Patent Abstract:
A tool and method for installing and/or removing fasteners in areas where access is limited. In one embodiment, the tool has a fastener engagement portion toward a first end, a fastener removal portion toward a second end, and an impact surface positioned between the fastener engagement and fastener removal portions. The fastener engagement portion is configured to releasably engage a fastener, and is offset from the impact surface to facilitate positioning a fastener in a confirmed space. The impact surface is configured to remain accessible once the fastener has been properly positioned for installation. A user can strike the impact surface to drive the fastener into a workpiece. The fastener removal portion is configured to engage an installed fastener to extract the installed fastener from the workpiece.

Full Description:
TECHNICAL FIELD 
     The present invention relates to a hand-held tool for installing and/or removing a fastener, and more particularly, to a hand-held tool for installing and/or removing a fastener when access to the fastener is limited, for example, when replacing a roofing shingle that may be positioned underneath another shingle. 
     BACKGROUND 
     The roofs of houses and other buildings are commonly covered with various types of overlapping shingles to protect the underlying structure from direct exposure to the elements. These shingles are installed in rows, starting at the lower edge of the roof and moving upward. Accordingly, each succeeding row of shingles partially overlaps the prior row and completely covers the fasteners that attach the prior row to the roof substructure. 
     Conventional roofing shingle materials include wood, slate, metal, tile, fiberglass and asphalt. Asphalt shingles represent the most widely used form of residential roofing and cover four out of every five homes in the United States today. Asphalt shingles are typically made from an organic or fiberglass base that is saturated with an asphalt coating and surfaced with weather resistant mineral granules. Accordingly, asphalt shingles are typically durable, versatile and economical. Furthermore, asphalt shingles are generally pliant when new, making them easy to install. Over time, however, the effects of aging and exposure to the sun harden asphalt shingles to the point that even modest flexing can cause the shingles to break or permanently deform. 
     Asphalt shingle roofs can last up to 20 years before replacement, and damage to individual shingles during this time (for example, due to high winds or human traffic) is not uncommon. A widespread problem faced by roofing contractors is to replace an individual damaged shingle without damaging the overlapping undamaged shingle in the process. 
     One conventional method for replacing shingles includes sliding a flat-bladed shovel-like device under the damaged shingle to pry loose the fasteners attaching the damaged shingle to the roof substructure. Unlike a conventional claw hammer, the flat-bladed device can access the fasteners without bending the overlapping undamaged shingle to the point that the undamaged shingle breaks. 
     Once the fasteners have been removed, the damaged shingle may be slipped out from under the overlapping undamaged shingle and a replacement shingle slipped in underneath the overlapping shingle. At this point, the contractor must generally use to a conventional hammer to install the fasteners in the replacement shingle. Because it is desirable to cover the installed fasteners with the overlapping undamaged shingle, installation requires positioning the fastener on the replacement shingle while simultaneously bending the overlapping undamaged shingle far enough back to allow the contractor to strike the fastener with the hammer. Bending the undamaged shingle in this manner often breaks the undamaged shingle, forcing the user to repeat the entire process for two damaged shingles instead of just one. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to methods and apparatuses for installing and/or removing fasteners. In one aspect of the invention, the apparatus can include a tool body with a fastener engagement portion toward a first end, a fastener removal portion toward a second end, and an impact surface located between the two ends. The fastener engagement portion can be offset from the impact surface in two directions and can have at least one fastener contact surface that is offset from and at least approximately parallel to the impact surface. The fastener engagement portion can be configured to releasably engage a fastener to install the fastener in a workpiece when a force is applied to the impact surface of the body. The fastener removal portion can also be offset from the impact surface in two directions, and can be configured to releasably engage an installed fastener to remove the fastener from a workpiece when a force is applied to the body. 
     In one aspect of the invention, the fastener engagement portion can further include first and second fastener guide surfaces. The first and second guide surfaces can be in a common plane and can be spaced apart from the fastener contact surface by a first gap distance sized to removably receive the head of a fastener. The first and second fastener guide surfaces also being spaced apart from each other by a second gap distance sized to removably receive the shank of the fastener. In a further aspect of the invention, the fastener removal portion can have first and second fingers extending away from the impact surface. The first finger of the fastener removal portion can include a first interior edge and the second finger can further include a second interior edge. The first and second interior edges can be in a common plane and can define a tapering gap that is sized to removably receive the shank of an installed fastener. In a still further aspect of the invention, the fastener removal portion toward the second end can be replaced with a scraper portion, a G-shaped pry-hook portion, or another fastener engagement portion, or the fastener removal portion can be eliminated. 
     In another aspect of the invention, a method for removing a fastener from a workpiece can include engaging a fastener between a first and second finger of an offset fastener removal portion of a fastener handling tool and applying a force to the tool body to remove the fastener from the workpiece. In a further aspect of the invention, the method can include engaging a fastener with an offset fastener engagement portion of a fastener handling tool inserting the offset fastener engagement portion into a confirmed space, positioning the engaged fastener on the workpiece, exposing an impact surface of the tool, and impacting the impact surface to drive the fastener into the workpiece. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a rear isometric view of a fastener installation and removal tool positioned to install a fastener in a replacement roofing shingle that is located underneath an installed shingle in accordance with an embodiment of the invention. 
     FIG. 2 is an enlarged rear isometric view of the fastener installation and removal tool shown in FIG. 1 positioned to remove a fastener from a damaged shingle that is located underneath an installed shingle. 
     FIG. 3 is an enlarged front isometric view of a fastener engagement portion of the tool and fastener shown in FIG.  1 . 
     FIG. 4 is an enlarged side elevation view of the fastener engagement portion of the tool and fastener shown in FIG.  1 . 
     FIG. 5 is an enlarged front elevation view of the fastener engagement portion of the tool and fastener shown in FIG.  1 . 
     FIGS. 6A,  6 B,  6 C and  6 D are isometric views of fastener installation tools having tool devices in accordance with other embodiments of the invention. 
     FIG. 7 is an isometric view of a fastener installation and removal tool having a non-offset impact surface in accordance with another embodiment of the invention. 
     FIG. 8 is an isometric view of a fastener installation and removal tool positioned to install a fastener in a replacement roofing shingle that is located underneath an installed shingle in accordance with yet another embodiment of the invention. 
     FIG. 9 is an isometric view of a fastener installation and removal tool having coupled portions in accordance with still another embodiment of the invention. 
    
    
     DETAILED DESCRIPTION 
     An apparatus and method for installing and/or removing fasteners is described herein. One embodiment of the invention includes a tool and method for installing fasteners in a replacement roofing shingle without damaging the previously installed overlapping shingle. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1-9 to provide a thorough understanding of such embodiments. One of ordinary skill in the art, however, will understand that the present invention may have additional embodiments, or that the invention may be practiced without several of the details described in the following description. 
     FIG. 1 is a rear isometric view of a hand-held fastener installation and removal tool  101  positioned to install a new fastener  140   a  in a workpiece, such as a replacement shingle  180 , without damaging a previously installed shingle  181 . The tool  101  can also be used to remove fasteners and damaged shingles from beneath the previously installed shingle  181  without damaging the previously installed shingle  181 . Accordingly, in one embodiment, the installation and removal tool  101  has a fastener engagement portion  110  toward a first end  150 , and a fastener removal portion  120  toward a second end  160 . An impact surface  130  is located between the fastener engagement portion  110  and the fastener removal portion  120 . As shown in FIG. 1, the fastener engagement portion  110  is offset from the impact surface  130  in a first direction  151  and in a second direction  152  transverse to the first direction  151 . Similarly, the fastener removal portion  120  is offset from the impact surface  130  in the second direction  152  and in a third direction  161  transverse to the second direction  152 . The impact surface  130  of the tool  101  is shaped to be struck with a conventional hammer  184  or other tool to provide the impact required to drive the fastener  140   a  through the replacement shingle  180  and into a roof substructure  183 . In one embodiment, the tool  101  can include a handle portion  102  between the impact surface  130  and the second end  160  for grasping and maneuvering the tool  101 . 
     In one embodiment, the tool  101  may be cast in steel and finish machined. In other embodiments, the tool  101  may be forged or machined from steel. In still further embodiments, the tool  101  can include materials other than steel having suitable strength and stiffness. 
     FIG. 2 is an enlarged rear isometric view of the tool  101  with the fastener removal portion  120  positioned to remove an installed fastener  140   b  from a workpiece such as a damaged shingle  182 . In one embodiment, the fastener removal portion  120  has a first finger  210  and a second finger  220  that both extend generally away from the impact surface  130  in the third direction  161 . The first finger  210  has a downwardly facing first heel surface  213  and a first interior surface  211  that are connected by a first interior edge  212 . The second finger  220  has a downwardly facing second heel surface  223  and a second interior surface  221  connected by a second interior edge  222 . As shown in FIG. 2, the first and second interior edges  212  and  222  define a tapering gap  201 . In one embodiment, the gap  201  tapers by an angle of from about 10 to about 30 degrees, and in another embodiment, the taper angle is about 14.25 degrees. In other embodiments, the gap  201  can taper by angles having other values. 
     In one embodiment, the gap  201  of the tool  101  is configured to releasably engage the installed fastener  140   b  and extract the fastener  140   b  from a damaged shingle  182  mounted to the roof substructure  183 . In one aspect of this embodiment, the fastener removal portion  120  of the tool  101  has a relatively low profile that projects by only a limited amount above the damaged shingle  182 . Accordingly, the installed fastener  140   b  can be removed by inserting the fastener removal portion  120  beneath the installed shingle  181  without bending the installed shingle  181  to the point of breaking. In another aspect of this embodiment, the user can produce an upward force on the head of the fastener  140   b  by applying a downward force to the impact surface  130  or the fastener engagement portion  110  of the tool  101  while the fingers  210  and  220  are engaged with the head of the fastener  140   b  to pivot the tool  101  about the first and second heel surfaces  213  and  223 . This upward force extracts the fastener  140   b  from the damaged shingle  182  and the roof substructure  183 . Alternatively, other tools may be used to extract the fastener  140   b  from the damaged shingle  182 . In either embodiment, the damaged shingle  182  can then be removed and the replacement shingle  180  can be installed without breaking the previously installed shingle  181  by using the fastener engagement portion  110 . 
     FIG. 3 is a front isometric view of the fastener engagement portion  110  of the tool  101  and the fastener  140   a , positioned above the replacement shingle  180 . FIG. 4 is a side elevation view and FIG. 5 is a front elevation view of the fastener engagement portion  110  and the fastener  140   a  shown in FIG.  3 . Referring to FIGS. 3,  4 , and  5 , the fastener engagement portion  110  has a first fastener contact surface  301  and a second fastener contact surface  390  that are offset from and at least approximately parallel to the impact surface  130 . The first fastener contact surface  301  can be offset from the impact surface  130  by a first distance  354  in the first direction  151 , and by a second distance  353  in the second direction  152  (FIGS.  3  and  4 ). In one embodiment, the first distance  354  can be between 0.5 and 5.0 inches, and the second distance  353  can be between 0.5 and 3.0 inches. In another embodiment, the second distance  353  can be about 1.64 inches. In other embodiments, the distances  353  and  354  can have other values that allow the tool to be operated in the manner described below. 
     The fastener engagement portion  110  also has a first fastener guide member  370  and a second fastener guide member  380  (FIGS.  3  and  5 ). The first fastener guide member  370  has a first fastener guide surface  310  and a first fastener alignment surface  320 . The second fastener guide member  380  has a second fastener guide surface  330  and second fastener alignment surface  340 . The first and second guide surfaces  310  and  330  are in a common plane and are spaced apart from the fastener contact surface  301  by a first gap distance  401  (FIGS. 4 and 5) to define a head slot  350  sized to accommodate a head  341  of the fastener  140   a . In one embodiment, the gap distance  401  can be about 0.10 inches, and in other embodiments, the distance can have other values that accommodate the head  341 . The first and second fastener alignment surfaces  320  and  340  oppose each other and are spaced apart by a second gap distance  501  (FIG. 5) to define a shank slot  360  sized to accommodate a shank  342  of the fastener  140   a . In one embodiment, the second gap distance  501  can be about 0.184 inches, and in other embodiments, the distance can have other values that accommodate the shank  342 . Accordingly, the head slot  350  is offset from and generally parallel with the impact surface  130 . The shank slot  360  intersects the head slot  350  and is transverse to the impact surface  130 . 
     Referring now to FIG. 3, the fastener engagement portion  110  of the tool  101  is configured to releasably engage the fastener  140   a  so that it may be driven into the replacement shingle  180  when the impact surface  130  is struck with a conventional hammer or a similar tool. In one embodiment, the fastener  140   a  is engaged with the fastener engagement portion  110  by removably positioning the shank  342  of the fastener  140   a  between the first fastener alignment surface  320  and the second fastener alignment surface  340 , and by removably positioning the head  341  of the fastener  140   a  between the fastener contact surface  301  and the first and second guide surfaces  310  and  330 . In an alternate embodiment, the surfaces  301  or  390  may also be magnetized to releasably engage the fastener  140   a  prior to installation. In either embodiment, when the user strikes the impact surface  130  with a conventional hammer or a similar tool, the fastener contact surface  301  drives the fastener into the replacement shingle  180 . After the user drives the fastener  140   a  part-way into the replacement shingle  180  (or completely through the replacement shingle  180  and part-way into the roof substructure  183 ), the user retracts the fastener engagement portion  110  to disengage it from the fastener  140   a , and then repositions the fastener engagement portion  110  so that the second fastener contact surface  390  is in contact with the head  341  of the fastener  140   a . The user then strikes the impact surface  130  with the hammer to drive the fastener  140   a  the rest of the way into the roof substructure  183 , so that the head  341  of the fastener  140   a  is now flush with the upper surface of the replacement shingle  180 . 
     In one embodiment of the invention, the user can operate the fastener installation and removal tool  101  to replace a damaged asphalt roofing shingle without damaging the previously installed overlapping shingle  181  in the process. For example, the user can remove the fastener  140   b  attaching the damaged shingle  182  to the roof substructure  183  by using the fastener removal portion  120  of the tool  101  (FIG.  2 ). The user can then slide the replacement shingle  180  into position underneath the overlapping shingle  181 , and releasably engage the fastener engagement portion  110  of the tool  101  with the new fastener  140   a  (FIG.  3 ). In one aspect of this embodiment, the fastener engagement portion  110  is offset from the impact surface  130 , and has a relatively low profile that projects only a limited amount above the replacement shingle  180 . Accordingly, the overlapping shingle  181  need only be lifted a lifting distance that is slightly more than the height of the fastener  140   a  to create an opening where the fastener engagement portion  110  can be slipped underneath the overlapping shingle  181  to position the new fastener  140   a  in the appropriate location on the replacement shingle  180  (FIG.  1 ). A conventional hammer  184  may then be used to strike the impact surface  130  of the tool  101 . When used in the manner described above, the tool  101  allows the replacement shingle  180  to be installed underneath the overlapping shingle  181  without lifting the overlapping shingle  181  so much that it breaks. 
     In other embodiments, the tool  101  can be used for other applications where access is limited. For example, the tool  101  can be used to install fasteners into a floor covering under an overhanging stair step, where the presence of the step creates a limited opening that makes the use of a conventional hammer alone impractical or awkward. In yet other embodiments, the tool  101  can have other configurations for fastener installation and other applications, as described below with reference to FIGS. 6A-9. 
     FIGS. 6A,  6 B,  6 C, and  6 D illustrate tools having second ends with other configurations in accordance with alternate embodiments of the invention. FIG. 6A is an isometric view of a tool  601  having a G-shaped pry-hook device  610  located toward the second end  160  for removing and/or loosening fasteners, or prying other objects. FIG. 6B is an isometric view of a tool  602  having a shingle remover or scraper  620  toward the second end  160  in accordance with another embodiment of the invention. FIG. 6C is an isometric view of a tool  603  wherein the fastener engagement portion  110  toward the first end  150  is a first fastener engagement portion, and the tool has a second fastener engagement portion  630  toward the second end  160  in accordance with yet another embodiment of the invention. FIG. 6D is an isometric view of a tool  604  in which the second end  160  simply supports the impact surface  130  in an offset position in accordance with still another embodiment of the invention. In other embodiments, the tool can have a second end with other configurations that can complement the function provided by the fastener engagement portion  110 . 
     FIG. 7 is an isometric view of a tool  701  having the fastener engagement portion  110  and the fastener removal portion  120  generally aligned with the impact surface  130  in accordance with another embodiment of the invention. Accordingly, the tool  701  can be easily stored when not in use. Conversely, an advantage of the tool  101  described above with reference to FIG. 1 is that the offset configuration can provide a more convenient impact surface for a hammer or a similar tool. 
     FIG. 8 is a rear isometric view of a tool  801  having an impact surface  830  that extends over the fastener engagement portion  110 . Accordingly, the impact surface  830  can provide a more direct line of action between the fastener  140   a  and the point at which the hammer impacts the tool  801 . An advantage of this feature is that the tool  801  can be easier to hold during use. In another aspect of this embodiment, an upper surface  815  of the fastener engagement portion  110  can include graduation marks  820  to provide a guide for positioning the fastener  140   a  under the overlapping shingle  181 . 
     FIG. 9 is a rear isometric view of a tool  901  that includes three joined parts in accordance with another embodiment of the invention. The tool  901  can include a fastener engagement portion  110  and a fastener removal portion  120  rigidly joined to a handle member  940  with permanent fasteners  950 . Alternatively, the tool  901  can include pivot pins instead of the permanent fasteners  950  so that the fastener engagement portion  110  and the fastener removal portion  120  can fold over the handle portion  940  for easy storage of the tool. 
     From the foregoing it will be appreciated that although specific embodiments of the invention may be described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. The teachings provided herein of the present invention may be applied to fastener installation and removal tools in general, and not only to the exemplary roofing tool described above. Accordingly, the invention is not limited by this disclosure, but instead the scope is to be determined entirely by the following claims.

Technology Classification (CPC): 1