Roofing Shingle Reduced-Width Headlap Design
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Solution Overview
Problem
Existing roofing shingles require excessive material for adequate water shedding performance, leading to high costs and transportation expenses, and current designs do not efficiently minimize material usage while maintaining aesthetic appeal and weather resistance.
Innovation Solution
The roofing system features shingles with a reduced-width headlap portion and unique dimensions, including headlap and buttlap projections and recesses, allowing for a uniform and expanded overlap region that reduces material usage while maintaining effective water shedding and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shingles are installed with contiguous lateral edges in overlapping courses, then water shedding performance is improved, but material usage increases
Solution Approach 1:
The shingle is divided into distinct functional zones: a headlap portion for overlapping with the course below, a buttlap portion for the exposed edge, and a reduced-width intermediate section. This segmentation allows each zone to perform its specific function efficiently, reducing overall material requirements while maintaining water shedding performance through proper zone configuration
Solution Approach 2:
The invention introduces a reduced-width portion that creates a dimensional variation in the shingle body. By reducing the width in the intermediate section between headlap and buttlap, the design optimizes material usage in the horizontal dimension while maintaining adequate overlap in the vertical dimension, thereby reducing material consumption without compromising water shedding
2Quantity of substance
If headlap portion width is reduced to minimize material usage, then material costs decrease, but water protection capability deteriorates
Solution Approach 1:
The shingle design applies local quality by providing different width characteristics in different portions: the headlap portion maintains adequate width for water protection and overlapping, the buttlap portion provides sufficient exposed edge, while the intermediate section is reduced in width. This localized differentiation ensures water protection capability is maintained where needed while reducing material usage in less critical areas
Solution Approach 2:
The invention uses partial action by providing headlap and buttlap portions with adequate dimensions for their specific functions, while the intermediate section uses reduced width. The headlap portion provides just enough overlap for water shedding, and the buttlap provides sufficient exposure, avoiding excessive material usage in the intermediate zone while maintaining overall water protection capability
3Reliability
If shingles require redundant overlapping for water shedding, then water infiltration resistance is improved, but transportation expenses increase
Solution Approach 1:
By segmenting the shingle into headlap, buttlap, and reduced-width intermediate portions, the design achieves water infiltration resistance through the properly configured headlap and buttlap zones while minimizing material in the intermediate section, thereby reducing overall weight and transportation expenses without sacrificing water shedding performance
Solution Approach 2:
The invention changes the dimensional parameters of the shingle by reducing the width of the intermediate portion while maintaining adequate dimensions for the headlap and buttlap portions. This parameter optimization reduces the overall material quantity and weight, decreasing transportation expenses while the maintained headlap and buttlap dimensions ensure adequate water infiltration resistance
Data Source
AI summary
A roofing shingle is provided comprising a reduced-with headlap portion including headlap projections, a buttlap portion including buttlap projections, a lateral leading edge, and a lateral trailing edge, wherein the headlap projection nearest the lateral leading edge has an increased breadth. A roofing system is also provided comprising a multiplicity of courses of shingles of the invention, wherein a lateral trailing edge of a shingle in a single course overlaps (side-laps) an adjacent previously installed shingle, and wherein a shingle in a subsequent course provides a generally uniform overlap region over the headlap portions of a first and second adjacent shingle in the first course and an expanded overlap region over the second adjacent shingle, wherein the expanded overlap region is due to the increased breadth of the headlap projection nearest the lateral leading edge of the second adjacent shingle in the first course.