The present invention relates to a Roof Snowmelt Cap Plate system which distributes heat in a manner to melt snow accumulation on a rooftop. The herein-disclosed invention further relates to methods of covering and heating the “Valley of a Roof Plane,” the roof position where heated panel endpoints need a concealed cap to house, cover and stabilize a heat cable.
In colder climates, winter typically brings precipitation in the form of snow. Unlike rain, which maintains its fluid nature and seeks the ground when it lands on a structure, snow accumulates on a structure until it melts. Sometimes, this pattern creates problems as rain gutters and downspouts may clog with snow and prevent proper drainage. Typically, this pattern occurs when snow accumulates by the edge of the roof, over or near the gutter, and then freezes into a more solid block of ice. When this phenomenon occurs, snow can melt behind this ice dam and form a pool of water on the roof itself. This will damage the shingle and roof surface and can cause significant damage to a building's roof.
One method of preventing this occurrence is to place heating cables along the roof line. Heating cables are typically a high voltage and high resistance cable which generates heat when activated. This heat melts snow and any ice forming along the roof line and keeps the gutters and area around them clear. Usually, when snow is melted in this fashion, it does not tend to refreeze while it is drained off the roof.
However, these cables are exposed on the roof and are usually deployed in a tight serpentine pattern as air does not conduct heat well and much of the thermal energy generated by the cable is lost as distance from it increases. As they are exposed, they can face potential damage from the elements over the course of a year. As they are tightly serpentine in their deployment, a large length of cable is usually required for a short span of roof. A new apparatus which can not only protect the cable but also lessen the length of cable needed to adequately protect a roof surface would be a benefit to the industry.
The present invention is a plating apparatus which not only secures cables to the roof, but also evenly distributes heat from the cables to a much further distance away from the cable than the cable can conduct alone. As such, less cable is needed for effective snow and ice melting and the cable remains protected throughout the year.
The present invention represents a departure from the prior art in that the system of the present invention provides a plate structure which is easily assembled and installed on a roof which also protects the cables and efficiently distributes heat from said cables in a manner which greatly lessens the length of cable needed to adequately protect a roof.
Regarding the herein-disclosed Valley Cap system, the Valley roof locations require that the Cable be positioned under a plate. As the cable transitions to the upper plate, it must tuck into a cavity through which the heat-cable runs.
This requirement requires a substantially diagonal-slot-cut on the top side of the plate to allow the heat-cable to pass from underneath the plate to transition over the upper end of the top portion of the plate.
The Valley locations also create a directional push from the opposite roof plane. This situation creates the need for an anchor at or near the valley location. The plate must attach to a valley-location fixture so it can withstand the directional push from the opposite roof plane. This circumstance requires a folded-insertion-lip that hooks to a cleat or s-bend.
The side of the plate opposite of the valley must also have either a vertical slot or similar appropriate feature to allow for snow to slide downward without catching the edge of the plate.
In addition, there are limitations to the size of pockets and cavities that can be created. Also, the insertion lip for the valley often requires “form-fitting” to a possible cleat or s-bend on the valley. Adjustments must account for the pitch of the roof. When the pitch of the roof changes, the valley angle changes. This means each cap plate would ordinarily need to be fabricated/tailored to the pitch of the roof.
The resulting system needs to allow the cable to transition from under the plate to a position over the top of the plate into a new cavity of the heated panel such that every edge of the plate would be sufficiently counter flushed by a material above it. The instant invention then protects against snow and ice sliding from above the system.
An improved snow melt system providing a protective plate which anchors and contacts a snow melt cable to evenly distribute heat. Such a system meets the following objectives: cost effective in its construction; easily-installed, adequately protects heating cables during their useful lifetime; allows said cables to be replaced at the end of their useful lifetime; accommodates various cable sizes; and efficiently distributes heat from the cables in a manner that effectively melts snow and ice from along a roof line As such, the new and improved snow melt system may comprise a plurality of metallic plates configured to support the cables and to clip together and to be secured under roofing shingles in order to accomplish these objectives.
With specific regard to the roof valley position, the herein-disclosed invention comprises, inter alia, at least one specially formed plate that mounts to the heated panel where it intersects with a valley position on a roof system.
The heat cable is inserted into the heated panels at roof valley locations. The heat cable transitions from one horizontal heated-cavity (inside the panel) to another horizontal heated-cavity (inside the panel), all the while exposed areas are covered by “valley caps.” At the transition point, the Valley Cap is placed over the top of the heat cable's transition position.
In some embodiments, the top side of the end cap slides into the cavity of the channel containing the heat cable. The side of the cap that intersects with the valley has an insertion lip that hooks into an s-style-fold to hold the plate to the valley.
There is also a small fold on the bottom side of the plate that hooks to the lower edge of the heated panel. At this position-point, optional screws are placed to secure the panel to the roof. An optional additional end cap is then placed over the first end cap, therein integrating the edges of the plate to the heated panels and valley.
The more notable features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in several ways. Also, it is to be understood that the phraseology and terminology employed herein are for description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions as far as they do not depart from the spirit and scope of the present invention.
With reference now to the drawings, a preferred embodiment of the snow melt system is herein described. It should be noted that the articles “a,” “an,” and “the,” as used in this specification, include plural referents unless the content clearly dictates otherwise.
With reference to
Drip edge cover 30 (
The middle plate 40 (
The terminal plate 50 features the same containment lip structure 53 as the middle plate, with its lower end folded over as an attachment insert 51 (
Variations to the system are possible. As can be seen in
Metal alloys are the preferred material from which the plates and drip edge cover may be formed. Many metals are notorious for their thermal conductivity and their elastic and plastic deformation ranges are such that permanent bends, such as the S-bends and the containment lips, may be easily and permanently formed while the structure may retain enough elasticity so that the pieces may be locked together and hold the heat cables. The ideal dimensions of the individual plates will vary depending upon the actual material from which they are made and the intended roofing material. A length between 3-4 feet (0.9 -1.2 meters) provides good coverage while also being manageable for installation while smaller length plates may be utilized as caps for even coverage over a roof without cutting the plates.
It is ideal that the plates have enough width to cover at least one exposed shingle face (typically 6 inches) or a roofing tile (12 inches) and have some overlap to fit underneath the next higher row of roofing material. The width should be enough to cover at least one type of roofing material, if not two, and have some overlap with the other plates and/or adjacent roofing material row. The only other concern for a maximum width is that the plate will conduct heat throughout its entire width. Therefore, a width of 12 to 14 inches (0.30 to 0.35 meters) is currently recommended, but a width of as little as 6 inches (0.15 meters) could be utilized.
Heat cables 60 may be threaded through the space formed by the containment lips or may be positioned as each plate is installed. They may also be slipped under each lip, using the metal's elasticity to harmlessly create enough space for installation. Removal and replacement of the cable 60 may be accomplished by either pulling it out, or by slipping it under the lip as well. The elasticity of the metal allows the lips to contain heat cable 60 in one position in the system, allowing for uniform operation. The lips may also accommodate various sizes of cable, including cable slightly larger than the space allotted by the lip construction. It is ideal for at least some contact to be had between the plates and the cable, generally with more being more effective.
The Valley End Cap
The additional Valley End Cap invention comprises primarily a specially formed cap plate that integrates with the heated panel. Once the heat cable is installed into the heated panel systems, cap plates will be used to fill cavities and finish off the ends of the panels. The process of the installation of these cap plates customarily involves working from the bottom of the system to the top. The top plate will be installed on top of the first plate. The system can accommodate multiple rows and/or plates to conceal the cable appropriately.
The Valley End Cap embodiment is engineered, positioned, and designed to mount to the terminated cut end of a heated panel at a valley location and conceal the heated cable under the cap. The cap's unique positioning, engineering and design accommodates the heat cable in a transition flow moving from one panel to another. In the process of concealing the existing heat cable, this cap also accounts for snow and ice that may slide down the roof to flow over the top of the heated panel system. Previously, these locations exposed the heat cable and made it vulnerable to ice and snow damaging the cable. The instant cap method and apparatus devices address these issues.
In some embodiments, after the primary heated panels for the roof are installed, the heat cable is then inserted into the heated panels at the Valley locations. The heat cable therefore transitions from one horizontal heated-cavity to another horizontal heated-cavity.
At the transition point(s), the Valley Cap is then placed over the top of the heat cable's transition position. In some embodiments, the top side of the end cap slides into the cavity of the channel containing the heat cable. The side of the cap that intersects with the valley has an insertion lip that hooks into a C-fold (or appropriately formed “Ledger”) to hold the plate to the valley.
There is also a small fold on the bottom side of the plate that hooks to the lower edge of the heated panel. At this position-point, optional screws are placed to secure the panel to the roof. An optional additional end cap is then placed over the first end cap, therein integrating the edges of the plate to the heated panels and valley (similar to the first end cap position).
Advantages to the Valley Cap System include, but are not limited to:
The valley cap system may be comprised of Kynar™-clad sheet metal. It is designed to be integrated into the heated Panel System (by, inter alia, Wasatch Heat Cable™). The integration of the cap plate conceals and protects the heat Cable in the system. Applying the cap plate protects for the cable and the Plate System of the roof by providing a smooth surface for anything sliding from the top of the roof to the bottom of the roof to flow over the top of the components without catching any edges. The Valley Cap System is therefore low-profile, therefore being aesthetically appealing to higher-end Roof Systems.
This middle structure, the roof valley flashing plate 480, is a special valley plate positioned in the roof's groove/valley. The valley flashing plate 480 comprises parallel channels running vertically (“longways,” as shown) such that that the cable 600 may go up and over (as shown on flashing plate 480 left side), or just run over and down (as shown on flashing plate 480 right side).
In a preferred embodiment, the flashing plate 480 is positioned in a roof valley 470, running substantially from the roof's top to its bottom. The flashing plate 480 comprises at least two substantially parallel channels, each channel having at least one entry/exit point.
Customarily, the heat cable 600 runs inside the flashing plate 480 at the roof valley location 470, and then the heating cable 600 exits the flashing plate 480 to enter another thermal panel 100/200 in a series/stacking fashion as shown in
In the preferred embodiment shown, Plate One's 300 Side One 301 features a “clean cut” with a [herein shown] vertical direction as to the plane of the roof. This side 301 overlaps atop the heated panel 100, therein allowing the system to “jump over” the Valley 470 (not shown in
Plate One 300 Side Two 302 features an insertion lip 330, the inner surface of side two's C-bend 430 that hooks into the corresponding C-bend 430 of Plate Two 500, therein fitting into and covering the Valley 470.
Plate One 300 Side Three 303 features a diagonal transition covering the heat cable 600, and transitions on top of the previous/next plate 500 (illustrated in
Plate 300 Edge Four 304 comprises an under-fold that hooks the bottom lip of the heated panel 100 (not shown), keeping the plate 300 secure to the panel 200 as shown in
The Plate's 300 Fifth Side 305 herein shows the “top side” of the plate 300 that inserts between (and partially covers) the heated panels 100, 200 (not shown) and underneath the heat cable line 600 (which is covered by Panel Two 200, not shown).
Plate 300 Side Six 306 is a diagonal notch that allows the heat cable 600 to transition/jump from underneath the plate 300 and transition/jump to the top of the plate 300 towards its own plate-side-number-One 301 and into the heated panel 200 (not shown) system.
This figure highlights the complete concealment of the heat Cable 600 inside the panel system, allowing the cable 600 to transition from one panel to another (safe from weather).
INSTALLATION: In the preferred embodiment, installing a cap plate (here Cap Plate One 300) would occur according to the following steps:
Plate one 300 Side Five 305 is inserted between the connecting joint of heated panel one 100 and heated panel two 200 underneath the heat tape line that runs between the two panels joints.
Plate One 300 Side Four 304 hooks onto the bottom of heated panel one 100.
Plate One 300 Side Two 302 inserts into the fold of the Valley Pan of the roof.
Plate two 500 Side three 503 covers the transition location of the previous plate 300.
Plate two 500 also features a C-shaped bend 430 at the outer edge of the plate 500. The edge bend 430 therein forms an interlocking-capable edge 430, wherein the edge height 440 is substantially the same as the edge height of Cap Plate One 300.
Note that the height differential 400 between panels (e.g., panel one 100 and panel two 200, shown in
Panel 500 side 504 overlaps atop heated panel two 200, therein allowing the system to “jump over” the Valley 470, therein allowing the Cable 600 to snake underneath plate two 500 (unencumbered by weather).
Plate Two 500 Side Two 502 similarly features an insertion lip 530 (inner surface of C-bend, herein not shown as it resides on the underside of Plate Two 500 Side Two 502). The inner surface of side two's 502's external C-bend 430 hooks into the corresponding C-bend 430 of Plate One 300, therein fitting into and covering the Valley 470.
Note that the additional “substantially mirror image” plates to the left of cap plates 300,500 illustrate how the instant roof “valley cap system” can cover valleys adjacent to and above/below already-installed-panels & plates, to cover a whole roof and all its valleys. Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
This Application is a Continuation in Part of U.S. Nonprovisional Utility patent application Ser. No. 16/245,956 filed Jan. 11, 2019, now U.S. Pat. No 11,525,266 issued Dec. 13, 2022, and incorporates the same by reference herein in its entirety. This Application therefore also claims priority to initially filed U.S. Provisional Utility Application No. 62/616,998, filed Jan. 12, 2018, and incorporates the same by reference herein in its entirety.
Number | Date | Country | |
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62616998 | Jan 2018 | US |
Number | Date | Country | |
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Parent | 16245956 | Jan 2019 | US |
Child | 18065382 | US |