In-Line Shingle Coating Extrusion Without Roll Film Handling
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Solution Overview
Problem
Existing methods for applying polymeric films to asphalt roofing shingles during manufacturing are inefficient due to the need for thick, durable rolls that increase costs and complicate the manufacturing process, and require frequent roll changes, leading to inflexibility and damage in the manufacturing line.
Innovation Solution
A method involving the extrusion of molten polymeric material directly onto a moving web of shingle material, allowing it to cure and form a thin film, which can be applied across the entire width or selectively, eliminating the need for prefabricated rolls and enabling continuous production without stopping the line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric film is applied from prefabricated rolls to the shingle web, then the film provides waterproof protection and eliminates back dusting, but the film thickness must be increased to prevent tearing during rolling and application, which increases material cost and manufacturing complexity
Solution Approach 1:
The patent replaces the mechanical roll-to-web film application system with an extrusion-based system. Instead of using prefabricated rolls that require mechanical handling and rolling, the polymeric material is extruded directly onto the moving shingle web in molten or liquid form, eliminating the need for large rolls and their associated handling complexities.
Solution Approach 2:
The patent changes the physical state and application parameters of the polymeric material. Rather than applying pre-formed solid film from rolls, the material is extruded in a molten or liquid state, allowing it to be deposited in thin layers that solidify upon contact with the cooler shingle web, achieving both thinness and integrity.
2Duration of action of stationary object
If large rolls of polymeric film are used for coating the shingle web, then continuous film supply is achieved, but the sourcing, storage, and manipulation of large rolls add complication and cost to the manufacturing process
Solution Approach 1:
The patent replaces the complex mechanical roll handling system with a simpler extrusion system. The polymeric material is fed through an extruder that melts and extrudes the material directly onto the web, eliminating the need for roll storage, mounting, and replacement mechanisms.
Solution Approach 2:
The patent segments the polymeric material supply into manageable portions handled by the extrusion system. Rather than dealing with large rolls, the material is processed through an extruder that delivers controlled amounts of molten or liquid polymer to the web, simplifying the supply mechanism.
3Strength
If the shingle web is made flexible to prevent damage during manufacturing, then fewer breaks occur at bend radiuses, but the web may stick together when stacked in bundles
Solution Approach 1:
The patent applies a thin polymeric film to the surface of the shingle web that provides both flexibility and non-stick properties. This film allows the web to bend without breaking during manufacturing while simultaneously preventing shingles from sticking together when stacked, as the film creates a smooth, low-friction surface.
Solution Approach 2:
The patent creates a composite structure by bonding a polymeric film to the shingle web. This composite provides the flexibility needed for manufacturing while the film's surface properties prevent sticking, combining multiple functions in a single material layer.
4Object-generated harmful factors
If traditional back dusting material is applied to the back surface, then shingles are prevented from sticking together, but adhesive bonding along glue lines is reduced due to the dusty surface
Solution Approach 1:
The patent uses a thin polymeric film applied to the back surface that serves dual functions: preventing shingles from sticking together while providing a clean, dust-free surface that enhances adhesive bonding. The film's smooth surface allows adhesives to bond effectively along glue lines while still providing non-stick properties for stacked shingles.
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 approach results in more flexible shingle webs, improved adhesive bonding, reduced manufacturing costs, and enhanced protection from the elements, as the extruded film provides a waterproof barrier and substitutes for traditional back dusting and asphalt coatings, reducing damage and increasing manufacturing efficiency.
Implementation Method 1
A film extrusion die 58 is located adjacent the bottom surface of the web of shingle material. The extrusion die 58 ejects a stream or streams, perhaps configured as a thin curtain or curtains, of liquefied polymeric material under pressure toward the web of shingle material 32.
Implementation Method 2
The extruded film material is then allowed to cure to form a thin film that is bonded to the web of shingle material.
Implementation Method 3
The extruded film provides a waterproof barrier and substitutes for traditional back dusting and asphalt coatings, reducing damage and increasing manufacturing efficiency.
Data Source
AI summary
A process for in-line extrusion of polymeric coatings onto roofing shingles during manufacturing includes moving a web of shingle substrate material in a downstream direction and extruding a liquefied coating of polymeric material onto at least one surface of the moving web to form a thin film. The liquefied coating may be a molten polymeric material that forms a thin film on a back surface of the shingle material to prevent sticking and eliminate the need for a traditional back dusting with material such as powdered stone. The polymeric film further may be applied to the substrate material in lieu of a saturation coating of asphalt, thus reducing cost and weight while providing a comparable moisture barrier and a lighter more flexible shingle.