Method of manufacturing a shingle with reinforced nail zone

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.

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.