Shingle with reinforcement 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 mat and an asphalt coating applied to the mat, and defining a headlap portion and a tab portion;
an underlay sheet including a mat and an asphalt coating applied to the mat, the underlay sheet being secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet; and
a woven reinforcement material secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet without extending into the tab portion, wherein the woven reinforcement material is configured to improve nail pull-through, wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay;
wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is greater than an otherwise identical shingle having no such reinforcement material; and
wherein the shingle further includes a plurality of granules secured to the headlap portion of the overlay sheet and substantially not secured to the woven 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 overlay sheet has a non-uniform thickness.
4. 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.
5. 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.
6. 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.
7. The roofing shingle of claim 1 , wherein the woven reinforcement material is formed from a polymeric material.
8. The roofing shingle of claim 1 , wherein the overlay member has a first height and the underlay member has a second height, the second height being one of less than one-half the first height and equal to one-half the first height.
9. The roofing shingle of claim 1 , wherein the woven reinforcement material is positioned such that a reinforced nail zone is provided at a substantially single-layer portion of the shingle.
10. The roofing shingle of claim 1 , wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is at least about 13 percent greater than an otherwise identical shingle having no such reinforcement material.
11. The roofing shingle of claim 1 , wherein the woven reinforcement material and the headlap portion provide a nail pull-through value within a range of from about 10 percent to about 100 percent greater than an otherwise identical shingle having no such reinforcement material.
12. The roofing shingle of claim 1 , wherein the tab portion of the overlay sheet includes a cutout having an upper edge spaced apart from a lower edge of the woven reinforcement material by a distance within a range of from about ¼ inch to about ¾ inch.
13. The roofing shingle of claim 1 , wherein the tab portion of the overlay sheet includes a cutout having an upper edge spaced apart from an upper edge of the woven reinforcement material by a distance within a range of from about 1¾ inch to about 2¼ inch.
14. The roofing shingle of claim 1 , wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a maximum distance of about 0.12 inches.
15. A roofing shingle comprising:
an overlay sheet including a mat and an asphalt coating applied to the mat, and defining a headlap portion and a tab portion;
an underlay sheet including a mat and an asphalt coating applied to the mat, the underlay sheet being secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet; and
a woven reinforcement material secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet without extending into the tab portion, wherein the woven reinforcement material is configured to improve nail pull-through, wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay;
wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is within a range of from about 10 percent to about 100 percent greater than an otherwise identical shingle having no such reinforcement material.
16. The roofing shingle of claim 15 , wherein the underlay sheet has a substantially uniform thickness.
17. The roofing shingle of claim 15 , wherein the overlay sheet has a non-uniform thickness.
18. The roofing shingle of claim 15 , wherein the woven reinforcement material is formed from a polymeric material.
19. The roofing shingle of claim 15 , wherein the overlay member has a first height and the underlay member has a second height, the second height being one of less than one-half the first height and equal to one-half the first height.
20. The roofing shingle of claim 15 , wherein the woven reinforcement material is positioned such that a reinforced nail zone is provided at a substantially single-layer portion of the shingle.
21. The roofing shingle of claim 15 , wherein the tab portion of the overlay sheet includes a cutout having an upper edge spaced apart from a lower edge of the woven reinforcement material by a distance within a range of from about 1/4 inch to about 3/4 inch.
22. The roofing shingle of claim 15 , wherein the tab portion of the overlay sheet includes a cutout having an upper edge spaced apart from an upper edge of the woven reinforcement material by a distance within a range of from about 1 3/4 inches to about 2 1/4 inches.
23. The roofing shingle of claim 15 , wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a maximum distance of about 0.12 inches.
24. A roofing shingle comprising:
an overlay sheet including a mat and an asphalt coating applied to the mat, and defining a headlap portion and a tab portion;
an underlay sheet including a mat and an asphalt coating applied to the mat, the underlay sheet being secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet; and
a woven reinforcement material secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet without extending into the tab portion, wherein the woven reinforcement material is configured to improve nail pull-through, wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay;
wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is greater than an otherwise identical shingle having no such reinforcement material; and
wherein the tab portion of the overlay sheet includes a cutout having an upper edge spaced apart from a lower edge of the woven reinforcement material by a distance within a range of from about 1/4 inch to about 3/4 inch, and spaced apart from an upper edge of the woven reinforcement material by a distance within a range of from about 1 3/4 inches to about 2 1/4 inches.
25. The roofing shingle of claim 24 , wherein the overlay sheet has a non-uniform thickness.
26. The roofing shingle of claim 24 , wherein the woven reinforcement material is positioned such that a reinforced nail zone is provided at a substantially single-layer portion of the shingle.
27. The roofing shingle of claim 24 , wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a maximum distance of about 0.12 inches.
28. The roofing shingle of claim 24 , wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is within a range of from about 10 percent to about 100 percent greater than an otherwise identical shingle having no such reinforcement material.
29. A roofing shingle comprising:
an overlay sheet including a mat and an asphalt coating applied to the mat, and defining a headlap portion and a tab portion;
an underlay sheet including a mat and an asphalt coating applied to the mat, the underlay sheet being secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet; and
a woven reinforcement material secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet without extending into the tab portion, wherein the woven reinforcement material is configured to improve nail pull-through, wherein the woven reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay;
wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is greater than an otherwise identical shingle having no such reinforcement material; and
wherein the woven reinforcement material is positioned such that a reinforced nail zone is provided at a substantially single-layer portion of the shingle.
30. The roofing shingle of claim 29 , wherein the woven reinforcement material and the headlap portion provide a nail pull-through value that is within a range of from about 10 percent to about 100 percent greater than an otherwise identical shingle having no such reinforcement material.
31. The roofing shingle of claim 29 , wherein the overlay sheet has a non-uniform thickness.