SEALED TABBED ASPHALT SHINGLE SYSTEM AND METHOD

Abstract

A sealed tabbed asphalt shingle system and method of sealing around the slots defining the tabs of the installed shingles, prevent the intrusion of water and preventing the lifting of installed shingles by wind forces.

Claims

1. A sealed tabbed asphalt shingle system for shingles having top and bottom faces, upper and lower areas when installed, and tabs in the lower areas defined by slots having a closed end, two parallel legs, and an open end, and a granular coating on the top face, the sealed tabbed asphalt shingle comprising: a sealant layer formed in a U-shaped configuration extending from immediately above the closed end and along two parallel legs of each slot on the bottom face of each shingle; where, in use, upon installation, said sealant layer on an upper shingle bonds to the upper area of the top face of a shingle below, creating a seal, preventing intrusion of water and preventing lifting by wind forces.

2. The sealed tabbed asphalt shingle system of claim 1, wherein said sealant layer comprises a sealant substance adapted to form a bond extending through the granular coating to the top face of the shingle below.

3. The sealed tabbed asphalt shingle system of claim 1, wherein said sealant layer comprises a manufacturer-applied sealant substance.

4. The sealed tabbed asphalt shingle system of claim 1, further comprising a detachable shielding tape positioned atop a manufacturer-applied sealant substance on the bottom face, said shielding tape being adapted to prevent bonding between stacked shingles during storage and transportation, when shingles are stacked directly one atop the other.

5. The sealed tabbed asphalt shingle system of claim 1, further comprising a moisture- and photo-degradable shielding tape positioned atop a manufacturer-applied sealant substance on the bottom face, said shielding tape being adapted to prevent bonding between stacked shingles during storage and transportation, when shingles are stacked directly one atop the other.

6. The sealed tabbed asphalt shingle system of claim 1, wherein said sealant layer is formed upon an area of the bottom face of the shingle corresponding to a location of nailing of a shingle below.

7. The sealed tabbed asphalt shingle system of claim 1, wherein said system further comprises a sealant applicator for depositing the sealant layer along the closed end and two parallel legs of each slot on the bottom face of each shingle at a time of installation of the shingle.

8. The sealed tabbed asphalt shingle system of claim 1, wherein said system further comprises a sealant activator and an activator applicator, said sealant activator being applied to said sealant layer at a time of installation with the activator applicator.

9. The sealed tabbed asphalt shingle system of claim 1, wherein said system further comprises a sealant activator and an activator applicator, said sealant activator being applied to said sealant layer at a time of installation with the activator applicator, where said sealant activator further comprises one part of a two-part epoxy.

10. The sealed tabbed asphalt shingle system of claim 1, wherein said system further comprises a sealant activator and an activator applicator, said sealant activator being applied to said sealant layer at a time of installation with the activator applicator, where said sealant activator further comprises a solvent acting upon said sealant layer.

11. A sealed tabbed asphalt shingle installation method, comprising: (i) providing shingles having top and bottom faces, upper and lower areas when installed, and tabs in the lower areas defined by slots having a closed end, two parallel legs, and an open end, and a granular coating on the top face; (ii) forming a sealant layer in a U-shaped configuration extending from immediately above the closed end and along two parallel legs of each slot on the bottom face of each shingle; and (iii) installing said shingles; where, in use, upon installation, said sealant layer on an upper shingle bonds to the upper area of the top face of a shingle below, creating a seal, preventing intrusion of water and preventing lifting by wind forces.

12. The sealed tabbed asphalt shingle method of claim 11, wherein said sealant layer comprises a sealant substance adapted to form a bond extending through the granular coating to the top face of the shingle below.

13. The sealed tabbed asphalt shingle method of claim 11, further comprising a step of forming the sealant layer during manufacturing.

14. The sealed tabbed asphalt shingle method of claim 11, further comprising a step of providing a detachable shielding tape positioned atop a manufacturer-formed sealant substance on the bottom face, said shielding tape being adapted to prevent bonding between stacked shingles during storage and transportation, when shingles are stacked directly one atop the other, said shielding tape being adapted to be removed after installation.

15. The sealed tabbed asphalt shingle method of claim 11, further comprising a step of providing a moisture- and photo-degradable shielding tape positioned atop a manufacturer-formed sealant substance on the bottom face, said shielding tape being adapted to prevent bonding between stacked shingles during storage and transportation, when shingles are stacked directly one atop the other, said shielding tape being adapted to be easily degradable after installation and exposure to the elements.

16. The sealed tabbed asphalt shingle method of claim 11, wherein said sealant layer is placed upon an area of the bottom face of the shingle corresponding to a location of nailing of a shingle below.

17. The sealed tabbed asphalt shingle method of claim 11, further comprising steps of forming the sealant layer with a sealant applicator for depositing the sealant layer along the closed end and two parallel legs of each slot on the bottom face of each shingle at a time of installation of the shingle.

18. The sealed tabbed asphalt shingle method of claim 11, further comprising steps of providing a sealant activator and an activator applicator, and applying the sealant activator to said sealant layer with the activator applicator at a time of installation.

19. The sealed tabbed asphalt shingle method of claim 11, further comprising steps of providing a sealant activator and an activator applicator, said activator comprising one part of a two-part epoxy, and applying the sealant activator to said sealant layer with the activator applicator at a time of installation.

20. The sealed-tabbed asphalt shingle method of claim 11, further comprising steps of providing a sealant activator and an activator applicator, said activator comprising a solvent acting upon said sealant layer, and applying the sealant activator to said sealant layer with the activator applicator at a time of installation.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0017] Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein:

[0018] FIG. 1 is a schematic view of the sealed tabbed asphalt shingle system of the invention, in use;

[0019] FIG. 2 is a perspective view of the sealed tabbed asphalt shingle of the invention;

[0020] FIG. 3 is a top view of the sealed tabbed asphalt shingle of the invention;

[0021] FIG. 4 is a side view of the sealed tabbed asphalt shingle of the invention;

[0022] FIG. 5 is a bottom view of the sealed tabbed asphalt shingle of the invention;

[0023] FIG. 6 is a schematic view of improved tabbed asphalt shingles stacked one upon another for storage and transport;

[0024] FIG. 7 is a schematic view of the sealed tabbed asphalt shingles as installed, with an offset overlap;

[0025] FIG. 8 is a schematic view of removal of shielding tape from installed improved tabbed asphalt shingles;

[0026] FIG. 9 is a schematic view of an embodiment of the improved tabbed asphalt shingle of the invention utilizing adhesive applied at the time of installation; and

[0027] FIG. 10 is a schematic view of an embodiment of the improved tabbed asphalt shingle of the invention utilizing an activating substance applied to a pre-placed adhesive strip at the time of installation.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Referring to FIG. 1, the sealed tabbed asphalt shingle system 10 of the invention is shown schematically in use on a building's roof. A sealant 1 is placed underneath and around the slots between tabs of the shingle. This sealant 1 prevents intrusion of water and wind through the slots and underneath the tabs of the shingle. In relation to the shingle as installed, the shingle is already sealed along the bottoms of the tabs, so there is no need to seal the bottom or open end of the slot. The sealant 1 is placed to seal the closed end of the slot and the two parallel legs of the slot, which, in existing tabbed-shingle methods, is not sealed, and would allow the intrusion of wind-driven water and of pooled water behind an obstruction such as a chimney, debris, or an ice dam on the roof.

[0029] Additionally, the sealant 1, placed above the closed end of the slot, is placed at the specified or recommended place for nailing the shingle to the underlayment. Therefore, the nail head will be directly covered by and protected by the sealant 1 against rust or corrosion from water and water vapor.

[0030] Referring to FIG. 2, FIG. 3, FIG. 4, & FIG. 5, different views of an exemplary shingle are provided, of an embodiment having pre-applied sealant 1 applied by the manufacturer. The sealant 1 is placed around each slot, on the bottom face of the shingle as installed. Optionally, in this embodiment, shielding tape 2 can be pre-applied to the corresponding top face of the shingle in order to prevent unwanted sealing when stacked for storage or transport. The sealant 1 should be capable of binding not only to the granular coated surface of the shingle, but also through that granular surface to the underlying main asphalt structure of the shingle.

[0031] Referring to FIG. 6, when the optional storage shield 2 is used in conjunction with pre-applied sealant 1, when shingles are stacked one upon another for storage or transportation, the sealant 1 on the bottom of an upper shingle rests upon the shielding tape 2 of the shingle beneath, and therefore the two shingles do not adhere to each other during storage and transportation.

[0032] Referring to FIG. 7, when the sealed tabbed asphalt shingles 10 are installed at the standard offset for such shingles, the sealant 1 areas are placed in contact with, and become sealed to, the upper, unexposed area of the shingle.

[0033] Referring to FIG. 8, after installation of an embodiment of the sealed tabbed asphalt shingle system 10, having optional shielding tape 2, the pieces of shielding tape 2 can be removed by brushing or sweeping, and discarded, or can be left to fall off in the first rainstorm, with the resulting liter picked up from the ground or cleaned out of the gutters. Optionally, the shielding tape 2 can be made of a material which is stable during storage and transportation of the shingles, but is easily degradable to eco-safe material after installation and exposure to the elements, which can be safely allowed to degrade and be blown and washed off of the roof.

[0034] Referring to FIG. 9, in an install-time embodiment 20 of the sealed tabbed asphalt shingle system and method, the sealant 1 can be applied to the proper areas on the underside of a standard tabbed shingle from an install-time sealant applicator 3.

[0035] Referring to FIG. 10, in a two-part sealant embodiment 30, the basic sealant 1 is activated or otherwise enhanced by an activator 4 from an activator applicator 5 at installation time. This two-part sealant can be an epoxy, or can be a sealant-and-solvent or sealant-and-activator combination. This two-part embodiment can provide a stronger bond overall, and can provide for installation under conditions such as extreme cold, where the heat of sunshine cannot be relied upon to set the seal, or where heating with a device such as a blowtorch cannot be utilized.

[0036] Many other changes and modifications can be made in the system and method of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims.