Patent Grant
10190316
The present invention relates generally to systems and methods for repairing and sealing asphalt shingles and, more particularly, to several embodiments of a shingle patch for repairing hail damage to an asphalt shingle.
Shingled roofs are typically laid in an overlapping pattern which necessarily requires the roofer to begin laying the shingles at the lowest point of the roof and moving horizontally until one row of shingles is complete. Asphalt shingles are typically nailed to the roof along the uppermost perimeter edge and the horizontal rows progress upwardly with each asphalt shingle slightly overlapping the one below it, thereby covering the nails securing the underlying shingle. With this progression, the shingles are laid in an overlapping specific pattern and it can be seen that at certain positions on the roof, for example, at edges abutting dormers, chimneys, and at the last row of shingles at the apex of the roof, the last course of nails will not be covered by an adjacent shingle and such uncovered nails are therefore exposed to the elements. If left exposed, such uncovered nails will corrode to the point that they may lose their grip or hold on the respective shingles that they are securing to the roof structure.
Shingled roofs are also subject to a wide variety of weather-related damage including hail damage, storm damage, wind damage and the like. In the particular case of hail damage, or any other damage to a particular asphalt shingle, the present methods for replacing damaged shingles are labor-intensive, time consuming and not very cost-effective, particularly, if the damaged shingles are located in the center portion of the roof structure. Current replacement methods typically require a roofer to remove the damaged shingles. Such repair also then requires removal or at least lifting and separating surrounding shingles since shingled roofs are laid in an overlapping fashion as explained above. Because replacing individual shingles is time consuming, labor-intensive, and may even cause damage to surrounding shingles, there does exist a need for a better, less labor-intensive, and faster system for repairing damaged asphalt shingles without necessarily removing the damaged shingle.
In view of the foregoing, it will be apparent to those skilled in the art that a need exists for a shingle patch for hail damage repair of asphalt shingles. The present invention addresses this need as well as other needs which will become apparent to those skilled in the art after reading the present disclosure.
The present invention is directed to several embodiments of a shingle patch system which can be used to repair hail damage and any other shingle damage associated with asphalt shingles.
In one aspect of the present invention, several embodiments of a shingle patch are disclosed wherein the patch can be overlaid on top of a damaged asphalt shingle such as a shingle having hail damage thereby eliminating the need for totally removing the damaged shingle. One embodiment of the present shingle patch includes a patch base member having one end portion of the base member specifically structured for sliding under an existing shingle such as the shingle located immediately above the damaged shingle, whereas the opposite end portion of the present shingle patch base member includes a roof nail built into the patch itself. The top portion of the base member includes colored granules that are embedded into the patch so as to match the color of the existing damaged shingle. In this regard, the present patch can be produced in multiple colors so as to match the known existing asphalt shingle colors in the marketplace, or the patch can be manufactured on site in the field by using a pre-made patch base member as will be hereinafter further explained and thereafter affixing colored granules to the patch base member in the field so as to match the existing colors of the roof to be repaired.
A sealant is associated with the bottom portion of the shingle patch base member and with that portion of the patch base member to be inserted under the existing shingle located above the damaged shingle. This sealant is preferably heat activated and can be factory applied and is typically activated by the sun. A cellophane tape or other material can be placed over the sealant areas so as to prevent the sealant from binding to any other material during shipment and storage. The tape is removed prior to installing the shingle patch over the damaged shingle. In this regard, a technician will lift the bottom edge of the shingle that lies just one row above the damaged shingle, remove the release tape from that portion of the shingle patch that slides under the existing shingle, and then insert that portion of the shingle patch under the raised shingle. The raised shingle is then lowered onto that portion of the shingle patch and that portion of the patch will bind to the existing shingle through the sealant. Once inserted under the existing adjacent shingle, the bottom portion of the shingle patch may also seal directly to the damaged shingle via the sealant located on the bottom portion of the present patch upon removing the tape previously covering the sealant of the bottom surface. Once inserted under the existing adjacent shingle, the opposite end portion of the shingle patch housing the integrated roof nail is then nailed to the damaged shingle thereby allowing the under surface of the shingle patch to seal directly to the damaged shingle via the sealant located on the bottom portion of the present patch. Once complete, the present shingle patch will overlay the damaged shingle and will match the color scheme of the roof. Since the damaged shingle remains in place, the present shingle patch provides a double layer of protection over the damaged shingle since the damaged shingle still provides some protection to the roof structure.
In another embodiment of the present shingle patch, the patch base member again includes one end portion that slides under an existing shingle, colored granules embedded in its top surface to match the color scheme of the roof shingle to be repaired, and a sealant covering both that portion of the base member which again slides under the existing shingle as well as covering the bottom surface of the base member. In contrast to the other embodiment of the present shingle patch, this patch embodiment includes a flap portion at its opposite end portion, the flap portion being lifted so that a standard roof nail can be nailed through the corresponding mating surface of the base member into the underlying damaged shingle. In this particular embodiment, an integrated roof nail is not associated with the patch. Instead, the inner surface of the flap portion and its corresponding mating surface are likewise covered with a sealant and both surfaces are likewise covered with a cellophane tape or other release tape to prevent such mating surfaces from bonding together until required. This embodiment of the present patch is again inserted under an existing shingle located immediately above the damaged shingle and once, so inserted, the flap portion at the opposite end portion of the base member is lifted, the release tape is removed and a standard roof nail is then nailed through the mating surface of the base member located under the flap portion and through the damaged shingle located below. Once the standard roof nail is hammered into place, the flap portion is lowered such that the flap will cover the head of the standard roof nail just hammered into place. As such, the flap portion serves as a roof nail seal and completely covers the nail head thereby preventing exposure to the elements. The sealant located on the bottom surface of the shingle patch as well as on the mating flap areas and on the area that slides under the existing shingle are all preferably activated either by the sun or by other heat sources thereby bonding the shingle patch to the existing shingle, the damaged shingle and to various portions of the patch itself. Here again, this embodiment of the present shingle patch overlays the damaged shingle and provides an extra layer of protection to the roof structure.
In a separate embodiment substantially similar to the first embodiment described above, the nail integrated into the roofing patch is omitted. Instead the sealant located on the bottom surface of the base member is sufficient in and of itself to secure the shingle patch to a damaged asphalt shingle.
In yet another embodiment of the present shingle patch, the patch is made up of two separate parts and again includes no nails. The shingle patch includes each an upper base member and a lower base member. The lower base member again includes one end portion that slides under an existing shingle just above the damaged shingle in need of repair. A sealant covers both its upper surface and its bottom surface. Both surfaces are likewise covered with a cellophane tape or other release tape to prevent them from bonding together or with other materials until desired. The top portion of the upper base member again includes colored granules that are embedded into its surface so as to match the color of the existing damaged shingle. Thus, like the single patch designs, the two-piece patch can be produced in multiple colors so as to match the known existing asphalt shingle colors in the marketplace, or the patch can be manufactured on site in the field by using a pre-made patch base member as will be hereinafter further explained and thereafter affixing colored granules to the patch upper base member in the field so as to match the existing colors of the roof to be repaired. A sealant covers the lower surface of the upper base member, and a cellophane tape or other release tape is provided on the lower surface to prevent it from bonding with the lower base member until required.
This embodiment of the present patch involves inserting the lower base member under an existing shingle located immediately above the damaged shingle. In this regard, a technician will again lift the bottom edge of the shingle just one row above the damaged shingle and remove the release tape from an end portion of the upper surface of the lower base member. The end portion of the lower base member may then slide under the existing, raised shingle. The raised shingle is then lowered onto that end portion of the shingle patch and that portion of the patch will bind to the existing shingle through the sealant. Once inserted under the existing adjacent shingle, the lower base member may also seal directly to the damaged shingle via the sealant located on the bottom portion of the lower base member (after tape associated therewith is removed). Subsequently, tape may be removed from the lower surface of the upper base member and the remaining upper surface of the lower base member before overlaying the upper base member on the lower base member. Sealant on the upper surface of the lower base member not located under the shingle one row above the damaged shingle may then adhere to sealant on the lower surface of the upper base member. With the upper and lower base members adhered to one another, the two-piece shingle patch will overlay the damaged shingle and will match the color scheme of the roof. This two-piece shingle patch provides a triple layer of protection over the damaged shingle since the damaged shingle still provides some protection to the roof structure.
Other embodiments include eliminating that portion of the present shingle patch that is inserted under the existing shingle located immediately above the damaged shingle and merely abutting one end portion of the present shingle patch with the edge of the existing shingle located immediately above the damaged shingle.
The various embodiments of the present shingle patch provide an improved roof repair system for repairing and/or replacing damaged shingles due to severe weather damage such as hail and the like. These and other specific aspects and advantages of the present embodiments will be apparent to those skilled in the art after reviewing the following detailed description of the illustrative embodiments set forth below which, taken in conjunction with the accompanying drawings, disclose improved structures for the roofing industry.
Several embodiments of the present invention will now be explained with reference to the accompanying drawings. It will be apparent to those skilled in the art from this disclosure that the following description of the various embodiments of the present invention is provided for illustration purposes only and not for the purpose of limiting the present invention as defined by the appended claims and their equivalents.
Referring to the drawings more particularly by reference numbers wherein like numbers refer to like parts, the number 10 in
The notched portion 14 also includes a sealant and/or adhesive 18 distributed across at least a portion of its upper surface as best illustrated in
The opposite end portion 20 of base member 12 includes a roofing nail 22 built into the base member 12. Roofing nail 22 can be any known conventional roofing nail suitable for asphalt shingles. The roofing nail 22 is attached or integrally formed with the shingle patch base member 12 during the manufacturing process or, nail 22 can be otherwise attached to member 12 after the manufacturing process so long as nail 22 and base member 12 form a one-piece unit.
A sealant 26 is likewise associated with at least a portion of the bottom surface 24 of base member 12 as best illustrated in
The top portion of base member 12 includes colored granules (not shown) that are embedded into the patch material so as to match the color of the existing damaged shingle to be repaired. In this regard, the present shingle patch 10 can be produced in multiple colors so as to match the known existing asphalt shingle colors present in the marketplace, or the base member 12 can be color-coordinated with the shingles to be repaired on-site in the field by using a pre-made shingle base member 12 with no color granules associated therewith and thereafter affixing colored granules to the member 12 in the field so as to match the existing colors of the roof to be repaired. Colored granules can be applied to any portion or the entire top surface of base member 12 in a known conventional manner using appropriate adhesives and/or other sealing materials.
Once notched portion 14 is inserted under the existing adjacent shingle 34, the opposite end portion 20 of base member 12 housing the integrated roofing nail 22 is then nailed to the damaged shingle 36 as best illustrated in
Shingle patch 42 differs from shingle patch 10 in that it does not include an integrated roofing nail. Instead, the opposite end portion 56 of base member 44 includes a flap portion 58 that can be moved or lifted away from its mating surface 60 as best illustrated in
Shingle patch 42 is attached overlaying a damaged shingle in a manner substantially similar to shingle patch 10 as illustrated and discussed with respect to
Importantly, flap portion 58 covers the head 68 of roofing nail 62 and serves as a seal thereby preventing the roofing nail 62 from being exposed to the elements. Again, the respective heat activated sealants 48, 54 and 64, if used, can all be activated either by the sun or by other heat sources thereby bonding the shingle patch 42 to the existing damaged shingle, the adjacent existing shingle, and the various portions of the mating flap portion 58. Here again, shingle patch 42 overlays the damaged shingle and provides an extra layer of protection to the roof structure. The method of positioning and attaching the shingle patch 42 over a damaged shingle is substantially identical to the procedure outlined with respect to shingle patch 10 as illustrated in
The notched portion 74 also includes a sealant and/or adhesive 78 distributed across at least a portion of its upper surface as best illustrated in
A sealant 82 is likewise associated with at least a portion of a bottom surface 84 of base member 72 as best illustrated in
The top portion of base member 72 again includes colored granules 88 that are embedded into the patch material so as to match the color of the existing damaged shingle to be repaired. In this regard, the present shingle patch 70 can be produced in multiple colors so as to match the known existing asphalt shingle colors present in the marketplace. In an alternative embodiment such as shown for the base member 12 of the shingle patch 10, the base member 72 can be color-coordinated with the shingles to be repaired on-site in the field by using a pre-made shingle base member with no color granules associated therewith and thereafter affixing colored granules to the member 72 in the field so as to match the existing colors of the roof to be repaired. Colored granules can be applied to any portion or the entire top surface of base member 72 in a known conventional manner using appropriate adhesives and/or other sealing materials.
The shingle patch 70 may be fitted to and adhered to a damaged shingle in a manner substantially similar to that described for shingle patch 10 and shown in
It is also recognized and anticipated that a factory or field applied adhesive that is aggressive enough to be applied at acceptable, ambient temperature using only sufficient downward pressure to laminate or attached the patch 70 to the existing roof can also be utilized. A small roller tool made from metal, rubber, wood or other similar material can be used to apply a concentrated pressure to the patch 70 to ensure adequate attachment. This attachment should provide a permanent waterproof bonding between the patch 70 and the existing roof. Other adhesives or sealants may also be used.
The patch 70 can be trimmed to fit the particular application at the factory, or by the installer in the field, to repair shingles of different shapes and sizes as well as lip and ridge and any other accessory products. The patch 70 is installed without nails as the adhesives alone provides the permanent and waterproof bonding together of all surfaces. The patch 70 can also be used to cover exposed nails such as those that exist as a result of headwalls, the final rows of field shingles on shed roof style roofs, on final ridge caps, and other applications.
Turning now to
The notched portion 94 also includes a sealant and/or adhesive 98 distributed across at least a portion of its upper surface as best illustrated in
Unlike the other shingle patches 10, 70, the upper portion of the lower base member 92 not including the notched portion 94 is also provided with a sealant and/or adhesive 102 distributed across at least a portion of its upper surface (best illustrated in
A sealant 106 is likewise associated with at least a portion of a bottom surface 108 of lower base member 92 as best illustrated in
The shingle patch 90 further includes an upper base member 112 that is adhered to the lower base member 92 when the shingle patch 90 is assembled. The upper base member 112 preferably is sized and shaped substantially similarly to the upper surface of the lower base member 92 not including the notched portion 94. The top portion of upper base member 112 includes colored granules 114 that are embedded into the patch material so as to match the color of the existing damaged shingle to be repaired. In this regard, the present shingle patch 90 can be produced in multiple colors so as to match the known existing asphalt shingle colors present in the marketplace. In an alternative embodiment such as shown for the base member 12 of the shingle patch 10, the upper base member 112 can be color-coordinated with the shingles to be repaired on-site in the field by using a pre-made shingle base member with no color granules associated therewith and thereafter affixing colored granules to the upper base member 112 in the field so as to match the existing colors of the roof to be repaired. Colored granules can be applied to any portion or the entire top surface of base member 112 in a known conventional manner using appropriate adhesives and/or other sealing materials.
A sealant 116 is likewise associated with at least a portion of a bottom surface 118 of upper base member 112 as best illustrated in
The shingle patch 90 is fitted and adhered to a damaged shingle in a manner somewhat different than that described for shingle patch 10 and shown in
Now assembled, the shingle patch 90 will overlay the damaged shingle 36 as illustrated in
It is also recognized and anticipated that the adhesives utilized with the bottom surface 108 of the lower base member 92, the upper surface of the lower base member 92, and the bottom surface 118 of the upper base member 112 may have different options for using adhesives that will supply a permanent and waterproof bonding both between the respective base members 92 and 112 as well as between the bottom surface 108 of lower base member 92 and the damaged shingle. These various options may include, for example, a factory or field applied adhesive that can be used with any of the above referenced surfaces that is aggressive enough to be applied at acceptable, ambient temperatures using only sufficient downward pressure so as to laminate or attach both the lower base member 92 to the damaged shingle and/or bonding the respective lower and upper base members 92 and 112 together. A small roller tool made from metal, rubber, wood or other suitable materials can be used to apply a concentrated pressure to the respective base members 92 and 112 to assure adequate attachment therebetween.
Still further, it is also recognized and anticipated that a factory or field applied adhesive that is sufficiently aggressive enough to bond to adjoining surfaces such as the bottom surface 118 of upper base member 112 to the upper surface of lower base member 92 may only need be applied to one of the two respective surfaces instead of applying an adhesive to both the bottom surface of upper base member 112 and the upper surface of lower base member 92. In this situation, only one of the respective surfaces need have an adhesive associated therewith.
The two-piece patch 90 can likewise be trimmed to fit the particular application at the factory, or it can be trimmed by the installer in the field, to repair shingles of different shapes and sizes as well as hip and ridge and other accessory products. Although the two-piece patch 90 is designed to be installed without nails as the adhesives associated with patch 90 alone provide the permanent and waterproof bonding necessary between all surfaces, patch 90 can likewise be utilized with nails. If nails are to be used, they will only be used on the lower base member 92 so that the upper base member 112 will then cover and seal all of the nail heads associated with the lower base member 92. The patch 90 can also be used to cover exposed nails such as those that exist as a result of headwalls, the final rows of field shingles on shed roof style roofs, on ridge caps, and on other applications.
It is also recognized and anticipated that the notched portion 74 associated with shingle patch 70 can also be formed by a very thin sheet of material such as a thin sheet of sheet metal, aluminum, copper, plastic or other suitable material which is merely attached to base member 72 via any suitable means of attachment such as a sealant, adhesive, or other attachment mechanism as best illustrated in
Use of a thin sheet of material such as the sheet of material 126 can likewise be utilized with the lower base member 92 associated with the two-piece shingle patch 90 (
Understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open-ended terms that specify the presence of the stated features, elements, components and/or groups, but do not exclude the presence of other unstated features, elements, components and/or groups. The foregoing also applies to words having similar meanings such as the terms “including”, “having” and their derivatives. The terms of degree such as “substantially”, “about” and “approximate” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.
Only selected embodiments have been chosen to illustrate the present inventions. The various constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principals of the present inventions. It is also recognized and anticipated that the size, shape, location and other orientation of the various components and/or elements associated with the present inventions can be changed as needed and/or as desired depending upon a particular application. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. In addition, the functions of one element can be performed by two elements, and vice versa. The structures and functions of one embodiment can also be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Thus, the foregoing descriptions of the embodiments according to the present inventions are provided for illustration only, and not for the purpose of limiting the inventions as defined by the appended claims and their equivalents.
Thus, there has been shown and described several embodiments of a novel shingle patch for damage repair of asphalt shingles. As is evident from the foregoing description, certain aspects of the present inventions are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications, applications, variations, or equivalents thereof, will occur to those skilled in the art. Many such changes, modifications, variations and other uses and applications of the present constructions will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses in applications which do not depart from the spirit and scope of the present inventions are deemed to be covered by the inventions which are limited only by the claims which follow.
This application is a continuation-in-part of application Ser. No. 14/965,559, filed Dec. 10, 2015.
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| Number | Date | Country | |
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| Parent | 14965559 | Dec 2015 | US |
| Child | 15486665 | US |
