depth through multi-dimensional tab arrangements where tabs extend at different levels and positions. The antecedent layer tabs protrude beyond the consequent layer tabs, establishing a stepped configuration that adds perceived thickness without increasing actual material volume.
2Ease of manufacture
If traditional single-layer tabs are used, then manufacturing is simpler, but wind failure resistance deteriorates
Solution Approach 1:
The shingle employs a composite structure with multiple layers (antecedent layer, intermediate layer, consequent layer) bonded together. This multi-layer composite construction creates interconnected tabs that provide enhanced structural integrity and wind resistance compared to single-layer tabs, while remaining manufacturable through standard lamination processes.
3Manufacturing precision
If uniform tab breadths are used, then manufacturing precision is easier to maintain, but aesthetic appearance deteriorates
Solution Approach 1:
The shingle features varying tab breadths at different locations and layers. The antecedent layer includes tabs with different breadths (first breadth and second breadth), and the intermediate layer has tabs with yet another breadth. This local variation in dimensions creates visual diversity and aesthetic interest while each individual tab maintains precise manufacturing tolerances.
Data Source
AI summary
A laminated roofing shingle is disclosed comprising a posterior layer with simulated tabs and an anterior layer with tabs spaced apart by openings, wherein each posterior simulated tab is partially covered by a corresponding anterior tab, wherein at least one anterior tab has a first anterior tab breadth and at least another anterior tab has a second anterior tab breadth, and wherein at least one anterior opening has a first anterior opening breadth that is about equal to the second anterior tab breadth and wherein at least another anterior opening has a second anterior opening breadth that is about equal to the first anterior tab breadth. Also disclosed is a roofing system comprising a plurality of courses of the shingle.