Roofing shingle including sheet as headlap

Abstract

A roofing shingle including a buttlap portion and a headlap portion is provided. The roofing shingle includes a coated mat having a roofing mat coated with an organic-based coating material. The coated mat has a width that extends entirely through the buttlap portion and does not extend more than 20% into the headlap portion of the roofing shingle. A water impermeable sheet is adjacent to the coated mat. The sheet has a width that extends from a head edge through at least 80% of the headlap portion and does not extend to a butt edge of the roofing shingle. A nail zone region is formed at an overlap of the coated mat and the water impermeable sheet. The nail zone region is marked by a dissimilar material.

1 . A roofing shingle including a buttlap portion and a headlap portion, the roofing shingle comprising:
 a coated mat comprising a roofing mat coated with an organic-based coating material, the coated mat having a width that extends entirely through the buttlap portion and does not extend more than 20% into the headlap portion of the roofing shingle; and   a water impermeable sheet adjacent to the coated mat, the sheet having a width that extends from a head edge through at least 80% of the headlap portion and does not extend to a butt edge of the roofing shingle;   wherein a nail zone region is formed at an overlap of the coated mat and the water impermeable sheet, and wherein the nail zone region is marked by a dissimilar material.   
     
     
         2 . The roofing shingle of  claim 1 , wherein the dissimilar material is sand. 
     
     
         3 . The roofing shingle of  claim 1  wherein the coated mat has a width that does not extend more than 10% into the headlap portion, and the sheet has a width that extends through at least 90% of the headlap portion of the roofing shingle. 
     
     
         4 . The roofing shingle of  claim 1  wherein the sheet is a nonlaminated sheet made from plastic or metal. 
     
     
         5 . The roofing shingle of  claim 1 , wherein the roofing shingle is a first roofing shingle, and the first roofing shingle has a weight reduction of at least about 25% compared to a second roofing shingle identical to the first roofing shingle except that the second roofing shingle does not include the water impermeable sheet and the coated mat extends to the head edge of the roofing shingle. 
     
     
         6 . The roofing shingle of  claim 5  wherein the first roofing shingle has a weight reduction of at least about 40% compared to the second roofing shingle. 
     
     
         7 . The roofing shingle of  claim 1  wherein the sheet does not have an ionic charge. 
     
     
         8 . The roofing shingle of  claim 1 , wherein the roofing shingle has a limited width characterized by at least one of the following: (a) the entire roofing shingle has a width of not more than about 17 inches (about 43 cm), (b) the buttlap portion of the roofing shingle has a width of not more than about 7 inches (about 18 cm), and (c) the sheet has a width of not more than about 8 inches (about 20 cm). 
     
     
         9 . A roofing shingle including a buttlap portion and a headlap portion, the roofing shingle comprising:
 a coated mat comprising a roofing mat coated with an organic-based coating material, the coated mat having a width that extends entirely through the buttlap portion and does not extend more than 20% into the headlap portion of the roofing shingle; and   a water impermeable sheet adjacent to the coated mat, the sheet having a width that extends from a head edge through at least 80% of the headlap portion and does not extend to a butt edge of the roofing shingle;   wherein a nail zone region is formed at an overlap of the coated mat and the water impermeable sheet, wherein the nail zone region is marked by a dissimilar material, and wherein the nail zone region marked by the dissimilar material is configured to form an area of reduced thickness of the roofing shingle.   
     
     
         10 . The roofing shingle of  claim 9 , wherein the dissimilar material is sand. 
     
     
         11 . The roofing shingle of  claim 9  wherein the coated mat has a width that does not extend more than 10% into the headlap portion, and the sheet has a width that extends through at least 90% of the headlap portion of the roofing shingle. 
     
     
         12 . The roofing shingle of  claim 9  wherein the sheet is a nonlaminated sheet made from plastic or metal. 
     
     
         13 . The roofing shingle of  claim 9 , wherein the roofing shingle is a first roofing shingle, and the first roofing shingle has a weight reduction of at least about 25% compared to a second roofing shingle identical to the first roofing shingle except that the second roofing shingle does not include the water impermeable sheet and the coated mat extends to the head edge of the roofing shingle. 
     
     
         14 . The roofing shingle of  claim 13  wherein the first roofing shingle has a weight reduction of at least about 40% compared to the second roofing shingle. 
     
     
         15 . The roofing shingle of  claim 9  wherein the sheet does not have an ionic charge. 
     
     
         16 . The roofing shingle of  claim 9 , wherein the roofing shingle has a limited width characterized by at least one of the following: (a) the entire roofing shingle has a width of not more than about 17 inches (about 43 cm), (b) the buttlap portion of the roofing shingle has a width of not more than about 7 inches (about 18 cm), and (c) the sheet has a width of not more than about 8 inches (about 20 cm).