U.S. patent application number 15/823815 was filed with the patent office on 2019-05-30 for sealed tabbed asphalt shingle system and method.
The applicant listed for this patent is Chad Strickland. Invention is credited to Chad Strickland.
Application Number | 20190161970 15/823815 |
Document ID | / |
Family ID | 66634967 |
Filed Date | 2019-05-30 |
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United States Patent
Application |
20190161970 |
Kind Code |
A1 |
Strickland; Chad |
May 30, 2019 |
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.
Inventors: |
Strickland; Chad; (Many,
LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Strickland; Chad |
Many |
LA |
US |
|
|
Family ID: |
66634967 |
Appl. No.: |
15/823815 |
Filed: |
November 28, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 1/26 20130101; E04D
2001/005 20130101; E04D 1/36 20130101; E04D 2001/3435 20130101 |
International
Class: |
E04D 1/36 20060101
E04D001/36; E04D 1/26 20060101 E04D001/26 |
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
BACKGROUND
[0001] This invention provides a sealed tabbed asphalt shingle
system, and method of sealing around the slots defining the tabs of
the installed shingles, preventing intrusion of water and
preventing the lifting of the installed shingles by wind
forces.
[0002] Tabbed asphalt shingles are commonly used on roofs because
they are relatively inexpensive and relatively simple to install.
The shingles most often used are "3-tab" shingles, which have three
tabs and measure one foot by three feet. Additionally, shingles
with seven tabs are also used in residential and commercial
properties, and architectural, or dimensional, shingles may also be
used in roofing. Each of the above shingles feature the discussed
tabs, and are subject to the same issues regarding sealant of the
tabbed shingles discussed below.
[0003] For sealant of the shingles along a roof of structures,
tabbed shingles are usually provided with a line of heat-activated
adhesive along the middle of the top face of the shingle. When the
shingles are installed in the usual manner, the line of
heat-activated adhesive on the top of a lower shingle is placed in
contact with the lower edges of the tabs of an upper shingle, and,
with post-installation activation by the heat of the sun, or from
another source, such as a blowtorch, the lower edges of the tabs
are sealed to the underlying shingles.
[0004] If a tab of a shingle is lifted by the wind, the tab acts as
a sail and tends to pull upward on the rest of the shingle and on
adjacent shingles. Wind-driven water can be forced up underneath
the shingle tabs, and can ultimately rust, degrade, or loosen the
nails holding the shingles to the roof.
[0005] The construction of a tabbed asphalt shingle provides for
tabs that are defined by slots cut into the asphalt, to a point
below the midline of the shingle. Typically, a half-slot is placed
at the side edges of a shingle so that when the shingles are
installed butted together, the pattern and spacing of tabs and
slots is maintained. Presently, the bottom face around these slots
is not sealed to the underlying shingle. This lack of sealing leads
to a number of environmentally-driven problems, which in turn lead
to significant damage to the shingles and, ultimately, premature
failure of the roof. For example, wind-driven water can be forced
under the shingle at the slots. Additionally, where the shingles
meet an obstruction, such as a chimney, debris, or an ice dam,
water will pool and seep under the shingle at the slots, whether by
capillary action or otherwise. The water can lead to degradation or
rotting of the shingle and of the underlayment, cladding, or
structure such as rafters, which leads to larger leaks and to
failure of the roof. The water can further leak into and cause
damage on the inside of the building. Lastly, water seepage can
locally weaken a shingle to the point where a subsequent high wind
might lift that shingle and start a chain effect, peeling multiple
shingles off of the roof.
[0006] While there have been systems that apply adhesive in varied
ways to attachment areas of shingles, there remains a need to
achieve better sealing of installed tabbed shingles, without losing
the lower cost and simple installation advantages of tabbed asphalt
shingles.
[0007] U.S. Pat. No. 5,895,536, issued on Apr. 20, 1999, covers a
"Method of Adhering Roof Tiles Using One-Component Adhesive and
Roof Construction Obtained Thereby." The method of adhering the
roof tiles, invented by Cris Damon Starr et al. and assigned to
Insta-Foam Products, utilizes a one-component adhesive and
particularly a one-component polyurethane adhesive foam applied to
the undersurfaces of the roof tiles in discontinuous patterns. The
adhesive is applied in the form of separate deposits at opposing
corners of the undersurfaces of the roof tiles, and those roof
tiles are laid on the roof in serial fashion and overlapping
courses.
[0008] U.S. Pat. No. 6,936,329 issued on Aug. 30, 2005 to assignee
ElkCorp for a "Fastener-Free Composite Roofing Product." The
roofing product, developed by inventors Matti Kiik et al., includes
a roofing material and an inter-ply material attached to this
roofing material, wherein the inter-ply material includes an
adhesive coating on one side. The inter-ply material is attached
adjacent to an edge of the roofing material to permit a major
portion of the inter-ply material to be folded away from the
roofing material for application to a roof. The adhesive is
effective to secure the roofing product to the roof without the use
of nails or other fasteners. The roofing material may be a roofing
shingle or roll roofing, and the inter-ply material is comprised of
a water-resistant material. In applying the shingle product, the
release film is removed and the inter-ply layer folded back,
initially to be essentially coplanar with the shingle layer. The
shingle product is then positioned at the roof edges to overlap the
preceding product along the hid and ridge, and pressed down against
the opposite roof surfaces to secure it in place. The lowermost
product is installed with the bottom edge of its shingle layer even
with, or extending slightly beyond, the roof edge, and is secured
to the opposite roof surfaces by the adhesive on the inter-ply
layer and sealant strips.
[0009] U.S. Pat. No. 9,511,566, issued to assignee Polyglass USA,
Inc. on Dec. 6, 2016, covers a "Building Construction Material with
High Solar Reflectivity." The concept, invented by Louis Lynn Grube
et al., covers a coating composition for granular roofing with a
liquid phase, such as water, vinyl copolymer, or a modified
acrylic, and a material with a high reflectance, such as
CaCO.sub.3, TiO.sub.2, ceramic microspheres, nanoparticles or so
forth dispersed therein to yield a low-viscosity coating. The
coating is applied to a granular surface in a thin layer that does
not significantly disturb the granular aesthetics, but covers the
base material (such as modified bitumen) at least partially, to
increase the overall reflectivity of the material. In some
embodiments, the coating improves the physical integrity of the
granular surface and increases resistance to environmental effects,
and may perform a pigment function. In one embodiment, the coating
is applied as a powder, followed by the application of a liquid. In
another embodiment, the coating includes a water repellant.
Physically, the roofing membrane has an inner sheet or mat composed
of polyester, fiberglass, or similar material. Bottom and top
layers of asphalt compound are laminated to opposing sides of the
fabric mat. The top layer has a plurality of granules disposed over
the upper surface thereof, forming a granular surface. Optionally,
the peripheral edges may be left smooth, without granules, to form
a substrate for beads or adhesive.
[0010] U.S. Pat. No. 4,731,284 was issued on Mar. 15, 1998 to
inventors Dieter Hailer and Kurt Schult for a "Thermally Bondable
Roofing Material." The patent covers a roofing material comprised
of a polybitumen sealing web, composed of a thermally weldable
closed homogeneous sealing layer. The sealing layer is formed along
an underside with parting and pressure equalizing means, allowing
for fluid communication over an internal region of juxtaposition of
the web with a roof surface. Also provided is a support of a
filamentary web, impregnated with a polymerbitumen on an upper
surface of the substantially fluid-impermeable web. In the system,
the sealing layer may be provided with planar adhesive borders for
the overlapping bonding of adjacent strips. Those flat edges can be
free from longitudinal and transverse grooves so that a flat
contact of overlapping edge portions of the strips can be
ensured.
[0011] U.S. Pat. No. 5,050,357 was issued to inventor Gregory E.
Lawson on Sep. 24, 1991, covering a "Sheet Roofing Organization."
The patent discloses a sheet-like member with a plurality of rows
of patterned shingle construction, defined by shingle face members
separated by associated grooves defined within a forward surface of
the sheet, with a rear surface of the sheet featuring spaced
parallel adhesive strips. A modification of the invention further
includes engagement ribs directed between the adhesive strips to
enhance positioning and gripping of a roof surface during securing
of the system thereon.
[0012] U.S. Publication No. 2009/0220720 was published on Sep. 3,
2009, following a Jan. 9, 2006 filing, by inventors Shaik Mohseen
and Natalino Zanchetta, disclosing a "Roofing Material with Release
Liner Having Adhesive." The concept covers a roofing material with
release tape having a substrate with adhesive capable of transfer
from the substrate to the roofing material, as well as a method of
producing same. The adhesive may be applied in varied forms to the
substrate.
[0013] U.S. Pat. No. 6,924,015, also invented by Shaik Mohseen and
Natalino Zanchetta, issued to assignee Polyglass, U.S.A. on Aug. 2,
2005 for a "Modified Bitumen Roofing Membrane with Enhanced
Sealability." The patent covers a self-adhering modified bituminous
roof covering composite that comprises a thermoplastic (APP),
elastomeric (SBS) or TPO modified bitumen compound on the front
side, and a factory-applied self-adhesive compound on the back side
of a reinforcement carrier sheet, with factory-applied tracts of
adhesive on the side lap and end lap sections of each roll, to
enhance adhesion. A method of manufacturing such a composite is
also disclosed, comprising coating an APP or SBS or TPO compound on
the upper surface and affixing a self-adhesive compound to the
lower surface of a reinforcement carrier support sheet, coating an
adhesive on the side lap and end lap areas, applying a release
liner to the tacky self-adhesive layer, and applying release films
to the side and end laps during manufacture, stripping the release
liner, selvage release film, and end lap film from the membrane
immediately prior to use, subsequently placing the exposed
self-adhesive side of the membrane directly on to the end lap areas
and side lap areas of adjacent rolls and applying force directly to
the sheet to enhance the bond between the two sheets, resulting in
a continuous roof covering.
[0014] U.S. Publication No. 2011/0041466, published Feb. 24, 2011
by inventors James Stephens and Gaylen Blosser, discloses a
"Shingle and Method of Using the Shingle." The shingle comprises an
upper surface with an attachment area and an exposed area having a
coating and an inkling. The attachment area is in a plane lower
than a plane of the exposed area, and extends longitudinally along
a top of the exposed area and horizontally along a side of the
exposed area. The shingle comprises a bottom surface opposite the
upper surface, and an adhesive layer applied to a length of the
attachment area adjacent the exposed area. The shingles are in turn
attached to each other by the adhesive layer.
[0015] There thus remains a need for a system that allows for
better sealing of installed tabbed shingles, while still allowing
for the lower cost and simple installation advantages of tabbed
asphalt shingles.
SUMMARY OF THE INVENTION
[0016] This invention provides a sealed tabbed asphalt shingle
system and method of sealing around the slots defining the tabs of
the installed shingles, preventing intrusion of water and
preventing lifting by wind forces. A sealant is applied to the
bottom face of the shingle around the slots defining the tabs. This
sealant can be pre-applied, or applied at time of installation. The
sealant can be a single-component adhesive or an adhesive using a
second part such as an epoxy or using an activator, applied at time
of installation. Where the sealant is pre-applied, shielding tape
can be pre-applied to the corresponding areas of the top faces to
prevent bonding during storage and transportation.
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.
* * * * *