Segmented Shim Layer Roofing Shingles for Weight Reduction
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Solution Overview
Problem
Conventional architectural roofing shingles are heavier and more expensive to manufacture due to their multi-layer composition, which increases the load on the roof deck and does not efficiently utilize material in the shim layer beneath the dragon's teeth arrangement.
Innovation Solution
A roofing shingle design that reduces material usage by eliminating unnecessary portions of the shim layer beneath the dragon's teeth, featuring a shim layer with tabs separated by gaps that align with the top shingle layer's dragon's teeth, allowing for reduced weight and cost while maintaining a layered appearance and water-shedding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If architectural shingles use a multi-layer composition with continuous bottom sheet, then layered appearance and water-shedding performance are improved, but shingle weight and manufacturing cost increase
Solution Approach 1:
The bottom bituminous sheet is segmented into discrete tabs rather than being continuous, with gaps between tabs. This segmentation reduces material usage and weight while maintaining water-shedding performance through the overlapping dragon's teeth configuration that directs water flow along the shingle surface.
Solution Approach 2:
The continuous bottom sheet material is extracted/removed in the form of gaps between tabs. Only the necessary tab portions are retained to provide structural support and water-shedding function, eliminating excess material that contributes to weight without adding functional value.
2Shape
If architectural shingles use a multi-layer composition with continuous bottom sheet, then layered appearance is improved, but manufacturing cost increases
Solution Approach 1:
The bottom sheet is divided into separate tabs with gaps between them, reducing the total amount of bituminous material required. This segmentation maintains the layered appearance when combined with the top sheet featuring dragon's teeth, while lowering material costs and manufacturing expenses.
Solution Approach 2:
Material is concentrated locally where needed - in the tabs of the bottom sheet and the dragon's teeth of the top sheet - rather than being distributed continuously. This local quality approach maintains the aesthetic layered appearance while reducing overall material consumption and manufacturing cost.
3Shape
If architectural shingles use a multi-layer composition, then layered appearance is improved, but load on roof deck increases
Solution Approach 1:
The continuous bottom sheet is segmented into discrete tabs with gaps, reducing the total mass of the shingle. This segmentation maintains the layered appearance through proper alignment of tabs with dragon's teeth, while decreasing the dead load transmitted to the roof deck structure.
Solution Approach 2:
Excess bituminous material is taken out from the continuous bottom sheet, creating gaps between tabs. This extraction reduces shingle weight and consequently the load on the roof deck, while the retained tabs and overlapping top sheet configuration preserve the desired layered appearance.
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 results in a lighter, cheaper-to-manufacture roofing shingle with similar visual appearance and performance to traditional multi-layer shingles, reducing the dead load on the roof deck and offering cost savings without compromising functionality.
Implementation Method 1
a top shingle layer at least partially laminated to the top surface of the shim layer
Data Source
AI summary
One aspect of the disclosure is roofing shingle including a shim layer having a top surface, a first side edge, and a second side edge positioned opposite the first side edge. The roofing shingle also includes a top shingle layer at least partially laminated to the top surface of the shim layer, where the top shingle layer includes a first side edge offset a sidelap distance from the first side edge of the shim layer such that a side portion of the top surface of the shim layer is exposed, and a second side edge extending beyond the second side edge of the shim layer so as to overlap the second side edge of the shim layer by the sidelap distance.