In high snow load regions, roof top snow can melt into water due to escaping heat from the structure's interior or thermal radiation from the sun. When this water drains to the colder overhang or other colder roof surfaces the water can refreeze creating an ice dam. Ice dams can also form in the valley between adjoining roof surfaces or next to roof protrusions such as chimneys, dormers or second story structures. A continuously heated drain path, including heated gutters and down spouts, ensure the water is drained away from the structure's foundation.
These ice dams can prevent additional snow melt water drainage and standing water is formed above the ice dam. Most slanted roofs are designed to shed moving water like an umbrella, not to hold standing water like a swimming pool. This standing water can penetrate a standard roof and enter the structure causing interior damage, mold, mildew and electrical issues. If this water is allowed to re-freeze, the change-of-state expansion can cause major structural damage.
To provide a heated drain path though the ice dam, the state of the art for professional installations utilizes self-regulating electrical heating cable that increases the heat output per foot when the cable is in direct contact with ice and snow. When the drainage path around the cable is established, the air pocket acts like a storm window and greatly reduces the thermal conduction between the heating cable and the ice and snow. As the electrically semi-conductive cable core heats up, the electrical resistance between the electrical bus wires increases and the electrical wattage used per foot decreases. A typical self-regulating ice and snow melt cable can create a load of 24 watts per foot in ice and snow at −10° F. but drops to about 6 watts per foot in ambient air at 32° F. So the air pocket around the cable becomes an important variable in the system and product design.
Increasing the size of the melt path has been the goal of the industry for many years. A single run of cable provides about a two inch wide drain path. A zig-zag placement of the cable provides a wider coverage area but ice can form between the zig and the zag and the additional cable length adds cost and requires more electrical power.
Embedding the cable in a fixed width cavity inside a thermally conductive metal panel system works quite well to increase the size of the melt path, which is the goal. Some heavy weight extruded panels are offered that have a high fixed thermal mass, ensuring maximum heat sinking and electrical power usage from the self-regulating heating cable. However, over time the thermal expansion and contraction of the cavity size of any current panel design reduces the contact area between the cable and the metal. A very small thermal air gap can reduce the self-regulating cable's heat output and the temperature of the metal panel dramatically.
Maintaining a long term, thermally conductive contact between the self-regulating heating cable and the snow melt metal panel or metal surface is the main focus of this disclosure. System cost and energy efficiency are also important. This invention uses low cost sheet metal panels with spring loaded members in the cable cavity that ensures firm, long term contact with the heating cable. To address energy efficiency, the variable thermal mass of light weight sheet metal becomes a factor. The light weight sheet metal panel system only uses large amounts of electrical power when loaded down with snow and ice which increases the thermal mass of the panel. When the snow and ice have drained away, the variable mass of the cleared panel decreases dramatically and the self-regulating cable current consumption goes down, saving energy.
In high snow load regions, snow melt water tends to refreeze on the colder lower areas of the roof. Higher on the roof the snow is exposed to the heat escaping from inside the structure. Top floor ceiling penetrations for overhead lights and ventilation duct work can create massive heat loss from inside the structure to the attic space which then heats the bottom side of the roof deck which can melt the snow on the top of the roof deck. Solar heating of the snow on the upper part of the roof also contributes to snow melt water in areas not shaded by trees. This snow melt water usually stays under the snow, much like the effect seen in a glass of ice water—the solid snow and ice float on top of a layer of water. This water then drains down the roof, under the snow and ice, and tends to re-freeze on the colder roof surface over the unheated roof overhang. This can lead to large ice formations at the roof drip edge which can fall to the ground causing damage to property and injury to people.
Colder roof surfaces can also be found where snow depth increases, for example in the valley between adjoining roof surfaces or behind roof protrusions like chimneys or second stories. The lower roof surfaces are sometimes shielded from solar heating due to the angle of the sun in winter or by trees planted too close to the structure. When this moving water is exposed to the colder roof surfaces it will sometimes refreeze creating what is called an ice dam. This sold ice formation builds in size and height and prevents continued drainage of the snow melt water coming down the roof. The standing water increases in depth and can leak back under the shingles or other roofing material into the interior of the structure. Normal roofs are designed to shed moving water like an umbrella, not to hold standing water like a swimming pool.
When this standing water leaks into the structure, it can cause mold, mildew and damage to electrical systems. It can leak through the ceiling and destroy furniture, carpet and other household goods. Often times this water re-freezes and the change-of-state expansion has the power to separate structural members that are nailed together or to destroy the glue or sealing bond between surfaces. If the water is permitted to collect around the structure's foundation and refreeze, the concrete foundation can crack and leak water into the basement. This structural damage may not be recognized for a period of time. The first priority under these conditions is to provide a continuously heated drain path for the snow melt water to drain off the roof, into a heated gutter and downspout and away from the structure's foundation.
Contrary to common belief, best practice is to provide a heated drain path for the snow melt water rather that to use the extra electrical energy required, due to the latent heat of fusion (hidden heat required for change of state from solid to liquid) to melt ice once it is formed. This suggests that a system using self-regulating heating cable powered 24 hours a day is more energy efficient than using a timer to turn off the system a night which allows the snow melt water to refreeze only to use additional electrical energy to melt the ice the next day so it can drain from the roof structure.
Over the years, many systems have been developed to deal with these drainage issues. The miner's shacks of the 1800's had metal slip sheets or snow slides placed at the roof edge, around the perimeter of the building. When these metal panels were heated by the sun and the up-roof snow melt drainage water, the snow and ice would lose adhesion and slide to the ground. Electrical constant-current heating cables were introduced in the mid 1900's and are still used today to provide a heated melt path for snow melt water.
Self-regulating heating cables were introduced in the late 1900's that had a semi-conductive carbon infused plastic core between two electrical buss wires that would lower the electrical resistance between the buss wires as the core became colder, and increase resistance between the buss wires as the core warmed up. This was a major energy saving improvement. The cable would use more electrical energy per foot the colder the core became. As the core warmed up, the electrical resistance between the buss wires would increase and the electrical energy used per foot would decrease.
These self-regulating heating cables would be placed on the roof surface and in the gutters and downspouts to create a heated drainage paths for the snow melt water until it was safely drained away from the structure's foundation.
Combining self-regulating heating cable with the slip sheets of the 1800's was the next step in the evolution. Some slip sheets were made from heavy extruded aluminum to present a high thermal mass heat sink to the self-regulating heating cable. Later, lower cost sheet metal slip sheets combined with self-regulating heating cable were introduced.
But both types of slip sheets had the same type of fixed size cavity for the self-regulating heating cable. A tight contact between the heating cable and the metal panel is very important for thermal conductivity. Any air space acts like thermal insulator, similar to a storm window. With this partial thermal insulation, the self-regulating heating cable core warms up prematurely and produces less heat output.
The heavy metal extrusion panel had a fixed size cavity that did not offer a tight flexible contact to the heating cable and a sheet metal cover that sometimes made cable replacement difficult. Over time, the thermal expansion and contraction of the sheet metal panel systems would cause metal fatigue and the cavity size would increase. Sometimes the heating cable would fall out of the cavity. In both cases, thermal conduction between the metal panel and the heating cable would degrade, the cable core would warm up and the heat output of the cable would decrease.
The inventions disclosed herein are an improvement to the previous designs by offering a multi-segment spring loaded or bellows type of metal to cable thermal contact that is flexible and not subject to metal fatigue. The multiple-segments act like leaf springs along the length of the cable raceway. Ease of cable insertion, long term cable retention and high thermal conductivity combined with the low cost advantage of sheet metal is the next generation of this type of product disclosed in this invention.
Certain embodiments of the invention have been described; however, they are examples only, and not intended to limit the invention recited in the claims. Variations and safety features which will be obvious to those of ordinary skill in the art, such as the use of any weather tolerant heating cable, and avoiding damage to the cable covering by bending any sharp edges of the spring member away from the cable, fall within the scope of the following claims.
Number | Name | Date | Kind |
---|---|---|---|
2699484 | Michaels | Jan 1955 | A |
3074676 | Watson | Jan 1963 | A |
3207211 | Winterfeldt | Sep 1965 | A |
3521029 | Toyooka et al. | Jul 1970 | A |
3691343 | Norman | Sep 1972 | A |
3725638 | Solin | Apr 1973 | A |
4189881 | Hawley | Feb 1980 | A |
4401880 | Eizenhoefer | Aug 1983 | A |
4848051 | Weisner et al. | Jul 1989 | A |
5391858 | Tourangeau | Feb 1995 | A |
5496005 | Dieringer | Mar 1996 | A |
5829206 | Bachman | Nov 1998 | A |
5836344 | Hovi, Sr. | Nov 1998 | A |
6225600 | Burris | May 2001 | B1 |
6499259 | Hockman | Dec 2002 | B1 |
6668491 | Bonerb | Dec 2003 | B1 |
6700098 | Wyatt | Mar 2004 | B1 |
6759630 | Tenute | Jul 2004 | B1 |
6852951 | Heise | Feb 2005 | B2 |
7071446 | Bench | Jul 2006 | B1 |
7104012 | Bayram | Sep 2006 | B1 |
7104013 | Gates et al. | Sep 2006 | B1 |
7287354 | Rivers et al. | Oct 2007 | B2 |
7448167 | Bachman | Nov 2008 | B2 |
7681363 | Banister | Mar 2010 | B2 |
8191319 | Nark | Jun 2012 | B2 |
8205397 | Nark | Jun 2012 | B2 |
8440940 | Backe | May 2013 | B2 |
8490336 | Nark | Jul 2013 | B2 |
8607509 | Gurr | Dec 2013 | B2 |
8782960 | Nark | Jul 2014 | B2 |
8946601 | Casey | Feb 2015 | B2 |
9045907 | Clark | Jun 2015 | B2 |
9095007 | McGillycuddy | Jul 2015 | B2 |
9121179 | Bublitz | Sep 2015 | B2 |
20010025839 | Jones | Oct 2001 | A1 |
20040140002 | Brown et al. | Jul 2004 | A1 |
20050139585 | Knappmiller | Jun 2005 | A1 |
20050193637 | Petroff | Sep 2005 | A1 |
20060037252 | Gosse et al. | Feb 2006 | A1 |
20060096968 | Livermore | May 2006 | A1 |
20060196124 | Bachman | Sep 2006 | A1 |
20060213129 | Bachman | Sep 2006 | A1 |
20060277831 | Bachman | Dec 2006 | A1 |
20060288652 | Gurr | Dec 2006 | A1 |
20080196352 | Grove | Aug 2008 | A1 |
20080302928 | Haddock | Dec 2008 | A1 |
20100024324 | Meinzer | Feb 2010 | A1 |
20110042366 | Martin | Feb 2011 | A1 |
20110047892 | Nark | Mar 2011 | A1 |
20110047927 | Nark | Mar 2011 | A1 |
20110047930 | Nark | Mar 2011 | A1 |
20110049118 | Nark | Mar 2011 | A1 |
20110089154 | Aussi | Apr 2011 | A1 |
20110209434 | Nark | Sep 2011 | A1 |
20110232210 | Backe | Sep 2011 | A1 |
20120067868 | Casey | Mar 2012 | A1 |
20120091116 | Casey | Apr 2012 | A1 |
20120132759 | Sager | May 2012 | A1 |
20120168419 | Bublitz | Jul 2012 | A1 |
20130319990 | Casey | Dec 2013 | A1 |
20140097178 | Whitcraft | Apr 2014 | A1 |
20140299593 | Casey | Oct 2014 | A1 |
20140326837 | Rumsey | Nov 2014 | A1 |
20150114947 | Casey | Apr 2015 | A1 |
Entry |
---|
Heat-line Freeze Protection Systems, Edge-Cutter(R) Roof De-icing System, Product Brochure, 2006, 4 pages. |
Raychem Corporation, IceStop GMK-RC Roof Clip and GM-RAKE Hanger Braket, product brochure, Mar. 1999, 4 pages. |
Raychem Corporation, IceStop product information sheet, Oct. 1984, 1 page. |
Chromalox.RTM Edge-Cutter.RTM. Roof De-Icing System product brochure, 2 pages, published on or before Aug. 24, 2008. |
Victorian Metal Shingle, Snow Belt System, 3 pages, offered for sale on or before Aug. 24, 2008. |
EN-RaychemIceStopRoofGutterDeIcing-IM-H58067 Mar. 2013 p. 37 J-hook heated panel http://pentairthermal.com/Images/EN-RaychemIceStopRoofGutterDeIcing-IM-H58067—tcm432-26320.pdf. |
Number | Date | Country | |
---|---|---|---|
20150184394 A1 | Jul 2015 | US |