Shingle Repair Patch With Notched Underlayment
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Solution Overview
Problem
Current methods for repairing hail damage to asphalt shingles are labor-intensive and time-consuming, requiring the removal of damaged shingles, which can cause additional damage to surrounding shingles and are not cost-effective, especially when the damage is located in the center of the roof.
Innovation Solution
A shingle patch system that can be overlaid on top of damaged shingles, featuring a base member with a notched portion for sliding under existing shingles and a heat-activated sealant, allowing the patch to be securely attached without removing the damaged shingle, and optionally including integrated nails or colored granules to match the roof's color scheme.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If damaged shingles are removed and replaced using traditional methods, then the damaged shingles can be completely replaced, but the repair process becomes labor-intensive and time-consuming
Solution Approach 1:
The patch is divided into distinct functional components: an adhesive layer for bonding, a reinforcement layer for structural integrity, and a granule layer for weather protection and aesthetic matching. This segmentation allows each layer to be optimized for its specific function while enabling rapid application as a complete unit.
Solution Approach 2:
The patch is pre-manufactured with all necessary layers and components in place, including pre-applied adhesive and embedded granules. This preliminary preparation eliminates the need for on-site mixing, cutting, and multiple application steps, allowing the patch to be installed as a complete repair unit in a single operation.
2Reliability
If damaged shingles are removed and replaced using traditional methods, then the damaged shingles can be completely replaced, but the repair process requires removal or lifting of surrounding shingles
Solution Approach 1:
The invention extracts the need to remove surrounding shingles from the repair process. The patch is designed to be applied directly over the damaged shingle in place, eliminating the requirement to lift or remove adjacent shingles. This is achieved by concentrating all repair functions within a compact patch that adheres to and protects the underlying damaged material.
Solution Approach 2:
The patch replicates the essential protective and aesthetic functions of a complete shingle without requiring actual shingle replacement. It copies the multi-layer structure (adhesive, reinforcement, granules) and applies it in a concentrated form factor that can be installed over the existing damaged shingle, maintaining the roof's protective envelope without disruption to surrounding areas.
3Reliability
If traditional shingle replacement methods are used, then damaged shingles can be replaced, but additional damage may occur to surrounding shingles
Solution Approach 1:
The patch provides beforehand protection by creating a protective barrier over the damaged shingle and its surrounding area. The reinforcement layer distributes stress and the adhesive layer secures the patch firmly, preventing further damage to the damaged shingle and surrounding areas during and after installation. This cushioning effect protects the roof structure from additional harm that might occur during traditional removal and replacement procedures.
4Productivity
If a patch is overlaid on damaged shingles, then repair time is reduced, but the patch must be securely attached without removing the damaged shingle
Solution Approach 1:
The patch employs a composite structure combining an adhesive layer for bonding, a reinforcement layer for structural strength, and a granule layer for protection and aesthetics. This composite material system provides both the secure attachment needed for reliability and the rapid application capability for productivity, as the layers are pre-integrated into a single installable unit.
Solution Approach 2:
Multiple essential functions are merged into a single patch component: the adhesive layer provides bonding, the reinforcement layer provides structural integrity, and the granule layer provides weather protection and aesthetic matching. This merging allows the patch to achieve secure attachment equivalent to full shingle replacement while maintaining the speed and simplicity of a single-step overlay installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The shingle patch system provides a faster, less labor-intensive method for repairing hail damage, offering an additional layer of protection to the roof while maintaining the integrity of the existing shingle structure and matching the roof's color, thus reducing repair time and costs.
Implementation Method 1
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.
Data Source
AI summary
A shingle patch for repairing damaged asphalt shingles including a base member having a notched portion or a thin sheet of material associated with one end thereof for sliding under the existing shingle located immediately above the damaged shingle, a sealant covering at least a portion of the notched portion or thin sheet of material and the bottom surface of the base member for attaching the base member to the damaged shingle, and color granules associated with at least a portion of the top surface of the base member. A nail may be embedded in the base member to further secure the shingle patch to a damaged shingle. An additional two-piece shingle patch is provided wherein the base member is further separated into two separate parts, an upper base member and a lower base member, the lower base member including the notched portion or a thin sheet of material.