Shingle with reinforced nail zone and method of manufacturing
A roofing shingle is provided. The roofing shingles 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. A reinforcement material is secured to the headlap portion of the overlay sheet. The reinforcement material is configured to improve nail pull-through. The reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a distance of about 0.12 inches or less.
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;
wherein the overlay sheet has a non-uniform thickness; and
a reinforcement material secured to the headlap portion of the overlay sheet, wherein the reinforcement material is configured to improve nail pull-through, wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet;
wherein the reinforcement material and the headlap portion provide a nail pull-through value that is at least 13.3 percent greater than an otherwise identical shingle having no such reinforcement material.
2. The roofing shingle of claim 1 , wherein the underlay sheet has a substantially uniform thickness.
3. The roofing shingle of claim 1 , wherein the shingle provides an average nail pull-through value of at least 90 newtons when measured at a temperature of 23° C.+/−2° C.
4. The roofing shingle of claim 1 , wherein the shingle provides an average nail pull-through value of at least 130 newtons when measured at a temperature of 23° C.+/−2° C.
5. The roofing shingle of claim 1 , wherein the shingle provides an average nail pull-through value of at least 104 newtons when measured at a temperature of 23° C.+/−2° C.
6. The roofing shingle of claim 1 , further including a plurality of granules secured to the headlap portion of the overlay sheet and not secured to the reinforcement material.
7. The roofing shingle of claim 1 , wherein the reinforcement material is formed from a woven material.
8. The roofing shingle of claim 7 , wherein the reinforcement material is formed from a polymeric material.
9. The roofing shingle of claim 1 , wherein the reinforcement material is secured to a top surface of the headlap portion and extends beyond the overlapping regions of the headlap portion and the underlay sheet a maximum distance of about 0.12 inches.
10. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion, wherein the overlay sheet has an overlay sheet height;
an underlay sheet secured to a bottom surface of the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet, wherein the underlay sheet has a height equal to approximately half of the overlay sheet height;
wherein the overlay sheet has a non-uniform thickness; and
a reinforcement material secured to a top surface of the headlap portion of the overlay sheet, wherein the reinforcement material is configured to improve nail pull-through, wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet.
11. The roofing shingle of claim 10 , wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a maximum distance of about 0.12 inches.
12. The roofing shingle of claim 10 , wherein the reinforcement material equal to half of the overlay sheet height+/−⅛ inch.
13. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion;
an underlay sheet secured to a bottom surface of the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet;
wherein the overlay sheet has a non-uniform thickness; and
a reinforcement material secured to a top surface of the headlap portion, wherein the reinforcement material is configured to improve nail pull-through, wherein the reinforcement material has a height, wherein the overlapping regions of the underlay sheet and the headlap portion of the overlay sheet have a height, wherein the ratio of the height of the overlapping regions to the height of the reinforcement material is in a range of from about 70% to about 100%.
14. The roofing shingle of claim 13 , wherein the ratio of the height of the overlapping regions to the height of the reinforcement material is in a range of from about 80% to about 95%.
15. The roofing shingle of claim 13 , wherein the ratio of the height of the overlapping regions to the height of the reinforcement material is in a range of from about 85% to about 90%.
16. The roofing shingle of claim 13 , wherein the underlay sheet has a substantially uniform thickness.
17. The roofing shingle of claim 13 , wherein the shingle provides an average nail pull-through value of at least 90 newtons when measured at a temperature of 23° C.+/−2° C.
18. The roofing shingle of claim 13 , further including a plurality of granules secured to the headlap portion of the overlay sheet and not secured to the reinforcement material.
19. The roofing shingle of claim 13 , wherein the reinforcement material and the headlap portion provide a nail pull-through value that is at least 13 percent greater than an otherwise identical shingle having no such reinforcement material.
20. The roofing shingle of claim 13 , wherein the reinforcement material is formed from a woven material.
21. The roofing shingle of claim 20 , wherein the reinforcement material is formed from a polymeric material.
22. A roofing shingle comprising:
an overlay sheet including a headlap portion and a tab portion, the tab portion including a plurality of cutouts, the plurality of cutouts having an upper edge;
an underlay sheet secured to a bottom surface of the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet;
wherein the overlay sheet has a non-uniform thickness; and
a reinforcement material secured to a top surface of the headlap portion, the reinforcement material is configured to improve nail pull-through, wherein the reinforcement material has a lower edge, wherein the distance from the upper edge of the plurality of the cutouts to the lower edge of the reinforcement material is about 0.25 inches or less;
wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet.
23. The roofing shingle of claim 22 , wherein the underlay sheet has a substantially uniform thickness.
24. The roofing shingle of claim 22 , wherein the shingle provides an average nail pull-through value of 90 newtons when measured at a temperature of 23° C.+/−2° C.
25. The roofing shingle of claim 22 , further including a plurality of granules secured to the headlap portion of the overlay sheet and not secured to the reinforcement material.
26. The roofing shingle of claim 22 , wherein the reinforcement material and the headlap portion provide a nail pull-through value that is at least 13.3 percent greater than an otherwise identical shingle having no such reinforcement material.
27. The roofing shingle of claim 22 , wherein the reinforcement material is formed from a woven material.
28. The roofing shingle of claim 27 , wherein the reinforcement material is formed from a polymeric material.