Lightweight roofing shingle and method for making same
A lightweight roofing shingle comprising a saturated mat having an exposed side and an unexposed side wherein a fabric reinforcing layer substantially replaces the bottom asphalt coating and the backing aggregate on the unexposed side of a conventional shingle. The lightweight shingle will have a top asphalt layer applied to the exposed side of the mat and a layer of granular material applied to the top asphalt layer opposite the mat per conventional construction, and the fabric reinforcing layer is adhered directly to the unexposed side of the saturated mat. In one embodiment, the fabric reinforcing layer covers an entire area of the unexposed side of the saturated mat. The reinforcing layer may preferably be a nonwoven fabric made from PET or polypropylene. The lightweight roofing shingle may also include a release tape layer applied to the reinforcing layer opposite the saturated mat.
1. A lightweight roofing shingle comprising:
a saturated mat having an exposed side and an unexposed side;
a top asphalt layer applied to the exposed side;
a layer of granular material applied to the top asphalt layer opposite the mat;
wherein the unexposed side of the saturated mat does not include a bottom asphalt layer;
a fabric reinforcing layer adhered directly to the unexposed side of the saturated mat,
a release tape applied directly to the unexposed side of the saturated mat proximate a mid-height position on said saturated mat; and
wherein the fabric reinforcing layer and the release tape in combination cover an entire area of the unexposed side of the saturated mat.
2. The lightweight shingle of claim 1 further comprising a tab portion of said reinforcing layer adhered directly to the unexposed side of the mat below said release tape.
3. The lightweight shingle of claim 1 further comprising a headlap portion of said reinforcing layer adhered directly to the unexposed side of the mat above said release tape.