Roofing Module With Textured Underlap for Adhesive Sealing

Solution Overview

Problem

Existing roofing and cladding systems face challenges in achieving a secure and weatherproof seal between overlapping modules, particularly in photovoltaic applications, due to inadequate adhesion between abutting faces.

Innovation Solution

The introduction of a roofing, cladding, or siding module design featuring an underlapping region with a textured surface area to increase contact with an adhesive, combined with a continuous forming process to create modules with three-dimensional surface features that enhance bonding and reduce the need for fasteners, thereby improving the sealing and wind resistance of overlapping modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive layers are used to join adjacent modules, then the modules can be assembled and fixed in place, but the abutting faces of adjacent modules are not adequately joined/sealed

Engineering Contradiction:

Improvesealing qualityVSAvoidadhesive application complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies a textured surface treatment specifically to the abutting faces of adjacent modules, creating localized enhanced adhesion zones. This textured surface area is specifically positioned at the interfaces where modules join together, providing improved bonding without requiring complex adhesive application procedures across the entire module surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent modifies the surface parameters of the abutting faces by introducing a textured surface area with increased surface roughness and surface area. This parameter change enhances the adhesive bonding capability by providing more contact points and mechanical interlocking opportunities, thereby improving the sealing quality between adjacent modules.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional roofing materials are used, then durability and weather resistance are achieved, but the weight is heavy and installation is difficult

Engineering Contradiction:

Improveweather resistanceVSAvoidmodule weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs composite material construction for the modules, combining multiple materials with complementary properties. This allows the modules to achieve the durability and weather resistance of traditional roofing materials while significantly reducing the overall weight, making installation easier and more efficient.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If PV panels are integrated into building cladding products, then aesthetics are improved and material usage is reduced, but the sealing between modules becomes inadequate

Engineering Contradiction:

Improvematerial efficiencyVSAvoidsealing quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies a textured surface treatment specifically to the abutting faces of adjacent modules, creating localized enhanced adhesion zones. This textured surface area is specifically positioned at the interfaces where modules join together, providing improved bonding without requiring complex adhesive application procedures across the entire module surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent modifies the surface parameters of the abutting faces by introducing a textured surface area with increased surface roughness and surface area. This parameter change enhances the adhesive bonding capability by providing more contact points and mechanical interlocking opportunities, thereby improving the sealing quality between adjacent modules.

Inventive Principle:

Principle #35Parameter changes

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

This solution results in a lightweight, durable, and aesthetically pleasing module system that provides a secure, weatherproof seal and enhanced wind resistance, while reducing material usage and installation costs, and allowing for efficient thermal energy management and solar energy generation.

Implementation Method 1

an upper surface of the underlapping region, and/or b) an underside of the exposed region, comprises a textured surface area for increasing the surface area in contact with an adhesive

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS11702840B2Roofing, cladding or siding module, its manufacture and use

Publication Date: 2023.07.18 ZINNIATEK

AI summary

A roofing, cladding or siding product which is light weight, easy to install, durable and resistant to environmental wear. The module comprises an underlapping region and an exposed region, wherein the underlapping region is adapted to be at least partially covered by the exposed region of an adjacent module when installed on a building surface. The module also includes a textured surface area on an upper surface of the underlapping region and/or an underside of the exposed region. In use, the textured surface (e.g. made up from a densely packed group of cones, pyramids or cylinders) presents an increased surface area for improved contact with an adhesive. The adhesive, e.g. in strip form, may by located on an aligning part of an adjacent module with the textured surface area.