Wedge-Shaped Multi-Layer Asphalt Shingle Edge Thickness
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Solution Overview
Problem
Traditional asphalt roofing products in North America lack the desired edge thickness and aesthetic appeal of natural materials like wood or sawn shakes, while also being thinner and lighter, necessitating a solution that combines the benefits of asphalt shingles with the appearance and thickness of natural wood.
Innovation Solution
A wedge-shaped, multi-layer asphalt roofing system is developed, comprising strata with varying widths, each consisting of a substrate, top and bottom asphalt layers, granular matter, and mineral matter, stacked and laminated together with adhesive, mimicking the appearance of natural wood shakes while conserving materials and allowing efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional asphalt roofing products are used, then cost is reduced and weight is decreased, but edge thickness and aesthetic appeal of natural materials are lost
Solution Approach 1:
The roofing shingle is divided into multiple separate strata (first stratum with substrate and top asphalt layer, second stratum with bottom asphalt layer and mineral matter) that are stacked and laminated together. This segmentation allows each layer to be optimized independently while achieving the overall wedge-shaped thickness profile that simulates natural wood shakes.
Solution Approach 2:
The shingle employs asymmetric width distribution across strata, where the first stratum has a greater width than the second stratum, creating a wedge-shaped profile. This asymmetric design provides the desired edge thickness at the exposure edge while maintaining the lightweight advantages of asphalt materials throughout the structure.
2Shape
If traditional asphalt roofing products are used, then cost is reduced, but aesthetic appeal and desired edge thickness of natural materials are lost
Solution Approach 1:
The manufacturing process produces separate strata that can be fabricated using standard asphalt shingle equipment, then stacks and laminates them together. This approach allows existing manufacturing infrastructure to be utilized while achieving the complex wedge-shaped profile that simulates natural wood shakes.
Solution Approach 2:
The asymmetric width configuration of strata is achieved through controlled application of asphalt layers and mineral matter to substrates of different widths, followed by lamination. This manufacturing approach creates the desired aesthetic edge thickness while using conventional asphalt roofing materials and processes.
3Shape
If multi-layer strata are stacked and laminated to simulate natural wood shakes, then appearance and thickness are improved, but device complexity increases
Solution Approach 1:
The shingle is constructed from discrete strata that can be produced separately and then laminated together. This segmentation simplifies the manufacturing process by allowing each layer to be made using standard asphalt shingle production methods, reducing the complexity of creating the multi-layer structure.
Solution Approach 2:
Multiple strata containing different components (substrate, asphalt layers, granular matter, mineral matter) are combined through lamination to create a unified shingle structure. This merging of separate elements achieves the complex appearance of natural wood shakes while maintaining the simplicity of asphalt material application.
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 system effectively simulates the appearance and thickness of natural wood shakes, offering a cost-effective solution with efficient coverage and longer tool life, while maintaining the advantages of asphalt shingles in terms of weight and cost.
Implementation Method 1
Each of the strata may comprise a substrate, a top asphalt layer on top of the substrate, granular matter on the top asphalt layer, a bottom asphalt layer on a bottom of the substrate, and mineral matter on the bottom asphalt layer
Data Source
AI summary
A roofing shingle includes strata that are stacked and laminated together by adhesive. Each of the strata may have a strata width that differs from the other strata. Each of the strata may include a substrate, a top asphalt layer on top of the substrate, granular matter on the top asphalt layer, a bottom asphalt layer on a bottom of the substrate, and mineral matter on the bottom asphalt layer.