Composite Shingle Polyketone Layer Weight Strength Trade-off
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Solution Overview
Problem
Existing composite roofing shingles are heavy due to multiple layers, making them difficult to transport and install, and they lack sufficient strength and flame retardancy.
Innovation Solution
Incorporating a polyketone layer in the composite shingle, which is in direct contact with an asphalt layer and an adhesive layer, reduces weight, increases strength, and enhances flame retardancy, allowing for a thinner and more resilient shingle with fewer layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers (asphalt, fiber glass, polyethylene/polypropylene) are included to add strength and durability, then the strength and durability of the composite shingle is improved, but the weight of the shingle increases making it difficult to transport and handle
Solution Approach 1:
The patent changes the material parameter from conventional polyethylene/polypropylene to polyketone, which has superior strength-to-weight ratio. This material substitution maintains the required strength and durability while reducing the overall weight of the shingle, making it easier to transport and handle during installation
Solution Approach 2:
The patent uses a composite structure combining particle layer, asphalt layer, and polyketone layer. This composite material approach allows the shingle to achieve enhanced strength and durability through the synergistic properties of different materials while keeping the overall weight lower than traditional multi-layer constructions
2Reliability
If polyethylene or polypropylene layers are used, then the shingle has sufficient basic properties, but the flame retardancy and strength are insufficient
Solution Approach 1:
The patent changes the chemical composition parameter by substituting polyketone for polyethylene or polypropylene. Polyketone inherently provides superior flame retardancy and strength properties, allowing the shingle to meet reliability requirements with fewer layers and reduced overall complexity
Solution Approach 2:
The patent extracts the reinforcing layer that is typically required when using polyethylene or polypropylene. By using polyketone instead, the shingle achieves the same or better strength and flame retardancy without needing the additional reinforcing layer, thereby reducing the number of layers and simplifying the overall structure
3Strength
If more layers are included to increase strength, then the strength is improved, but the shingle becomes thicker and heavier
Solution Approach 1:
The patent changes the material parameter to polyketone, which has higher inherent strength. This allows the shingle to achieve the required strength with a thinner polyketone layer compared to the thickness that would be needed with polyethylene or polypropylene, resulting in an overall thinner shingle profile
Solution Approach 2:
The patent removes the reinforcing layer from the traditional multi-layer structure. By using polyketone's superior strength properties, the shingle achieves adequate strength without this additional layer, thereby reducing the overall thickness of the composite shingle
Data Source
AI summary
Various embodiments disclosed relate to a composite shingle. The composite shingle includes a particle layer and a polyketone layer proximate to the particle layer.