Shingle with reinforced nail zone and method of manufacturing
A method of making a laminated shingle is provided. The method includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, adhering a reinforcement member to a portion of the asphalt-coated sheet, covering the asphalt-coated sheet, and optionally covering the reinforcement member, with granules to make a granule-covered sheet, dividing the granule-covered sheet into an overlay sheet and an underlay sheet, wherein the overlay sheet has a tab portion normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, and wherein the reinforcement member is adhered to the lower zone of the headlap portion and laminating the overlay sheet and the underlay sheet to make the laminated shingle.
1. A method of reducing humping of a bundle of stacked laminated roofing shingles, each laminated roofing shingle having an overlay sheet laminated with an underlay sheet, the overlay sheet having a tab portion with cutouts normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, the method comprising:
providing a groove in the lower zone having substantially no granules adhered thereto;
providing a reinforcement member in the groove;
stacking the shingles such that every other of the shingles is at least one of inverted and turned 180 degrees relative to an adjacent one of the shingles, thereby defining a bundle of stacked laminated roofing shingles,
wherein the bundle defines a central area that substantially encompasses the lower zones and wherein the laminated roofing shingles are double-layered, and
wherein the lack of granules in the grooves of the lower zones of the stacked shingles results in the central area of the bundle having a height substantially identical to a height of a remainder of the bundle outside the central area; and
wherein the lack of granules in the grooves of the lower zones of the stacked shingles results in the stacked shingles weighing less than an otherwise identical stack of roofing shingles having no reinforcement members.
2. The method according to claim 1 , wherein the reinforcement member defines a nail zone.
3. The method according to claim 1 , wherein the reinforcement members of the laminated roofing shingles have substantially no granules adhered thereto.
4. A method of reducing humping of a bundle of stacked laminated roofing shingles, each laminated roofing shingle having an overlay sheet laminated with an underlay sheet, the overlay sheet having a tab portion with cutouts normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, the method comprising:
providing a groove in the lower zone;
providing a reinforcement member in the groove, wherein the reinforcement members of the laminated roofing shingles have substantially no granules adhered thereto;
stacking the shingles such that every other of the shingles is at least one of inverted and turned 180 degrees relative to an adjacent one of the shingles, thereby defining a bundle of stacked laminated roofing shingles,
wherein the bundle defines a central area that substantially encompasses the lower zones and wherein the laminated roofing shingles are double-layered, and
wherein the grooves of the lower zones of the stacked shingles results in the central area of the bundle having a height substantially identical to a height of a remainder of the bundle outside the central area.
5. The method according to claim 4 , wherein the reinforcement member defines a nail zone.