Note: Descriptions are shown in the official language in which they were submitted.
INTEGRAL NAIL/DISK STRUCTURE FOR
ELIMINATING EXPOSED ROOF NAILS
Cross-Reference to Related Applications
[00011 This application is related to U.S. Patent Application Serial No.
15/428,521 filed
February 9, 2017, which application is a divisional application of U.S. Patent
Application
Serial No. 14/965,559 filed December 10, 2015.
Background of the Invention
.. [0002] 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 and to an integral nail/disk
combination structure
for eliminating exposed roof nails when applying new or replacement shingles
to a roof
structure.
.. [0003] 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
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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.
100041 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, which
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.
100051 Still further, since the last course of nails typically associated with
an asphalt shingled
roof are exposed to the elements, many building codes typically require that
this last row of
exposed roofing nails be sealed with some type of sealant. Roofers typically
attempt to seal
the exposed roof nails by using caulking to cover such nails. This is
typically messy and an
inefficient process. Almost all asphalt shingles come with a 25 or 50-year
manufacturer's
warranty. Caulking applied to the uncovered nail heads that are exposed to the
elements will
typically degrade and only last a few years. This breakdown in the caulking or
other sealant
also exposes the roof/shingle system to premature leaks and other damage
thereby mandating
that the sealing procedure be repeated to preserve the integrity of the roof
structure. In
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addition, once a tube of caulking is opened, unavoidable exposure of the
contents prevents
reuse of leftover caulking at another job site. As a result, caulking is
wasted and is usually
discarded if not entirely used. As a result, there is likewise a need to
develop a system for
eliminating exposed roof nails, which system would last the life of the new
shingles, match the
colors of the existing shingles, and save time and money if caulking and other
sealants could
be eliminated from the roofing process.
[0006] In view of the foregoing, it will be apparent to those skilled in the
art that a need exists
for both a shingle patch for hail damage repair of asphalt shingles as well as
an integral
nail/disk structure for eliminating exposed roof nails. The present invention
addresses both of
these needs as well as other needs which will become apparent to those skilled
in the art after
reading the present disclosure.
Summary of the Invention
[0007] The present invention is directed to several embodiments of a shingle
patch and an
asphalt emulsion injector system which can be used to repair hail damage and
any other
shingle damage associated with asphalt shingles as well as to an integrated
nail/disk structure
which can be used around dormers, chimneys, the last course of nails on a
shingled roof, and
other places where exposed nail heads would typically exist thereby
eliminating any exposed
roof nails on any shingled roof.
.. [0008] 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
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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.
100091 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 opposite end portion of
the shingle patch
housing the integrated roof nail is then nailed to the damaged shingle thereby
allowing the
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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.
[0010] 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
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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.
100111 In still another aspect of the present invention, an asphalt emulsion
ejector system is
also disclosed for repairing a damaged shingle. In this method, a sealant or
appropriate
emulsion is injected under the damaged shingle so as to cover the area where
the damage
occurred and to likewise seal the bottom of the damaged shingle to the shingle
located
therebelow. The upper surface of the damaged shingle is then filled with a
liquid emulsion to
seal the damaged area located on the top surface of the damaged shingle and
color granules are
placed in the emulsion to match the granules associated with the damaged
shingle. In this
method, no specific shingle patch is utilized.
[0012] In addition, several tools are disclosed which are specifically
designed to raise the
bottom edge of the shingle to be lifted so as to create enough space so as to
slide the present
shingle patch under the raised shingle. One of the disclosed tools also
includes a trowel
portion with optional saw teeth located along one or both opposed side edge
portions thereof
for breaking up the sealed asphalt associated with the already installed
shingle to be lifted.
The trowel portion of this tool can likewise optionally include a heated
portion to facilitate the
break-up of the seal associated with the shingle to be lifted.
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[0013] In still another aspect of the present invention, an integral nail/disk
structure is
disclosed which eliminates the need of having any exposed nails associated
with a shingled
roof. In this aspect of the present invention, a color matching asphalt
shingle disk or other
disk material is integrally formed with a nail structure such that both the
disk and nail are
manufactured together. The body of the disk can take on any shape such as a
round shape, a
rectangular shape, or a square shape made of hail impact resistant shingle
type material or
other material which can include a reinforcing layer. A sealant again can
optionally cover the
underside portion of the disk thereby allowing the disk to permanently seal to
the existing
shingle when the nail/disk structure is nailed into an existing shingle. The
sealant helps to
prevent water from entering under the disk. The nail structure itself may
include a barbed
structure to further improve attachment to the existing shingle.
[0013a] In still another aspect of the present invention, there is provided a
roofing nail
structure comprising: a body member having top and bottom surfaces; a roofing
nail having a
head portion, the head portion of the roofing nail having top and bottom
surfaces and being
incorporated into said body member such that the top surface of the head
portion of the
roofing nail lies flush with the top surface of the body member; and color
granules associated
with at least a portion of the top surface of said body member.
[0013b] In still another aspect of the present invention, there is provided a
nail-disk structure
comprising: a disk having top and bottom surfaces; a roofing nail having a
head portion, the
head portion of said roofing nail having top and bottom surfaces and being
integrally formed
with said disk such that the bottom surface of the head portion of the roofing
nail lies flush
with the bottom surface of the disk; color granules associated with at least a
portion of the top
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surface of said disk; and a sealant covering at least a portion of the bottom
surface of said
disk.
[0014] The present nail/disk structure can be used in all places where an
exposed nail head
would typically exist on a shingled roof. More specifically, this nail/disk
structure would be
used as the last course of nails on a typical shingled roof as well as around
dormers, chimneys
and the like. The present nail/disk structure eliminates the need for caulking
or using other
sealants to cover exposed nail heads and likewise saves time, money and
improves the sealing
capacity associated with the last course of nails in a typical shingled roof.
The present system
and structure will last the life of the new roof shingles; it will match the
colors associated with
.. a typical roof; and it eliminates exposed nail heads.
[0015] 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, and the integrated integral nail/disk structure provides a
weather-proof
roofing nail seal combination that prevents corrosion of nail heads due to
exposure to the
elements and also provides leak protection and eliminates exposed roofing
nails.
[0016] 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.
Brief Description of the Drawings
[0017] Fig. 1 is a top planform view of one embodiment of the present shingle
patch
constructed in accordance with the teachings of the present invention.
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[0018] Fig. 2 is a side elevational view of the shingle patch of Fig. 1.
[0019] Fig. 3 is a side elevational view of a typical shingled roof showing
the overlaying
pattern arrangement of shingles before the present shingle patch is applied
for repair.
[0020] Fig. 4 is a side elevational view similar to Fig. 3 showing the present
shingle patch of
Figs. 1 and 2 in exploded view prior to insertion for repair.
[0021] Fig. 5 is a side elevational view similar to Fig. 4 showing the present
shingle patch of
Figs. 1 and 2 positioned and attached to the existing roof structure and
overlaying the damaged
shingle.
[0022] Fig. 6 is a side elevational view of another embodiment of the present
shingle patch
constructed in accordance with the teachings of the present invention.
[0023] Fig. 7 is a perspective view of another aspect of the present invention
illustrating one
embodiment of the present nail/disk structure for eliminating exposed nail
heads constructed
in accordance with the teachings of the present invention.
[0024] Fig. 7A is a perspective view similar to Fig. 7 showing the nail head
incorporated into
the body member of the nail/disk structure of Fig. 7.
[0025] Fig. 8 is a side elevational view of the nail/disk structure
illustrated in Fig. 7.
[0026] Fig. 8A is a side elevational view similar to Fig. 8 showing the nail
head incorporated
into the body member of the nail/disk structure of Fig. 8.
[0027] Fig. 8B is a side elevational view similar to Fig. 8A showing another
embodiment of
the nail head incorporated into the body member of the present nail/disk
structure.
[0028] Fig. 8C is a side elevational view similar to Figs. 8A and 8B showing
still another
embodiment of the nail head incorporated into the body member of the present
nail disk
structure.
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[0029] Fig. 9 is a perspective view of one embodiment of a tool that is
specifically designed to
raise the bottom edge of a shingle to create enough space to slide the present
shingle patch
thereunder.
[0030] Fig. 10 is a top plan view of another embodiment of a tool for breaking
the seal of an
already installed asphalt shingle without damaging the shingle, the tool
likewise functioning to
further lift the bottom edge of a shingle to create space for sliding the
present shingle patch
thereunder.
[0031] Fig. 11 is a representative schematic view illustrating another method
for repairing a
damaged shingle.
Detailed Description of the Invention
[0032] 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.
[0033] Referring to the drawings more particularly by reference numbers
wherein like
numbers refer to like parts, the number 10 in Figs. 1 and 2 refers to one
embodiment of a
shingle patch used to repair damaged asphalt shingles constructed in
accordance with the
teachings of the present application. The shingle patch 10 includes a base
member 12 sized
and shaped similarly to a conventional asphalt shingle or smaller depending
upon the
particular application, one end portion which includes a notched portion 14
which is
specifically shaped and designed for sliding under an existing shingle, such
as the shingle
CA 3017882 2018-09-18
located immediately above the damaged shingle, as will be hereinafter further
explained. The
notched portion 14 of base member 12 includes an overall height or thickness
which is less
than the overall height or thickness of the remainder of base member 12 as
clearly illustrated
in Fig. 2. The notched portion 14 is sized so as to be inserted under an
existing shingle located
immediately above the damaged shingle such that at least a portion of the
existing shingle will
mate with and rest on top of notched portion 14. Notched portion 14 is thinner
than the
remainder of base member 12 to likewise avoid creating a hump under the
existing shingle
when it is overlaid on top of notched portion 14. A wall or ledge portion 16
(Fig. 2) is formed
between notched portion 14 and the remainder of base member 12 and functions
as a stop or
abutment surface for the existing shingle when overlaid on top of notched
portion 14 thereby
limiting the travel of the existing shingle when the notched portion 14 is
inserted under the
existing shingle. This arrangement also helps to prevent rain water from
infiltrating under the
patch 10. The overall length L of notched portion 14 can be varied depending
upon the
particular application and depending upon the particular size and style of
asphalt shingles to be
repaired.
[0034] 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 Fig. 2 for mating
with and attaching to
the undersurface of the existing shingle when the existing shingle is overlaid
on top of notched
portion 14. The sealant 18 is preferably a heat activated sealant which can be
factory applied
.. and is typically activated by the sun, although other heat sources can be
applied to the notched
portion 14 to activate the sealant material. Preferably, the sealant 18 covers
the entire upper
surface of the notched portion 14. A cellophane tape or other release material
19 can be
placed over the sealant 18 so as to prevent the sealant from binding to any
other material or
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object during shipment and storage. The tape 19 is removed prior to installing
the shingle
patch 10 as will be hereinafter further explained.
[0035] 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.
[0036] A sealant 26 is likewise associated with at least a portion of the
bottom surface 24 of
base member 12 as best illustrated in Fig. 2. Similar to sealant 18, sealant
26 is preferably a
heat activated sealant and is likewise preferably factory applied and is
typically activated by
the sun. Here again, sealant 26 preferably covers the entire bottom surface 24
of base member
12. A cellophane tape or other material 27 is likewise placed over sealant 26
so as to again
prevent the sealant from binding to any other material or object during
shipment and storage.
The tape 27 is removed prior to installing the shingle patch 10 over a damaged
shingle as will
be hereinafter further explained.
[0037] 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
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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.
[0038] Fig. 3 illustrates a typical asphalt shingled roof wherein the
underlying roof structure
30 is typically plywood or some other wood product. Typical asphalt shingles
32, 34, 36, 38
and 40 are overlaid in a typical overlapping pattern as illustrated in Fig. 3.
Assuming that
asphalt shingle 36 is damaged by hail or any other weather event, Figs. 4 and
5 illustrate the
method for repairing damaged asphalt shingle 36 using the present shingle
patch 10. Repair
will typically begin as illustrated in Fig. 4 where a technician will lift the
bottom edge of the
shingle that lies immediately above the damaged shingle. As illustrated in
Fig. 4, the bottom
edge of shingle 34 lies just one row above the damaged shingle 36. Lifting of
the bottom edge
of shingle 34 can be accomplished with known tools in the trade or with the
tools illustrated in
Figs. 9 and 10 as will be hereafter further explained. Once the bottom edge of
shingle 34 is
lifted as illustrated, the technician will remove the release tape 19 and 27
associated with
notched portion 14 and the bottom surface 24 of base member 12 respectively
and then slide
notched portion 14 of base member 12 under the raised portion of shingle 34.
The raised
shingle portion of shingle 34 is then lowered onto notched portion 14 and the
heat activated or
other sealant 18 associated therewith. As stated, prior to inserting notched
portion 14 under
the raised shingle 34, the release tape 27 associated with the bottom portion
24 of shingle
.. patch 10 is likewise removed prior to installation.
[0039] 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 Fig. 5. Once nailed, the
undersurface of base
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member 12 is sealed directly to the damaged shingle 36 via the sealant 26
located across its
bottom surface. Once completed, the shingle patch 10 will overlay the damaged
shingle 36 as
illustrated in Fig. 5 and the colored granules associated with the top surface
of base member
12 will match the color scheme of the other shingles 32, 34, 36, 38 and 40
associated with the
.. roof structure. The heat activated sealant 18 and 26 will bind to their
respective mating
surfaces by the heat generated from the sun if a heat activated sealant is
used. Other heat
sources can be used to immediately activate the sealant 18 and 26 if so
desired. This could
include using heat blowers, or using a different type of sealant. Since the
damaged shingle 36
remains in place, the present shingle patch 10 provides an extra layer of
protection since the
damaged shingle 36 still provides some protection to the roof structure.
Depending upon the
size of the damaged area associated with shingle 36, shingle patch 10 can be
sized and
dimensioned so as to adequately overlay the damaged area of shingle 36. In
this regard,
shingle patch 10 can merely cover a portion of shingle 36 or, in other
embodiments, it can
cover substantially all of shingle 36 if so desired. Shingle patch 10 can be
made according to
any dimensions up to and including covering the entire damaged asphalt
shingle.
[0040] Fig. 6 illustrates another embodiment 42 of the present shingle patch,
namely, shingle
patch 42. Patch 42 includes as a base member 44 again having a notched portion
46
associated with one end portion thereof which is constructed substantially
similar to notched
portion 14 associated with shingle patch 10 including having a sealant 48
covering at least a
portion of the upper surface of notched portion 46 and likewise including an
abutment
surface, ledge or stop portion 50 for positioning and overlaying the existing
adjacent shingle
which will be positioned on top of notched portion 46 as previously explained.
Shingle patch
42 likewise includes colored granules (not shown) embedded into its top
surface to match the
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color scheme of the roof shingles to be repaired, and a sealant 54 covering at
least a portion of
the bottom surface 52 of base member 44 similar to sealant 26 associated with
shingle patch
10.
[0041] 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 Fig. 6 so
that a standard roofing nail 62 can be nailed through the mating surface 60 of
base member 44
into the underlying damaged shingle as will be hereinafter explained. The flap
portion 58
includes a sealant 64 associated with its inner surface 65 and its mating base
portion 60 can
likewise optionally include a sealant 64 as well for mating with and sealing
with flap portion
58. Both flap surfaces 65 and 60 covered with a sealant 64 are likewise
covered with a
cellophane tape or other release tape 66 so as to prevent these mating
surfaces from bonding
together until required. Again, sealant 64 can be a heat activated sealant.
Flap portion 58
should be sufficiently large enough so as to allow a roofing technician to
hammer a
conventional roofing nail through base member mating surface 60 and end
portion 56 so as to
complete the attachment of shingle patch 42 to the damaged shingle.
[0042] 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 Figs.
3-5. In this regard,
the notched portion 46 of shingle patch 42 is again inserted under an existing
shingle located
immediately above the damaged shingle as discussed above with respect to
shingle patch 10.
Here again, the release tape 49 covering sealant 48 is removed prior to
insertion under the
existing shingle. In similar fashion, the release tape 55 associated with
sealant 54 is likewise
removed prior to insertion of the notched portion 46 under the existing
shingle located
CA 3017882 2018-09-18
immediately above the damaged shingle to be repaired. Once the notched portion
46 is
properly positioned, shingle patch 42 is lowered and positioned so as to
overlay the damaged
area of the damaged shingle and the sealant 54 associated with the bottom
surface 52 of
shingle patch 42 is then allowed to seal directly to the damaged shingle via
the sealant 54 as
previously explained. At this point, the flap portion 58 is lifted, the
release tape 66 associated
with both sealant surfaces 64 is removed and a standard roofing nail 62 is
then nailed through
the mating surface 60 of base member 44 and through the damaged shingle
located below.
Once the standard roofing nail 62 is hammered into place, the flap portion 58
is lowered and
the sealant 64 associated with flap portion 58 and/or mating surface 60 are
allowed to bond as
previously explained.
[0043] 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 Figs. 3-5 except for using a standard roofing nail
62 as explained
above. Like shingle patch 10, shingle patch 42 can be sized and dimensioned as
previously
explained and depending upon the particular application.
[0044] Figs. 9 and 10 disclose tools that can be used to easily lift the
bottom edge of a shingle
for sliding the notched portion 14 or 46 under the lifted shingle edge
portion. Tool 82
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illustrated in Fig. 9 is L-shaped in configuration and includes tool portions
84 and 86. Tool
portion 86 is used as a wedging member for sliding under the bottom edge
portion of a shingle
and may include a tapered edge portion 88 to facilitate the insertion process.
This tool is
specifically designed to raise the bottom edge of the shingle to create enough
of a space to
slide the shingle patch 10 or 42 under the raised shingle. This is
accomplished by lining up
tool 82 with the bottom of the shingle edge such that tool portion 86 and
tapered portion 88
abut the bottom edge of the shingle. A hammer can be used to hit the tool
carefully to force
the tool portion 86 under the lap of the shingle. The length or depth of tool
portion 86 need
only be as long as the overall Length of the notched portion 14 or 46. Once
tool portion 86 is
positioned under the shingle edge portion, a prying force can be exerted
against tool portion 84
to lift the bottom edge of the shingle.
[0045] Tool 90 illustrated in Fig. 10 can be used to beak the seal of an
already installed
asphalt shingle without damaging the shingle. The tool 90 is a trowel shaped
tool having a
handle 92 and a trowel portion 94. The trowel portion 94 may include saw teeth
or a serrated
edge portion 96 located along one or both opposed edge portions as illustrated
in Fig. 10 to
help break up the sealed asphalt as the trowel portion 94 is inserted under
the bottom edge of a
shingle. In addition, trowel portion 94 may also be heated to further improve
and facilitate the
break-up of the seal associated with the shingle to be lifted. Heat can be
provided to trowel
portion 94 in a conventional manner such as the method used in an iron or
curling iron. Tool
90 could also be used to life the bottom edge of a shingle to be raised once
the seal has been
broken or tool 82 could be used after tool 90, if necessary.
[0046] Fig. 11 illustrates still another method for repairing a damaged
shingle, namely, an
asphalt emulsion injection system 98.
This method includes injecting a sealant or
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emulsion/adhesive underneath the damaged shingle and then sealing the top
damaged surface
of the shingle with an emulsion and applying colored granules into the
emulsion to match the
color of the damaged shingle. In one aspect of the system 98, a small hole is
made in the
center of the hale impacted or damaged area of the shingle such as hole 100
illustrated in Fig.
11. A sealant is then injected or pumped under the damaged shingle through the
use of a tube
102 and an applicator device 104. The applicator device can be any known
device capable of
pumping, pushing and/or moving a liquid asphalt emulsion/adhesive or any other
appropriate
sealant from the device 104 through the tube 102 and through the hole 100 made
in the
damaged shingle to the area located under the damaged shingle. In this regard,
the terminal
.. end of the tube 102 is inserted into the hole 100 such that the sealant
pumped therethrough
will spread underneath shingle around the area where the damage occurred. The
sealant then
seals and glues the bottom of the damaged shingle to the shingle located
therebelow and seals
the space therebetween. The hole and upper face of the damaged shingle is then
filled with a
liquid emulsion to seal the hole and the upper damaged shingle area and
colored granules are
then placed in the emulsion to match the granules associated with the damaged
shingle. The
applicator device can be as simple as a caulking gun where the tube 102 would
be the nozzle
associated with an adhesive, sealant or emulsion container.
[0047] In another aspect of the asphalt emulsion ejector system 98, tube 102
can be
manipulated under the damaged shingle by using any one of the tools 82, 90 or
any other
suitable tool and the liquid emulsion can again be pumped or moved under the
damaged
shingle and around the damaged area to again seal the bottom of the damaged
shingle to the
shingle located therebelow. In this aspect of system 98, no hole 100 need be
made through the
damaged shingle. Once a sealant is pumped under the damaged area, the damaged
upper face
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of the shingle is filled with an emulsion to seal the damaged area and colored
granules are
again placed in the emulsion to match the granules associated with the damaged
shingle.
Either method of system 98 will adequately seal and repair the damaged
shingle.
[0048] Figs. 7 and 7A are perspective views of still another aspect of the
present invention
illustrating one embodiment 70 of a one-piece nail/disk structure for
eliminating exposed nail
heads associated with a typical asphalt shingled roof Figs. 8 and 8A
illustrate side elevational
views of the nail/disk structure 70 of Figs. 7 and 7A and includes a color
matching disk or
body member 72 which is integrally formed with a roofing nail 74 such that
both the disk 72
and the nail 74 are manufactured together. The body of the disk 72 can be made
from an
asphalt shingle and it can take on any shape including, but not limited to, a
round shape, a
rectangular shape, or a square shape. The disk 72 can also be made of a hail
impact resistant
shingle type material which can include a reinforcing layer (not shown), or
any other suitable
material. The top portion 76 of disk 72 includes colored granules embedded
into its top
surface so as to match the color scheme of the particular asphalt shingles
being used for a
.. particular application. In this regard, the disk 72 can be made from a
different material other
than asphalt and the color granules 76 can be applied and attached thereto in
any conventional
manner. In another embodiment, disk 72 and color granules 76 can be one
unitary structure
formed from a color matching asphalt shingle itself Either way, the disk
portion 72 is color
coordinated to the asphalt shingles to which it will be applied.
[0049] More particularly, Figs. 7A and 8A show the one-piece nail/disk
structure 70 as well as
the nail 74 which is incorporated or encapsulated into the body member 72. As
clearly shown
in Figs. 7A and 8A, the nail 74 includes a body or shank portion 75A and a
head portion 75B.
As clearly illustrated in Fig. 8A, the head portion 75B of nail 74 is
completely incorporated
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CA 3017882 2018-09-18
into or encapsulated within the body member 72 of the one-piece integral roof
nail/disk
structure 70 such that the head portion 75B of the nail 74 lies between the
top and bottom
surfaces of the body member 72. This is clearly shown in Fig. 8A. It is also
recognized and
anticipated that the nail head 75B can likewise lie equal to or flush with the
top surface of the
body member 72 such that it again lies within the body member 72 and extends
below the top
surface of the body member 72 as illustrated in Fig. 8B. In similar fashion,
it is recognized
and anticipated that the nail head 75B can likewise lie equal to or flush with
the bottom
surface of the body member 72 such that it again lies within the body member
72 and extends
above the bottom surface of the body member 72 as illustrated in Fig. 8C. The
nail/disk
structure 70 is a one-piece integrally formed structure such that the nail 74
and the disk or
body member 72 are one structure. The dotted outline of head portion 75B in
Figs. 7A, 8A,
8B and 8C illustrate the position and location of the nail head within the
body member 72
when the nail 74 is incorporated or encapsulated into the disk or body member
72.
[0050] A sealant 78 can optionally cover the underside portion of disk 72 as
best illustrated in
Figs. 8 and 8A thereby allowing the disk to permanently seal to the existing
shingle when the
present nail/disk structure 70 is nailed into an existing shingle. The sealant
can be a heat
activated sealant which is preferably activated by the sun although other heat
sources can be
used to bond the disk 72 to an existing shingle. Other adhesives can likewise
be used in place
of sealant 78. Regardless, the sealant 78 or other adhesive helps to prevent
water from
entering under the disk surface. The nail structure 74 may include a barbed
structure 80 to
further improve attachment to the existing shingle.
[0051] The present nail/disk structure 70 represents an improvement over the
structures
disclosed in Applicant's U.S. Patent No. 9,206,835 as well as the other known
structures
CA 3017882 2018-09-18
disclosed in the prior art. The present structure 70 is a one-piece structure
which can be used
in all places where an exposed nail head would typically exist on a shingle
roof. This could
include use as the last course of nails on a typical shingled roof at the apex
of the roof, at
edges abutting dormers and chimneys, and at other places where an exposed nail
head would
occur. The present nail/disk structure 70 eliminates the need for caulking or
using other
sealants, adhesives or granules to cover exposed nail heads such as the
exposed nail heads
disclosed in U.S. Patent No. 9,206,835, and its use saves time, money and
improves the
sealing capacity associated with exposed nails in a typical shingled roof. A
roofing technician
would carry a plurality of the nail/disk structures 70 along with typical
roofing nails and
would use the present structure 70 at all locations where the roofing nail
will not be covered
by another shingle. The present system and structure would be compatible with
the life of
new roof shingles; it will match the colors associated with a particular roof;
and it eliminates
exposed nail heads.
[0052] A cellophane tape or other release tape 81 can be placed over the
sealant 78 so as to
prevent the sealant from binding to any other material during shipment and
storage. The roof
technician would have to remove the release tape prior to nailing the present
structure 70 into
an asphalt shingle. The present one-piece structure 70 provides a water-proof
roofing nail seal
combination that prevents corrosion of nail heads due to exposure to the
elements and also
provides leak protection since the disk or body member 72 substantially
overlays and overlaps
the hole formed in the existing shingle through which the nail 74 is hammered.
In addition,
the sealant 78 likewise provides additional leak protection if used. If a
sealant is used, the
sealant causes the disk 72 to permanently seal to the existing shingle and
further prevents
water from entering under the disk 72. There are no exposed nail heads
associated with the
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CA 3017882 2018-09-18
integral nail/disk member 70 since the nail head 75B is incorporated into or
encapsulated
within the disk or body member 72. Other advantages and features of the
present nail/disk
structure 70 will be apparent to those skilled in the art.
[0053] 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.
[0054] 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
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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.
[0055] Thus, there has been shown and described several embodiments of a novel
shingle
patch for damage repair of asphalt shingles as well as an integral nail/disk
structure for
eliminating exposed roofing nails. 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.
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