Method of manufacturing a shingle with reinforced nail zone

Patent metadata

Field	Value
Publication number	US-RE46177-E
Application number	US-201514700201-A
Country	US
Kind code	E1
Filing date	Apr 30, 2015
Priority date	Jul 29, 2011
Publication date	Oct 11, 2016
Grant date	Oct 11, 2016

Abstract

A method of manufacturing a roofing shingle includes applying an asphalt coating to a substrate to define an asphalt coated sheet, the asphalt coated sheet including a headlap portion and a tab portion. Reinforcement material is applied from a spool to the asphalt coated sheet, wherein the reinforcement material is wound in a waywind pattern on the spool payed out from a roll. The reinforcement material is then secured to the headlap portion of the asphalt coated sheet. Prior to applying the reinforcement material to the asphalt coated sheet, the reinforcement material has a first width. The method further includes shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion.

First claim

What is claimed is:

1. A method of manufacturing a roofing shingle comprising:
applying an asphalt coating to a substrate to define an asphalt coated sheet, the asphalt coated sheet including a headlap portion and a tab portion;
applying reinforcement material from a spool to the asphalt coated sheet, wherein the reinforcement material is wound in a waywind pattern on the spool payed out from a roll; and
securing the reinforcement material to the headlap portion of the asphalt coated sheet;
wherein prior to applying the reinforcement material to the asphalt coated sheet, the reinforcement material on the spool has a first width, the method further including shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion.

2. The method according to claim 1 , wherein the reinforcement material is formed from woven material.

3. The method according to claim 1 , wherein the roll comprises a spool, wherein the spool has a width of at least about 10.0 inches and the wound reinforcement material has an outer diameter of at least about 19.0 inches.

4. The method according to claim 3 , wherein an initial weight of the reinforcement material on the spool is greater than about 30 lbs.

5. The method according to claim 1 , wherein the reinforcement material has a thickness within the range of from about 3 mils to about 20 mils.

6. The method according to claim 1 , wherein the reinforcement material has a thickness within the range of from about 5 mils to about 15 mils.

7. The method according to claim 1 , wherein the reinforcement material has a thickness of about 9.5 mils.

8. The method according to claim 1 , wherein the first width is within the range of from about 1.125 inches and about 1.25 inches.

9. The method according to claim 1 , wherein the second width is about 1.0 inches.

10. A method of manufacturing a roofing shingle comprising:
applying an asphalt coating to a substrate to define an overlay sheet including a headlap portion and a tab portion;
securing an underlay sheet to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet;
applying reinforcement material from a spool to the overlay sheet, wherein the reinforcement material is wound in a waywind pattern on the spool payed out from a roll; and
securing the reinforcement material to the headlap portion of the overlay sheet;
wherein prior to applying the reinforcement material to the overlay sheet, the reinforcement material on the spool has a first width, the method further including shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion.

11. The method according to claim 10 , wherein the reinforcement material is formed from woven material.

12. The method according to claim 10 , wherein the roll comprises a spool, wherein the reinforcement material initially on the spool has a weight within the range of from about 30 lbs, to about 40 lbs.

13. The method according to claim 10 , wherein the roll comprises a spool, wherein the reinforcement material initially on the spool has a weight within the range of from about 65 lbs, to about 75 lbs.

14. The method according to claim 10 , wherein the reinforcement material has a thickness within the range of from about 3 mils to about 20 mils.

15. The method according to claim 10 , wherein the first width is within the range of from about 1.125 inches and about 1.25 inches.

16. The method according to claim 10 , wherein the second width is about 1.0 inches.

17. A method of manufacturing a roofing shingle comprising:
applying an asphalt coating to a substrate to define an asphalt coated sheet, the asphalt coated sheet including a headlap portion and a tab portion;
applying reinforcement material from a spool to the asphalt coated sheet, wherein the reinforcement material is wound in a waywind pattern on the spool payed out from a roll; and
securing the reinforcement material to the headlap portion of the asphalt coated sheet by pushing the reinforcement material into an asphalt coating of the asphalt coated sheet, wherein prior to applying the reinforcement material to the overlay sheet, the reinforcement material on the spool has a first width, the method further including shrinking the reinforcement material to a second width narrower than the first width upon securing the reinforcement material to the headlap portion.

18. The method according to claim 17 , wherein the reinforcement material is formed from woven material.

19. The method according to claim 18 , wherein the first width is within the range of from about 1.125 inches and about 1.25 inches.

20. The method according to claim 18 , wherein the second width is about 1.0 inches.

21. The method according to claim 1, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to an upper surface of the asphalt coated sheet.

22. The method according to claim 1, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to a lower surface of the asphalt coated sheet.

23. The method according to claim 10, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to an upper surface of the asphalt coated sheet.

24. The method according to claim 10, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to a lower surface of the asphalt coated sheet.

25. The method according to claim 17, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to an upper surface of the asphalt coated sheet.

26. The method according to claim 17, wherein applying the reinforcement material to the asphalt coated sheet comprises applying the reinforcement material to a lower surface of the asphalt coated sheet.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Vermilion Donn
• Rinne Stephanie A
• Ugorek Michael S
• Scowden John
• Lewis Barry M
• Hendershot D Greg
• Ault Russell L
• Belt James S

Classifications

• Y10T156/1089

  of discrete laminae to single face of additional lamina · CPC title

• E04D1/26 Primary

  Strip-shaped roofing elements {simulating a repetitive pattern, e.g.} appearing as a row of shingles · CPC title

• B32B37/12 Primary

  characterised by using adhesives · CPC title

• B32B37/144 Primary

  using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825) · CPC title