Laminated Shingle Pattern Randomization via Dynamic Cutting
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Solution Overview
Problem
Laminated roofing shingles produced with a continuous and repeating pattern cut design often result in undesirable patterns when applied to a roof, such as a straight line of 'dragon's teeth', which can be aesthetically unpleasing.
Innovation Solution
A novel shingle cut pattern design that incorporates mixing of production lanes and varying cutter configurations to produce shingles with a more random application pattern, including different numbers of teeth per linear yard and varying centerline spacings between teeth, along with different orientations and stacking arrangements to enhance randomness and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous and repeating pattern cut design is used in shingle production, then manufacturing efficiency is improved, but undesirable patterns appear when shingles are applied to a roof
Solution Approach 1:
The patent applies dynamics by making the cutting pattern variable rather than fixed. Multiple cutting patterns are programmed into the system, allowing the pattern to change between shingles or groups of shingles. This dynamic adjustment prevents the repetition of the same pattern while maintaining efficient automated production, thus resolving the contradiction between manufacturing efficiency and pattern uniformity.
Solution Approach 2:
The patent implements periodic action by cycling through multiple predetermined cutting patterns in a sequence. Instead of using a single continuous repeating pattern, the system periodically switches between different patterns (e.g., pattern A, B, C, D) to create visual variety in the installed shingles while maintaining regular, efficient production rhythms.
2Manufacturing precision
If shingles are produced with a fixed cutting pattern, then manufacturing precision is improved, but aesthetic appearance deteriorates due to visible repeating patterns
Solution Approach 1:
The system maintains manufacturing precision through automated controlled cutting while dynamically varying the pattern design. The computer-controlled cutting mechanism ensures precise execution of each pattern, while the ability to switch between multiple patterns prevents aesthetic monotony, thus resolving the contradiction between precision and appearance.
Solution Approach 2:
The patent applies parameter changes by modifying cutting pattern parameters (such as tooth spacing, tab dimensions, or cut depths) across different patterns. These parameter variations create diverse visual appearances while the automated control system maintains consistent manufacturing precision across all pattern variations.
Data Source
AI summary
A method of producing laminated roofing shingles is provided, wherein the shingles are of a dragon's tooth type, and shingles made in accordance with the method, and packages of such shingles.