Shingle with reinforced nail zone and method of manufacturing

Patent metadata

Field	Value
Publication number	US-9657478-B2
Application number	US-201615093925-A
Country	US
Kind code	B2
Filing date	Apr 8, 2016
Priority date	Aug 5, 2005
Publication date	May 23, 2017
Grant date	May 23, 2017

Abstract

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.

First claim

What is claimed is:

1. A roofing shingle comprising:
an overlay sheet including a mat and an asphalt coating applied to the mat, and defining an upper headlap portion and a lower 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 reinforcement material secured directly to the asphalt coating of the headlap portion of the overlay sheet without extending into the tab portion to provide a reinforced nail zone that extends along a longitudinal axis of the shingle, wherein the reinforcement material is configured to improve nail pull-through, with the reinforcement material and the headlap portion providing a nail pull-through value that is greater than an otherwise identical shingle having no such reinforcement material;
wherein the shingle further includes a granular material secured to the headlap portion of the overlay sheet, with no granular material adhered to the reinforcement material; and
wherein the headlap portion of the overlay sheet includes a depressed surface extending along said longitudinal axis of the shingle.

2. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet.

3. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a front surface of the headlap portion of the overlay sheet.

4. The roofing shingle of claim 1 , wherein the depressed surface is on a front surface of the headlap portion of the overlay sheet.

5. The roofing shingle of claim 1 , wherein the depressed surface is on a rear surface of the headlap portion of the overlay sheet.

6. The roofing shingle of claim 1 , wherein the distance between an upper edge of the tab portion of the overlay sheet and an upper edge of the reinforcement material is about 1¾ to about 2¼ inches.

7. The roofing shingle of claim 1 , wherein the depressed surface is covered by the reinforcement material.

8. The roofing shingle of claim 1 , wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet such that at least a portion of the reinforcement material extends along a single-layer portion of the shingle.

9. The roofing shingle of claim 1 , wherein the reinforcement material extends along a single-layer portion of the shingle and at least a portion of the reinforcing material extends along the overlapping portions of the headlap portion and underlay sheet.

10. The roofing shingle of claim 1 , wherein the reinforcement material extends into the overlapping regions of the headlap portion and the underlay sheet a distance of no greater than ⅛ inch.

11. The roofing shingle of claim 1 , wherein the depressed surface is recessed from an outer surface defined by the granular material secured to the headlap portion of the overlay sheet.

12. The roofing shingle of claim 1 , wherein the reinforcement material has a thinner cross-section than the granular material.

13. The roofing shingle of claim 12 , wherein the reinforcement material is disposed between first and second portions of the headlap portion of the overlay sheet, with the granular material being secured to the first and second portions of the headlap portion of the overlay sheet, such that the reinforcement material defines the depressed surface.

14. The roofing shingle of claim 1 , wherein the depressed surface reduces a thickness of the shingle along said longitudinal axis of the shingle.

15. The roofing shingle of claim 1 , wherein at least about 70% of the reinforcement material is disposed on a dual-layer portion of the shingle.

16. The roofing shingle of claim 1 , wherein at least about 79% of the reinforcement material is disposed on a single-layer portion of the shingle.

17. The roofing shingle of claim 1 , wherein the reinforcement material comprises a woven material.

18. The roofing shingle of claim 1 , wherein the reinforcement material comprises a non-woven material.

19. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet, and wherein the depressed surface is on a front surface of the headlap portion of the overlay sheet.

20. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a front surface of the headlap portion of the overlay sheet, and wherein the depressed surface is on the front surface of the headlap portion of the overlay sheet.

21. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a rear surface of the headlap portion of the overlay sheet, and wherein the depressed surface is on the rear surface of the headlap portion of the overlay sheet.

22. The roofing shingle of claim 1 , wherein the reinforcement material is secured directly to the asphalt coating on a front surface of the headlap portion of the overlay sheet, and wherein the depressed surface is on a rear surface of the headlap portion of the overlay sheet.

23. 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 reinforcement material secured directly to the asphalt coating of the headlap portion of the overlay sheet without extending into the tab portion to provide a reinforced nail zone along a longitudinal axis of the shingle, wherein the reinforcement material is configured to improve nail pull-through, with the reinforcement material and the headlap portion providing a nail pull-through value that is greater than an otherwise identical shingle having no such reinforcement material, and wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet such that a portion of the reinforced nail zone is disposed on a single-layer portion of the shingle;
wherein the headlap portion of the overlay sheet includes a depressed surface extending along said longitudinal axis of the shingle, with a portion of the depressed surface being disposed on the single-layer portion of the shingle.

24. The roofing shingle of claim 23 , wherein the reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet such that at least a portion of the reinforcement material extends along a single-layer portion of the shingle.

25. The roofing shingle of claim 23 , wherein the reinforcement material extends along a single-layer portion of the shingle and at least a portion of the reinforcing material extends along the overlapping portions of the headlap portion and underlay sheet.

26. The roofing shingle of claim 23 , wherein the reinforced nail zone extends into the overlapping regions of the headlap portion and the underlay sheet by a distance no greater than ⅛ inch.

27. The roofing shingle of claim 23 , whe

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Belt James S
• Elliott Bert W

Classifications

• E04D2001/3491

  made of flexible material, e.g. shingles · CPC title

• B32B2260/023

  Two or more layers · CPC title

• E04D2001/3452

  characterised by the location of the fastening means · CPC title

• E04D1/20 Primary

  of plastics; {of asphalt;} of fibrous materials · CPC title

• Y10T428/24752

  Laterally noncoextensive components · CPC title