Web for shingle with reinforced nail zone

Abstract

A roofing shingle includes a substrate having a headlap portion and a tab portion. Reinforcement material is secured to the headlap portion, wherein the reinforcement material is formed from woven material.

1 . A roofing shingle comprising:
 a substrate having a headlap portion and a tab portion; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from woven material.   
     
     
         2 . The roofing shingle according to  claim 1 , wherein the reinforcement material has a width within the range of from about 0.5 inch to about 2.0 inch. 
     
     
         3 . The roofing shingle according to  claim 1 , wherein the woven reinforcement material is formed from fabric yarns within the range of from about 100 denier to about 200 denier. 
     
     
         4 . The roofing shingle according to  claim 1 , wherein the reinforcement material has a density within the range of from about 65 yarns per inch to about 90 yarns per inch in a warp direction and within the range of from about 35 yarns per inch to about 55 yarns per inch in a cross-machine direction. 
     
     
         5 . The roofing shingle according to  claim 1 , wherein the reinforcement material has a weight within the range of from about 1.5 ounces/yard 2  to about 4.5 ounces/yard. 
     
     
         6 . The roofing shingle according to  claim 1 , wherein the reinforcement material has a thickness within the range of from about 3 mils to about 20 mils. 
     
     
         7 . The roofing shingle according to  claim 1 , wherein the reinforcement material has an air permeability within the range of from about 160 cm 3 /s/cm 2  to about 260 cm 3 /s/cm 2 . 
     
     
         8 . The roofing shingle according to  claim 1 , wherein the reinforcement material is formed from polyester. 
     
     
         9 . 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, thereby defining a two-layer portion and a single-layer portion of the roofing shingle; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from woven material.   
     
     
         10 . The roofing shingle according to  claim 9 , wherein the reinforcement material has a width within the range of from about 0.5 inch to about 2.0 inch. 
     
     
         11 . The roofing shingle according to  claim 9 , wherein the woven reinforcement material is formed from fabric yarns within the range of from about 100 denier to about 200 denier. 
     
     
         12 . The roofing shingle according to  claim 9 , wherein the reinforcement material has a density within the range of from about 65 yarns per inch to about 90 yarns per inch in a warp direction and within the range of from about 35 yarns per inch to about 55 yarns per inch in a cross-machine direction. 
     
     
         13 . The roofing shingle according to  claim 9 , wherein the reinforcement material has a weight within the range of from about 1.5 ounces/yard 2  to about 4.5 ounces/yard. 
     
     
         14 . The roofing shingle according to  claim 9 , wherein the reinforcement material has a thickness within the range of from about 3 mils to about 20 mils. 
     
     
         15 . The roofing shingle according to  claim 9 , wherein the reinforcement material has an air permeability within the range of from about 160 cm 3 /s/cm 2  to about 260 cm 3 /s/cm 2 . 
     
     
         16 . The roofing shingle according to  claim 9 , wherein the reinforcement material is formed from polyester. 
     
     
         17 . 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, thereby defining a two-layer portion and a single-layer portion of the roofing shingle; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from non-woven material.   
     
     
         18 . The roofing shingle according to  claim 17 , wherein the reinforcement material has a basis weight within the range of from about 0.5 lbs/csf to about 1.5 lbs/csf. 
     
     
         19 . The roofing shingle according to  claim 17 , wherein the non-woven reinforcement material comprises about 10 percent glass fiber and about 90 percent bi-component fiber. 
     
     
         20 . The roofing shingle according to  claim 19 , wherein the bi-component fiber includes a polyethylene terephthalate core and a polyethylene sheath. 
     
     
         21 . The roofing shingle according to  claim 20 , wherein the sheath to core ratio of the bi-component fiber is within the range of from about 40:60 to about 60:40. 
     
     
         22 . The roofing shingle according to  claim 20 , wherein the sheath to core ratio of the bi-component fiber is about 50:50. 
     
     
         23 . The roofing shingle according to  claim 18 , wherein the reinforcement material improves the nail pull-through value of the roofing shingle relative to the nail pull-through value of an otherwise identical roofing shingle having no such reinforcement material. 
     
     
         24 . The roofing shingle according to  claim 17 , wherein at least a portion of the reinforcement material is adhered to the single-layer portion of the roofing shingle. 
     
     
         25 . The roofing shingle according to  claim 17 , wherein the underlay sheet has a substantially uniform thickness. 
     
     
         26 . 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, thereby defining a two-layer portion and a single-layer portion of the roofing shingle; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from non-woven material, wherein the reinforcement material improves the nail pull-through value of the roofing shingle relative to the nail pull-through value of an otherwise identical roofing shingle having no such reinforcement material, and wherein the reinforcement material has a basis weight within the range of from about 0.5 lbs/csf to about 1.5 lbs/csf.   
     
     
         27 . A non-woven mat comprising:
 glass fiber; and   bi-component fiber;   wherein the ratio of glass fiber to bi-component fiber is about 10:90, and wherein the bi-component fiber includes a polyethylene terephthalate core and a polyethylene sheath.   
     
     
         28 . The non-woven mat according to  claim 27 , wherein the sheath to core ratio of the bi-component fiber is within the range of from about 40:60 to about 60:40. 
     
     
         29 . The non-woven mat according to  claim 27 , wherein the sheath to core ratio of the bi-component fiber is about 50:50. 
     
     
         30 . The non-woven mat according to  claim 27 , wherein the non-woven mat defines reinforcement material for a shingle. 
     
     
         31 . The non-woven mat according to  claim 27 , wherein the ratio of glass fiber to bi-component fiber is within the range of from about 5:95 to about 25:75.