Method of sealing overlapping installed shingles

Abstract

A roofing shingle includes a headlap portion and a tab portion. A bead of tab sealant extends longitudinally on a back side of the tab portion. Reinforcement material is secured to the headlap portion and includes outwardly extending attachment members configured to penetrate and mechanically bond with the tab sealant of an overlapping roofing shingle when installed on a roof.

1 . A roofing shingle comprising:
 a headlap portion and a tab portion;   a bead of tab sealant extending longitudinally on a back side of the tab portion; and   reinforcement material secured to the headlap portion, wherein the reinforcement material includes outwardly extending attachment members configured to penetrate and mechanically bond with the tab sealant of an overlapping roofing shingle when installed on a roof.   
     
     
         2 . The roofing shingle according to  claim 1 , wherein the bead of tab sealant is a discontinuous bead of tab sealant adhered to a lower surface of a back side of the tab portion adjacent and parallel to a leading edge of the roofing shingle. 
     
     
         3 . The roofing shingle according to  claim 1 , wherein the reinforcement material is formed from woven material. 
     
     
         4 . The roofing shingle according to  claim 3 , wherein the attachment members are outwardly extending fibers of yarns used to form the woven reinforcement material. 
     
     
         5 . The roofing shingle according to  claim 3 , wherein yarns used to form the woven reinforcement material are crimped yarns. 
     
     
         6 . The roofing shingle according to  claim 3 , wherein yarns used to form the woven reinforcement material are texturized yarns. 
     
     
         7 . The roofing shingle according to  claim 6 , wherein the outwardly extending attachment members include one of the broken ends of individual fibers and loops of fiber. 
     
     
         8 . The roofing shingle according to  claim 3 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein yarns used to form the woven reinforcement material are formed from non-continuous fibers twisted together, such that ends of the non-continuous fibers extend outwardly of the second broad face of the reinforcement material. 
     
     
         9 . The roofing shingle according to  claim 3 , wherein the attachment members are outwardly extending hooks. 
     
     
         10 . The roofing shingle according to  claim 3 , wherein the attachment members are outwardly extending loops. 
     
     
         11 . The roofing shingle according to  claim 3 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein the attachment members comprise a plurality of individual fibers inserted through the reinforcement material such that ends of the individual fibers extend outwardly of the second broad face of the reinforcement material. 
     
     
         12 . The roofing shingle according to  claim 11 , wherein ends of the individual fibers further extend outwardly of the first broad face of the reinforcement material. 
     
     
         13 . The roofing shingle according to  claim 3 , wherein an outwardly facing surface of the headlap portion defines a broad face of the roofing shingle, wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, the attachment members extending outwardly of the second broad face of the reinforcement material, wherein the attachment members further extend outwardly of the broad face of the roofing shingle, and wherein when a plurality of the roofing shingles are stacked in a bundle, the outwardly extending attachment members are compressed by an adjacent one of the roofing shingles to be at or below the broad face of the roofing shingle. 
     
     
         14 . The roofing shingle according to  claim 13 , wherein when the roofing shingles are removed from the bundle, the outwardly extending attachment members again extend outwardly of the broad face of the roofing shingle, the outwardly extending attachment members thereby configured to engage and bond with the tab sealant of an overlapping roofing shingle when installed on a roof. 
     
     
         15 . The roofing shingle according to  claim 1 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein the second broad face of the reinforcement material includes a coating of a material which lowers the viscosity of the tab sealant of an overlapping roofing shingle when installed on a roof. 
     
     
         16 . The roofing shingle according to  claim 15 , wherein the coating is one of a sealant, oil, and a low melting temperature wax. 
     
     
         17 . The roofing shingle according to  claim 1 , wherein the reinforcement material is formed from plastic film. 
     
     
         18 . 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;   a bead of tab sealant extending longitudinally on a back side of the underlay sheet; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from woven material, and wherein the reinforcement material includes outwardly extending attachment members configured to penetrate and mechanically bond with the tab sealant of an overlapping roofing shingle when installed on a roof.   
     
     
         19 . The roofing shingle according to  claim 18 , wherein the attachment members are outwardly extending fibers of yarns used to form the woven reinforcement material. 
     
     
         20 . The roofing shingle according to  claim 18 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein yarns used to form the woven reinforcement material are formed from non-continuous fibers twisted together, such that ends of the non-continuous fibers extend outwardly of the second broad face of the reinforcement material. 
     
     
         21 . The roofing shingle according to  claim 18 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein the attachment members comprise a plurality of individual fibers inserted through the reinforcement material such that ends of the individual fibers extend outwardly of the second broad face of the reinforcement material. 
     
     
         22 . The roofing shingle according to  claim 18 , wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, and wherein the second broad face of the reinforcement material includes a coating of a material which lowers the viscosity of the tab sealant of an overlapping roofing shingle when installed on a roof. 
     
     
         23 . 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 a bead of tab sealant longitudinally on a back side of the tab portion;   modifying reinforcement material such that the reinforcement material includes outwardly extending attachment members configured to penetrate and mechanically bond with the tab sealant of an overlapping roofing shingle when installed on a roof; and   applying and securing the reinforcement material to the headlap portion of the asphalt coated sheet.   
     
     
         24 . A roofing shingle comprising:
 a headlap portion and a tab portion;   a bead of tab sealant extending longitudinally on a back side of the tab portion; and   reinforcement material secured to the headlap portion, wherein the reinforcement material is formed from compressible material.   
     
     
         25 . The roofing shingle according to  claim 24 , wherein an outwardly facing surface of the headlap portion defines a broad face of the roofing shingle, wherein the reinforcement material has a first broad face engaging the headlap portion and a second broad face opposite the first broad face, wherein a portion of the reinforcement material extends outwardly of the broad face of the roofing shingle, and wherein when a plurality of the roofing shingles are stacked in a bundle, the outwardly extending portion of the reinforcement material is compressed by an adjacent one of the roofing shingles to be at or below the broad face of the roofing shingle. 
     
     
         26 . The roofing shingle according to  claim 25 , wherein the roofing shingles are removed from the bundle, the portions of the reinforcement material expand to again extend outwardly of the broad face of the roofing shingle, the reinforcement material thereby configured to engage and bond with the tab sealant of an overlapping roofing shingle when installed on a roof.