Roofing Shingles with Side Lap Extension for Water Sealing
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Solution Overview
Problem
Conventional shingle installations often result in potential leak points due to the removal of a significant portion of the headlap, leading to incomplete water sealing between adjacent shingles, which can compromise the integrity of the roof.
Innovation Solution
A roofing shingle design featuring a water impermeable sheet extending from the shingle body, providing a side lapping structure that closes the roof to water penetration, with structural elements and sealants to direct moisture downward and prevent intrusion, allowing for reduced material usage while maintaining aesthetic and functional effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a significant portion of the headlap is removed to reduce material usage, then material consumption is reduced, but water sealing capability deteriorates due to potential leak points between adjacent shingles
Solution Approach 1:
The shingle is divided into distinct functional zones: an exposure zone with conventional shingle material providing aesthetic appearance, a fastening zone for structural attachment, and a headlap zone with water impermeable material providing weather protection. This segmentation allows each zone to be optimized for its specific function while using appropriate materials.
Solution Approach 2:
Different materials are used in different zones of the shingle based on local requirements. The exposure zone uses conventional asphalt impregnated organic or inorganic web with granules for aesthetic appearance, while the headlap zone uses water impermeable materials such as thermoplastic polymers for water sealing. This local quality approach ensures material efficiency while maintaining protective functionality.
2Weight of stationary object
If conventional shingle material is reduced in the headlap area, then cost and weight are reduced, but protection against water penetration is compromised
Solution Approach 1:
The material composition parameter is changed in the headlap zone from conventional asphalt impregnated materials to water impermeable thermoplastic polymer materials. This parameter change provides superior water impermeability with reduced weight, as the thermoplastic materials inherently provide water resistance without the need for heavy asphalt saturation.
3Productivity
If the headlap is shortened to improve installation efficiency, then installation speed increases, but the overlap coverage between adjacent shingles is insufficient
Solution Approach 1:
The shingle employs a composite construction combining conventional roofing materials in the exposure zone with water impermeable thermoplastic materials in the headlap zone. This composite approach allows the headlap to be sufficiently long for proper overlap coverage while the overall shingle design optimizes installation efficiency through consistent material properties and simplified fastening requirements.
Data Source
AI summary
A roofing shingle includes a shingle body having a buttlap portion with a butt edge and a headlap portion with a head edge. The shingle body also has a first side edge, a second side edge, and an exposure zone extending from the butt edge toward the headlap portion that is configured to be exposed to the environment when the shingle is installed on a roof. A water impermeable sheet is attached to the shingle body. The sheet has a width, length, first end and second end. The width extends from approximately the head edge to approximately the butt edge of the shingle body. The length extends from the first end to the second end. At least a portion of the length extends beyond the first side edge of the shingle body by at least about 2 inches. The sheet is formed from a different material than the shingle body.