Power tool system and method for removing roof shingles

A system and method for removing shingles from a roof with an automatic triggering of power to a fastener engaging member which is accomplished with the aid of relative movement occurring when a leading edge of the system encounters a fastener coupled to a substrate with shingle coupled thereto.

FIELD OF THE INVENTION

The present invention generally relates to power tools for removing roof shingles.

BACKGROUND OF THE INVENTION

In the past, various tools have been used to remove roof shingles. One of such tools is the Rapid Roof Remover, described at www.rapidroofremover.com. This device uses pneumatic pressure to lift the shingles from the roof deck. Another tool is the Shingle Hog described at www.shinglehog.net. This device operates much like the Rapid Roof Remover except it pivots at a different point.

The Rapid Roof Remover, weighs approximately 50 lbs. The Shingle Hog is lighter, but still about 25 lbs. The weight of these tools is a significant factor affecting their use.

While these tools have enjoyed some success and have been used in the past, they are in need of some improvements.

These mechanisms are so heavy that in some situations their weight makes them difficult to maneuver and to carry onto a roof. The weight of such machines above also prevent their effective use on steep-pitched roofs. The weight of these machines above also increases the risk to the roofer of falling off the roof because the forward momentum of the heavy device can pull the roofer forward and off balance should the front teeth fail to engage with the roof.

Additionally, these use relatively little leverage in their powertrains and consequently have relatively large actuators which fill relatively slowly. The operators often have to wait for the machine to work.

In addition, the lack of an automatic trigger mechanism consistently costs time in having to push the button.

These systems are bulky in size. This factor is similar to weight but independently troublesome. Carrying such systems up a ladder to a rooftop without the help of a second person or the use of some other device(s) would often be difficult and dangerous.

These devices can be dangerous owing to stored energy being continuously supplied to the moving parts, especially in situations when debris gets caught in the mechanism. Such energy supplied to the moving parts could injure the operator when they are trying to remove the debris.

Consequently, there exists a need for improved methods and systems for removing shingles from a roof.

SUMMARY OF THE INVENTION

It is an object of one aspect of the present invention to provide a system of reducing the effort expended and time required to remove shingles from a roof.

It is a feature of one aspect of the present invention to utilize in the actuator a relatively small piston, with a quick charging time. Such an actuator, in combination with a powertrain design with mechanical advantage, can provide ample force for removing shingles.

It is an advantage of the present invention to reduce user initial start-up waiting time.

It is an additional feature of the present invention to provide a lightweight and compact device.

It is an additional advantage of this embodiment of the present invention to provide for ease of use and deployment to a roof in a safe manner.

Accordingly, the present invention is a system for removing shingles from a roof, the system comprising:a lower unit150;a lower handle130;a lower handle grip131having a lower handle grip longitudinal axis;a lower handle shaft133having a lower handle shaft longitudinal axis, disposed between and coupled with each of said lower unit150and said lower handle130;an upper handle110;an upper handle grip111having a upper handle grip longitudinal axis;an upper handle shaft113, having an upper handle shaft longitudinal axis, disposed between and coupled to each of said lower handle130and said upper handle110;said lower unit150having a lift plate160and an actuator158;said lower handle shaft longitudinal axis being substantially colinear with respect to said upper handle shaft longitudinal axis;said lower handle grip longitudinal axis and said upper handle grip longitudinal axis being substantially parallel;an actuation device132responsive to contact between said lift plate160and a fastener to be removed; andsaid actuation device132being capable of causing said actuator158to manipulate said lift plate160.

A method of removing shingles from a roof comprising the steps of:providing a power tool for removing shingles100;moving a leading edge of a lift plate160of said power tool for removing shingles100under a shingle and into contact with a fastener extending through a shingle and into a substrate;said power tool for removing shingles100being configured so that said contact automatically causes a powered movement of said lift plate160to provide a force on an underside of a portion of a shingle or a fastener, thereby causing a lifting of said shingle or fastener;removing said leading edge from said contact;terminating lifting of said shingle or fastener; andrepeating said step of moving a leading edge of a lift plate160.

Additionally a system for removing shingles from a roof comprising:a lower unit150;a lower handle130;a lower handle shaft133having a lower handle shaft longitudinal axis; disposed between and coupled with each of said lower unit150and said lower handle130;an upper handle110;an upper handle shaft113, having an upper handle shaft longitudinal axis, disposed between and coupled to each of said lower handle130and said upper handle110;said lower unit150having a lift plate160and an actuator158;an actuation device132responsive to contact between said lift plate160and a fastener to be removed; andsaid actuation device132being capable of causing said actuator158to manipulate said lift plate160when relative movement is detected.

DETAILED DESCRIPTION

Now referring to the drawings wherein like numerals refer to like matter throughout and more particularly referring toFIG.1, there is shown a perspective view of a power tool for removing shingles, generally designated100, and including an upper handle portion110, with upper handle grip111, a lower handle portion130with lower handle grip131a lower handle shaft133, a lift plate160.

Power tool for removing shingles100is shown as a full assembly, where the lower unit150contains power generation and transmission mechanisms used to raise the leading edge of the tool, i.e. the saw tooth portion of lift plate160. Above and to the rear of the lower unit150is lower handle130, this is where the operator holds the power tool for removing shingles100, with one hand. The lower handle130contains the actuation device and the enablement device (both not shown). Above and rearward of the lower handle130is upper handle110.

Now referring toFIG.2, the tool100is used to remove shingle and fastener200from a supporting surface (not shown). One example of this would be a roof covered with shingles which are fastened to the roof deck using nails. To operate the machine100, the operator grasps the tool100by the Lower Handle130and the Upper Handle110and sets the Lower Unit150onto the surface. The operator will then place the leading edge of the lift plate160under the material to be dislodged from the work surface with a sliding motion. While sliding forward, the leading edge of lift plate160will impact one or more fasteners holding the material to the deck. When this occurs, the Lower Unit150will be impeded from further forward movement, but the forward motion of the operator will apply additional pressure on the Lower Handle130and activate the actuation device plunger (FIG.14#1335) in the Lower Handle130. This causes the machinery within the Lower Unit150to raise the leading edge which dislodges the material from the deck. Once the material is dislodged, the leading edge of lift plate160automatically lowers to the starting position and the operator repeats the cycle by sliding the machine forward again into the fastened materials.

One advantage of the present invention over the current state of the art is that the design of the power generation and transmission mechanism is more compact and lightweight. This makes the device100easier to transport to the work surface, which may be on top of a multi-story building. The low weight and compact size also makes the machine100more maneuverable with less energy than the current state of the art.

A second advantage of the present invention over the state of the art is the automatic actuation mechanism. This reduces the time required to operate the machine. From the perspective of the operator, there is no second step required to activate the machine. They simply move the machine into place and the dislodging action occurs without thought or need for further action.

A third advantage to this machine is the additional operator safety provided with the enablement mechanism. The present invention may require the operator to be actively grasping and controlling the machine before it will operate. This prevents accidental triggering of the automatic actuation mechanism when the operator is not presently engaging the controls.

Now referring toFIG.2, there is shown a side view of the power tool for removing shingles100ofFIG.1. The arrow away from the shingle and fastener200shows the direction of motion of the shingle and fastener200as the lift plate160is actuated upwardly.

Now referring toFIG.3, there is shown a lower Unit subassembly150from above. The lower unit frame151, lift plate160and lift plate bracket312can be seen in this view. The Lift Plate Bracket312pivotably orients the Lift Plate160within reach of the drivetrain components by providing the plate arm pivot shaft164for the lift plate bracket312and attached lift plate160to pivot toward and away from the lower unit frame151.

Now referring toFIG.4, there is shown, from below, in addition to some items ofFIGS.1-3, skid plate166and a partial view of the actuator/piston158, which resides within the lower unit frame151. The Skid Plate166is the point of contact that the tool100makes with the work surface and should be made of a material that allows the machine to slide freely upon the work surface.

Now generally referring toFIGS.5-10, and first specifically toFIGS.5,7and9, which represent the power tool for removing shingles100with some parts omitted from view to show the more internal components of the lower unit150while the lift plate160is in the retracted orientation. Next referring specifically toFIGS.6,8and10which depict actuated orientation The Powertrain within the Lower Unit Assembly150are shown with actuator158, piston assembly157, lever arm152, center linkage155, center cam910, driveshaft1162, outside cams163, and outer linkage154(FIG.11). Together, this system generates the force to actuate the lift plate160, multiplies the force to obtain more lifting ability, and redirects the force from a predominately horizontal direction to a mostly vertical direction. The Actuator158could be a pneumatic cylinder in the primary embodiment, but other embodiments could utilize hydraulic cylinders, electric linear actuators, and combustion cylinders. The actuator158is powered in both directions in the primary embodiment and is powered in the direction of actuation but returned to the original position utilizing spring force built into the actuator158.

The geometry of the components and their attachment points to the lower unit frame151combine to provide the mechanical advantage and direction change to the force applied by the actuator158within a compact space. A more thorough understanding of the power tool for removing shingles100can be aided by now referring toFIG.11, which is an exploded view of the drive train components of the lower unit150, note that hoses for transferring working fluids have not been shown in the exploded figures.

Two embodiments are described below in detail with additional embodiments expressed as part of each discussion. These embodiments all operate off of the same fundamental concept explained above where the forward motion of the operator serves to trigger the actuation event when the extraction plate engages with a fastener.

Now referring toFIGS.12and13, which are the left and right side view of the lower handle130ofFIGS.1and2, where some exterior portions are omitted from view to expose underlying otherwise internal details.

The Lower Handle subassembly130and the Upper Handle110provide the operator a place to grasp the device and to control machine enablement and actuation. These subassemblies are connected to the Lower Unit subassembly150using the Lower Handle Shaft133. The Upper handle110is connected to the Lower Handle subassembly130using the Upper Handle Shaft113. The Lower Handle Subassembly130comprises Lower Housing1210, the Upper Housing1212, and the Lower handle130. The Enablement Lever1331is located within the Lower Handle130. The Enablement Device1333is found in the Upper Housing1212the Power Supply Connecter1214can be found within the Upper Handle110. Within the Primary Enablement, the Actuation Device132is housed within the Upper Housing1212, in another embodiment (SeeFIGS.17-22) the Actuation Device132is found within the Lower Housing1210. SeeFIG.2for an external overview of the assembly andFIGS.12and13for illustrations of internal components of the primary embodiment.

Tool100works by the operator grasping the Lower Handle and therefore pulling the distal end of the Enablement Lever1331upward. The proximal end of the Enablement Lever1331rotates around the enablement lever pivot point1335and pushes on the plunger1334to go within the Enablement Device1333which triggers the Enablement Device1333to supply energy to the Actuation Device132. This energizes the system and it is ready for an actuation event.

Note that while the primary embodiment of this machine only optionally includes this enablement functionality, other embodiments of this need not include it. The Primary Embodiment is powered with compressed air, thus the enablement device132is a pneumatic valve. Other Embodiments utilize pressurized liquids, electricity, or combustion events. The Enablement Device1331in such cases is a hydraulic valve, electric switch, and fuel supply valve, respectively.

Actuation is accomplished using the Actuation Device132and the relative motion between the Lower Housing1210and the Upper Housing1212when the operator pushes against the Lower handle and/or the Upper Handle. The operator pushes the machine forward using the Lower Handle130and the Upper Handle110. The machine will slide forward on the Skid Plate166until a fastener contacts the leading edge of the Lift Plate160. The machine will stop moving forward, but the continued forward pressure on the Lower Handle130and the Upper Handle will cause the top edge of the Lower Housing1210and the Upper Housing1212to move towards each other. This motion pushes upon the enablement plunger1334built into the actuation device132, causing it to activate which supplies the compressed air (or pressurized liquid or electricity or combustion gas for hydraulic, electric, or combustion embodiments, respectively) to the drivetrain within the Lower Unit150. For machine embodiments utilizing an Actuator158that is powered in both directions, the Actuation device will supply power to the actuator158in the opposite direction to return the machine to its retracted state. This occurs when the operator stops applying forward push on the handles or when the enablement lever1331is released.

Now referring toFIGS.14and15in the primary embodiment, the motion between the lower housing1210and the upper housing1212is rotational around the pivot point1410where the housings are attached to each other. Other embodiments use linear motion along shafts connecting the housings.

As discussed above, various different types of power sources could be utilized in the present invention depending upon the specific application (e.g. pneumatic, hydraulic, electrical, and/or mechanical). In each of these specific applications, the activation energy is only supplied to the Activation Device132when tool100has been enabled using the enablement device1331. The source of power is provided from the Power Supply Connector to the enablement device1333, then to the actuation device132, and finally to the Lower Unit drivetrain using hoses or wires, which are not pictured in the diagrams for clarity.

The above-described features may be better understood by referring toFIG.16, which is an exploded view of the actuation and enablement features of the present invention. These above-described configurations are believed to possibly be preferred. However, it is understood that the following alternate embodiment could be beneficial in some situations.

1. Other apparatuses could be made to be wider or narrower.

2. They could be made to be more powerful with a bigger piston or with larger lever arms in the drivetrain.

3. They might come up with a different angle or adjustable angle for the leading edge of the tool.

4. They might move the pivot points of the various levers.

5. They might put wheels or rollers on it.

6. They might have the lift plate brackets within a frame.

7. They could change the angle that the handle exits the lower unit.

8. The actuation mechanism could be done in a number of ways.

Now referring toFIG.17, the handle could slide back and forth within the entry point to the lower unit and trigger a switch with the sliding motion. Also inFIG.17is an embodiment where the lower handle slides into the handle assembly and causes activation from the sliding motion. This occurs at17e.

Now referring toFIG.18, it should be understood that there could be a sliding mechanism built into the hinge of the lift plate where the impact of the nail hitting the lift plate fires the tool100using the triggering device at17b.

Now referring toFIG.19, the resting position of the lift plate could be actuated slightly. This would cause the trigger action by compressing the lift plate downward.

Now referring toFIGS.20and21, the automatic triggering could be omitted and a manual trigger could be placed into either one of the handles.

There is shown inFIG.20first Actuation Option d.

Actuation device within a manual trigger.

Alternatively, this manual trigger at17d1or17d2could be used to activate the enablement device and the actuation could occur as discussed with the primary and alternative embodiments discussed above. Shown inFIG.21is a second alternate upper handle embodiment with:

Actuation device within a manual trigger.

The enablement device is activated by this manual trigger within the upper handle.

Now referring toFIG.22, there could be a sliding mechanism in the lower handle assembly instead of the rotating action that this device uses.

The lower handle could pivot without the upper handle shaft having to rotate with it causing the upper housing to slide into the lower housing, causing the plunger on the actuation device to be pressed without the need for rotation.

Actuation Option f Lower handle moves forward without upper handle motion moving forward upon sides built into the upper housing.

It is thought that the method and apparatus of the present invention will be understood from the foregoing description and that it will be apparent that various changes may be made in the form, construct steps and arrangement of the parts and steps thereof without departing from the spirit and scope of the invention or sacrificing all of their material advantages. The form herein described is merely a preferred exemplary embodiment thereof.