Shrinkable Reinforcement for Asphalt Shingle Nail Zones

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Solution Overview

Problem

Asphalt shingles face issues with nail blow-through during installation and wind uplift due to inadequate reinforcement in the nail zone, leading to potential roof leaks and installation challenges.

Innovation Solution

The method involves applying reinforcement material, such as woven or non-woven fabric, to the nail zone of asphalt shingles, which is then shrunk to a narrower width after application, enhancing the bonding surface for tab sealants and improving the nail pull-through resistance and wind resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If reinforcement material is applied to the nail zone of asphalt shingles, then nail pull-through resistance and wind resistance are improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvenail pull-through resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The reinforcement material is applied to the nail zone before the shingle is completed, preparing the area in advance to withstand nail installation forces and wind uplift. This preliminary reinforcement ensures that when nails are driven into the shingle during installation, the reinforced zone provides immediate resistance to nail blow-through and pull-through forces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Rather than reinforcing the entire shingle, the reinforcement material is applied specifically to the nail zone area where mechanical fastening occurs. This localized application provides targeted strength enhancement exactly where needed for nail resistance, while leaving other areas of the shingle with their original properties and weight.

Inventive Principle:

Principle #3Local quality

2Reliability

If reinforcement material is applied to the nail zone, then wind resistance and shingle stability are improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveshingle stability in high windVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The shingle construction incorporates multiple materials including the base asphalt shingle layers and the additional reinforcement material applied to the nail zone. This composite structure combines the weathering and sealing properties of the asphalt shingle with the enhanced mechanical strength of the reinforcement material, creating a multi-functional building material that resists both environmental degradation and wind-induced forces.

Inventive Principle:

Principle #40Composite materials

3Strength

If the reinforcement material width is reduced after application, then the bonding surface for tab sealants is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvebonding surface for tab sealantsVSAvoidreinforcement material width control

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The width of the reinforcement material is changed as part of the manufacturing process. The reinforcement material is initially applied at a wider width and then reduced to a narrower width, allowing optimization of both the bonding surface area for tab sealants and the overall performance characteristics of the reinforced nail zone.

Inventive Principle:

Principle #35Parameter changes

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 solution significantly reduces nail blow-through and shingle lift in high winds, while also improving the installer's efficiency by providing a clear nail zone and increasing the force required to pull nails through the shingles, thus enhancing the overall performance and durability of the roofing material.

Implementation Method 1

shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion

Methodology Applied

Scientific EffectShrinkage: Thermal Contraction

Data Source

PatentUSRE46177E1Method of manufacturing a shingle with reinforced nail zone

Publication Date: 2016.10.11 OWENS CORNING INTELLECTUAL CAPITAL LLC

AI summary

A method of manufacturing a roofing shingle includes applying an asphalt coating to a substrate to define an asphalt coated sheet, the asphalt coated sheet including a headlap portion and a tab portion. Reinforcement material is applied from a spool to the asphalt coated sheet, wherein the reinforcement material is wound in a waywind pattern on the spoolpayed out from a roll. The reinforcement material is then secured to the headlap portion of the asphalt coated sheet. Prior to applying the reinforcement material to the asphalt coated sheet, the reinforcement material has a first width. The method further includes shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion.