Molded Synthetic Hip Shingle Bending Mechanism
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Solution Overview
Problem
The use of natural materials for shingles is expensive and can increase roof weight, necessitating additional support, while synthetic materials lack the aesthetic appeal and proper fitting on roofs.
Innovation Solution
A molded synthetic hip, ridge, or rake shingle is created using a core material and capstock, extruded onto carrier plates, then molded with a compression process that includes a unique bending mechanism to fit angled roof surfaces, allowing for efficient production and alignment on roofs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If natural materials are used for shingles, then aesthetic appearance is improved, but weight increases requiring additional roof support
Solution Approach 1:
The patent changes the material parameter from natural materials to synthetic polymer materials (such as polypropylene or polyester), maintaining the aesthetic appearance through molded surface configurations while dramatically reducing the weight parameter. The synthetic materials can be formulated to match the visual characteristics of natural shingles without the associated weight burden.
Solution Approach 2:
The patent employs composite material structures, particularly in the multi-layer construction of the shingles combining different synthetic materials to achieve both aesthetic appearance and weight reduction. The composite nature allows optimization of visual properties separate from structural weight.
2Shape
If natural materials are used for shingles, then aesthetic appearance is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses molded synthetic materials to copy or replicate the aesthetic appearance of natural shingles rather than using the actual natural materials. The surface configurations are molded to mimic the visual characteristics of slate, wood, or other natural materials, providing the same aesthetic effect at lower cost through mass-producible synthetic replicas.
Solution Approach 2:
The patent changes the material parameter from expensive natural materials to cost-effective synthetic materials, maintaining aesthetic appearance through careful formulation and molding of the synthetic materials to replicate natural textures and patterns.
3Weight of moving object
If synthetic materials are used for shingles, then weight is reduced, but fitting on angled roof surfaces deteriorates
Solution Approach 1:
The patent incorporates curved and contoured surface configurations in the molded shingles, including variable radii of curvature along the shingle length, to enable proper fitting on angled roof surfaces. The molded shapes include specific curvatures that allow shingles to nestle and align correctly on hip, ridge, and rake portions of roofs.
Solution Approach 2:
The patent applies different surface configurations and curvatures to different portions of the shingle, with specific radius variations along the length to optimize fitting at different locations. The headlap portion may have different curvature characteristics than the exposure portion, allowing precise fitting on angled surfaces throughout.
4Manufacturing precision
If molding time is extended to achieve proper shape, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent incorporates the desired surface configurations and curvatures directly into the molding process itself, rather than requiring subsequent shaping operations. The compression mold pre-forms the shingles with the correct hip, ridge, and rake geometries, eliminating the need for extended processing time while maintaining precision.
Solution Approach 2:
The patent combines multiple operations into a single molding step, forming the shingle body, surface configuration, and curvature all in one compression molding cycle. This integration achieves both high precision and fast production by eliminating sequential processing steps.
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 solution provides a cost-effective, lightweight shingle that fits snugly on roofs, aligns properly, and maintains its shape, addressing the weight and aesthetic issues of natural materials while enhancing installation efficiency.
Implementation Method 1
The shingle precursor is heated so that the overall shape of the shingle precursor conforms to the shape of the rack
Implementation Method 2
The shingle precursor is then cooled, either in the zone of the support rack, or alternatively, is delivered to a cooling zone, in each case where the bent shape becomes 'set' or permanent
Implementation Method 3
Shingle material preferably comprising a core material and a capstock material is extruded onto a series of carrier plates
Implementation Method 4
the carrier plates with the shingle material are then delivered to a compression mold so that the entire process is of the short cycle type, wherein the surface configuration that is desired is molded into the shingle material
Data Source
AI summary
A molded hip, ridge or rake shingle is provided that is shaped to fit over angled intersecting planar surface of a roof hip, ridge or rake, by making a shingle precursor and draping it in heated condition over a rack having surfaces that have an included angle therebetween to cool and take form, such that portions of the shingle precursor conform to the surfaces of the rack, at a desired predetermined included angle between the shingle precursor portions, to form a hip, ridge or rake shingle with shingle portions having the desired included angle between the shingle portions. The shingle is formed according to the process, and on an apparatus, to produce the shingles that can be applied to a roof, in an array of shingles.