Shingle with reinforced nail zone and method of manufacturing
A roofing shingle is provided. The roofing shingle includes an overlay sheet including a headlap portion and a tab portion and an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet. Said underlay sheet has a substantially uniform thickness. A reinforcement member is secured to the headlap portion. The reinforcement member is formed from a material selected from the group consisting of paper, film, scrim, woven, and non-woven material. The reinforcement member and the portion of the headlap portion to which the reinforcement member is secured to improve nail pull-through. At least some of the reinforcement member does not overlap the overlapping regions of the headlap portion and the underlay sheet. Said reinforcement member provides said overlay sheet with a non-uniform thickness.
1. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion;
an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet, said underlay sheet having a substantially uniform thickness; and
a reinforcement member secured to the headlap portion, the reinforcement member being formed from a material selected from the group consisting of paper, film, scrim, woven, and non-woven material, wherein the reinforcement member and the portion of the headlap portion to which the reinforcement member is secured improve nail pull-through, wherein at least some of the reinforcement member does not overlap the overlapping regions of the headlap portion and the underlay sheet; and
wherein said reinforcement member provides said overlay sheet with a non-uniform thickness.
2. The roofing shingle defined in claim 1 , wherein the nail pull-through value has an average value of 90 newtons when measured at a temperature of 23° C.±2° C.
3. The roofing shingle defined in claim 1 , wherein the nail pull-through value has an average value of 130 newtons when measured at a temperature of 23° C.±2° C.
4. The roofing shingle defined in claim 1 , wherein the nail pull-through value has an average value of 104 newtons when measured at a temperature of 0° C.±2° C.
5. The roofing shingle defined in claim 1 , wherein the nail pull-through value has an average value of 180 newtons when measured at a temperature of 0° C.±2° C.
6. The roofing shingle defined in claim 1 , further including a plurality of granules secured the headlap portion of the overlay sheet and not secured to the reinforcement member.
7. The roofing shingle defined in claim 1 , wherein the reinforcement member and the headlap portion define a nail pull-through value that is at least 13.3 percent greater than an otherwise identical shingle having no said reinforcement member.
8. The roofing shingle defined in claim 1 , wherein the reinforcement member and the headlap portion define a nail pull-through value that is at least 62.3 percent greater than an otherwise identical shingle having no said reinforcement member.
9. The roofing shingle defined in claim 1 , wherein the reinforcement member and the headlap portion define a nail pull-through value that is at least 86.0 percent greater than an otherwise identical shingle having no said reinforcement member.
10. The roofing shingle defined in claim 1 , wherein the reinforcement member and the headlap portion define a nail pull-through value that is at least 112.7 percent greater than an otherwise identical shingle having no said reinforcement member.
11. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a paper material.
12. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a film material.
13. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a scrim material.
14. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a non-woven material.
15. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a woven material.
16. The roofing shingle defined in claim 1 , wherein the reinforcement material is formed from a polymeric material.
17. The roofing shingle defined in claim 16 , wherein the polymeric material is polyethylene.
18. The roofing shingle defined in claim 17 , wherein the reinforcement material is formed from a woven material.
19. The roofing shingle defined in claim 18 , wherein the overlay sheet has an overlay sheet height, and wherein the underlay sheet has a height approximately equal to half of the overlay sheet height.
20. The roofing shingle defined in claim 18 , wherein the overlay sheet has an overlay sheet height, and wherein the underlay sheet has a height less than approximately half the overlay sheet height.
21. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion;
an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet, said underlay sheet having a substantially uniform thickness; and
a reinforcement member secured to the headlap portion, the reinforcement member being formed from a woven material, wherein at least some of the reinforcement member does not overlap the overlapping regions of the headlap portion and the underlay sheet, and wherein the headlap portion defines a first nail pull-through value, and wherein the reinforcement member and the headlap portion define a second nail pull-through value that is at least 13.3 percent greater than the first nail pull-through value, and
wherein said reinforcement member provides said overlay sheet with a non-uniform thickness.
22. The roofing shingle defined in claim 21 , wherein the reinforcement member and the headlap portion define a second nail pull-through value that is at least 62.3 percent greater than-the first nail pull-through value.
23. The roofing shingle defined in claim 21 , wherein the reinforcement member and the headlap portion define a second nail pull-through value that is at least 86.0 percent greater than the first nail pull-through value.
24. The roofing shingle defined in claim 21 , wherein the reinforcement member and the headlap portion define a second nail pull-through value that is at least 112.7 percent greater than the first nail pull-through value.
25. The roofing shingle defined in claim 21 , wherein the woven material is a polymeric material.
26. The roofing shingle defined in claim 25 , wherein the polymeric material is polyethylene.
27. The roofing shingle defined in claim 21 , wherein the nail pull-through value has an average value of 90 newtons when measured at a temperature of 23° C.±2° C.
28. The roofing shingle defined in claim 21 , wherein the nail pull-through value has an average value of 130 newtons when measured at a temperature of 23° C.±2° C.
29. The roofing shingle defined in claim 21 , wherein the nail pull-through value has an average value of 104 newtons when measured at a temperature of 0° C.±2° C.
30. The roofing shingle defined in claim 21 , wherein the nail pull-through value has an average value of 180 newtons when measured at a temperature of 0° C.±2° C.
31. The roofing shingle defined in claim 21 , further including a plurality of granules secured the headlap portion of the overlay sheet and not secured to the reinforcement member.
32. The roofing shingle defined in claim 21 wherein said reinforcement member is positioned such that a reinforced nail zone is provided at a substantially single-layer portion of said roofing shingle.
33. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion;
an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet, said underlay sheet having a substantially uniform thickness; and
a reinforcement member secured to the headlap portion, the reinforcement member being formed from a woven material, wherein the reinforcement member and the portion of the headlap portion to which the reinforcement member is secured improve nail pull-through, wherein at least some of the reinforcement member does not overlap the overlapping regions of the headlap portion and the underlay sheet; and
wherein said reinforcement member provides said overlay sheet with a non-uniform thickness.