Exposed structure heating apparatus and methods of making and use

Abstract

Structure heating systems and methods of making and use. One embodiment has a unitary or integral roof edge heating element with a single heating cable mounted in a heating cable channel running laterally through the heating element and a roof edge heating panel extending from the portion of the heating element bearing the heating cable. Another embodiment includes a single heating cable mounted in a heating element surrounded by a heating element cover. Some embodiments can reduce the amount of heat transfer contact with supporting roof or adjacent structure, reducing heat transfer to the supporting roof or other adjacent structure.

Claims

1. A roof edge heating apparatus mountable adjacent an edge of a roof of a building, the roof edge heating apparatus comprising in combination: A. a unitary heating element having a thickened outer flange and a laterally-extending thinner section extending at a 90 degree angle from the thickened outer flange and extendable laterally over a portion of the roof adjacent the roof edge; B. a U-shaped heating cable channel within the thickened outer flange of the unitary heating element, the heating cable channel being extendable along and adjacent the edge of the roof of the building, the channel having sidewalls and an inner end opposite the roof edge; C. a heating cable mountable in the heating cable channel through an open portion of the heating cable channel extendable along and adjacent the edge of the roof, the heating cable contacting the sidewalls and inner end of the heating cable channel and extendable along the edge of the roof; and D. a fastener passage extending through the laterally-extending heating element section, whereby the unitary heating element can be fastened to the roof adjacent the edge of the roof.

2. The roof edge heating apparatus of claim 1 wherein the roof edge heating apparatus includes a roof edge seal abuttable against the edge of the roof.

3. The roof edge heating apparatus of claim 1 wherein the laterally-extending section has a thin heating section adjacent a top surface of the roof, the thin heating section having a predominantly planar upper surface and being thinner in an upper portion than the thickened outer flange.

4. The roof edge heating apparatus of claim 1 wherein the heating element comprises copper or aluminum.

5. The roof edge heating apparatus of claim 3 wherein differing thicknesses provide a plurality of support surface contact areas and the laterally-extending section provides an upper heating surface having an upper heating surface area at least 60% greater than the support surface contact areas.

6. The roof edge heating apparatus of claim 5 wherein the heating element comprises copper or aluminum.

7. The roof edge heating apparatus of claim 1, wherein the thickened outer flange of the unitary heating element has a downwardly sloped, curved upper surface extending downwardly from a junction with the laterally extending section.

8. The roof edge heating apparatus of claim 7, wherein the upper surface terminates at a lower end of the thickened outer flange in a transversely extending lower surface.

9. The roof edge heating apparatus of claim 8, wherein the transversely extending lower surface is extendable to abut the roof edge.

10. The roof edge heating apparatus of claim 1, wherein the cross-sectional thickness of the laterally-extending section is at least 50 percent or less of the cross-sectional thickness of the thickened outer flange.

11. The roof edge heating apparatus of claim 1, wherein the cross-sectional thickness of the laterally-extending section is between 75 percent and 30 percent of the cross-sectional thickness of the thickened outer flange.

12. The roof edge heating apparatus of claim 1, wherein the heating cable channel is a single channel formed in the unitary heating element.

13. The roof edge heating apparatus of claim 1, wherein a cross-sectional thickness of the end of the laterally-extending section is at least 75 percent or less of the cross-sectional thickness of the thickened outer flange.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The preferred and other embodiments are shown in the accompanying drawings in which:

(2) FIG. 1 is a perspective, partially cross-sectional view of a unitary heating cover embodiment of a structure heating system mounted about a roof edge on the roof of an underlying house;

(3) FIG. 2 is a partial cross-sectional view of the unitary heating cover embodiment of FIG. 1 mounted to the roof edge and upper roof surface;

(4) FIG. 3 is a perspective, partially cross-sectional view of an alternative embodiment of a structure heating system mounted about a roof edge on the roof of an underlying house, having a heating cover surrounding an underlying heating element and included heating cable;

(5) FIG. 4 is a partial cross-sectional view of the alternative embodiment of FIG. 5 mounted to the roof edge and upper roof surface, with the underlying heating element, which would normally be covered by the heating element cover panel, partially exposed;

(6) FIG. 5 is a photograph of an embodiment of the heating system of FIG. 3 mounted to a roof with a central heating cable distribution system for each of two heating elements and associate heating element covers extending from opposed roof edges; and

(7) FIG. 6 is another photograph of the embodiment of FIG. 6 closer up and with the underlying heating element partially exposed.

DETAILED DESCRIPTION OF THE PREFERRED AND OTHER EMBODIMENTS

(8) Heating apparatus and methods of use are described. Although the heating apparatus is described primarily in the context of the roof structure shown, it should be appreciated that the referenced structure, concepts, and features may be used in a variety of other settings or structures that would be recognized by those of ordinary skill in the art. Also, it should be understood, that the features, advantages, characteristics, etc., of one embodiment may be applied to any other embodiment to form an additional embodiment unless noted otherwise.

(9) With reference now to FIG. 1, one embodiment of a building, generally 10, has a sloped roof 12 with a lower roof edge 14 extending along the lower most portion of the roof 10. A laterally extending heating element 16 is mounted along the lower roof edge 14. The heating element 16 has a laterally extending thickened outer section or flange 17 having a laterally extending heating cable channel 18 with a heater cable 20 mounted within and penetrating the outer U-shaped heater cable channel 18 along the entire lateral length of the heating element 16. In this embodiment, the outer end 21 of the heater cable 20 is spaced from the lower roof edge 14 to allow the heating cable 20 to be mounted within the heating cable channel 18 after the heating element 16 is mounted on the roof 12. In other embodiments, however, an outer end 21 of the heater cable 20 can extend slightly outwardly from heater cable channel 18 to abut the lower roof edge 14, which can bias the cable 20 into tight contact with surface of the heater cable channel 18 as well has help create a seal between the roof edge 14 and the abutting edge abutting end 19 of the heating element flange 17.

(10) A heating panel 22 extends transversely from the upper edge 24 of the outer flange 17. The heating panel 22 has a central panel section 24 extending from the outer flange 17, a downwardly sloped panel section 25 extending from the central section 24 opposite the junction 26 with the outer flange 17, and an outer panel section 28 generally parallel to the plane of the central panel section 24 extending from the end 30 of the downwardly sloped panel 25. The central panel section 24 has a generally planar upper surface 27.

(11) The central panel section 24 has relatively thicker laterally extending lower support section 32 and thicker laterally extending central support section 34 as compared to a substantially thinner (i) laterally extending intermediate section 36 between the lower support section 32 and the central support section 34, and (ii) upper end section 38 extending from the central support section 34. On some embodiments, the intermediate section 36 and upper end section 62 are 30-75% thinner in cross-sectional thickness than the lower support section 32 and central support section 38. One exemplary thickness of intermediate section 32 and upper end section 62 is 0.100 inches, with the exemplary thickness of the associated lower support section 32 and central support section 38 at 0.140 inches. The percentage difference can be other than 50%, however. In some embodiments, there may be no percentage difference, and thus the percentage difference could range from 0% up the highest number providing any needed structural integrity. In some embodiments, a 70% to 90% difference or more may be suitable.

(12) The thickened outer flange 17 of the heating element 16 has a downwardly sloped, slightly curved upper surface 42 extending downwardly from the junction 26 with the central panel section 24. The upper surface 42 terminates at its lower end 44 in a transversely extending lower surface 46 that extends to abut the roof eave edge 14.

(13) The heating element 16 is held in position on the roof 12 by fasteners, e.g., 46, 48. In this embodiment, the outer panel section 28 fits under a roof and tightly abuts the lower side of a roof shingle 50, tile, or other outer roofing structure secured to the roof 12.

(14) The heater cable 20 can be formed of one continuous heater cable. Such cable can consist of Tyco Thermal's GM-1X or GM-2X self regulating heater cable with an output of up to 12 watts per foot.

(15) The power supply (not shown) is a 110V or 208-277V electrical circuit, typically connected in an electrical junction box is attached to the heater cable in a fashion well known in the art. Similarly, the heater cable is terminated at its end opposite the power supply in a fashion well known in the art.

(16) The entire heating element 16 may be made of any material that can transfer heat generated by the heater cable 20. Some such materials include various metals, alloys, etc. One such metal is copper and another is mill finish 6063 aluminum alloy. In some embodiments, the heating element 16 is formed by extrusion, although any other suitable forming techniques may be utilized. The extruded heating element 16 is thus one unitary piece and transfers heat from the heater cable 20 throughout the heating element 16 to melt ice or snow on or sufficiently close to the heating element upper surface 52.

(17) With reference now to FIG. 2, the fastener 48 is a Torx T-25 pan head low profile screw with a waterproof gasket and metal dome washer. The fastener 48 penetrates a mating fastener passage 54 in the central support section 34 of the heating element 16 to penetrate the underlying, generally planar roof support surface 56. When threaded fully and tightly into position, the head 58 of the fastener 48 creates a seal between the fastener 48 and abutting upper surface of the central support section 38. The lower planar surfaces 60, 62 of each of the lower support section 32 and central support section 38, respectively, abut the roof support surface 56, thus providing insulating air spaces 68, 70 between the roof support surface 56 and planar lower surfaces 64, 66 of the intermediate section 36 and upper end section 40, respectively, of the heating element 16. In some embodiments, insulating material can be injected or otherwise placed within one or both of these spaces 68, 70.

(18) When secured to the roof 12, the roofing structure, e.g., 50, and tightly abuts, and thus provides a seal between, the upper surface of the outer panel section 28. Similarly, the outer panel section 28 tightly abuts, and thus provides a seal between, the upper surface 56 of the roof 12.

(19) In one embodiment, the heating element 16 is made of 6063-T6 aluminum and has a width W of 7.375 inches and thickness T of 0.943 inches. The weight of the heating system (the heating element 16, fasteners, e.g., 58, and heating cable) is 1.22 lbs. per lineal foot of lateral length of the system along the roof edge. The typical lateral length of the extruded heating element 16 is 96.″ These specifications can vary by application, however. One or more of these specifications can vary, for example, by plus or minus 20%, 40%, 80%, 120%, or more. The lateral length of the heating system may vary as desired. Pre-formed sections may be cut to length as desired and as is well to known those skilled in the art.

(20) Embodiments of the heater system of FIG. 1 can be effective in most winter conditions experiences in most of the United States, such as for example in Lake Tahoe, California. At the same time, some embodiments of the FIG. 1 heating system can be reduce the cost of ordering, manufacturing, shipping and installing the product more affordable than comparable systems in the prior art.

(21) In locations subject to more severe winter conditions, however, some embodiments of the heating- element-and-cabling-structure of FIG. 2 can provide a more reliable solution. With reference now to FIG. 3, this alternative heating system has: (i) a laterally extending heating element 100 mounted to an underlying roof 102 and roof edge 104; (ii) a laterally extending heat radiant heating element cover 106 surroundingly abutting the exposed portions of the heating element 100; (iii) a single heating cable 108 running through a heating cable channel 110 extending upwardly in the heating element flange 111 so that the upper end 112 of the heating cable 108 abuts the underside 114 of the heating element cover 106; and (iv) fasteners, e.g., 116, penetrating mating passages, e.g., 118, in the heating element cover 106 and heating element 100. The heating element cover 106 is held in position by (i) its wrap around, laterally extending lower edge 120 gripping the laterally extending lower edge 122 of the heating element flange 112 and (ii) at its opposed laterally extending upper end 124 by fasteners, e.g., 126, penetrating mating passages in the upper end 124, which underlies an abuts the lowermost shingles, e.g., 128, on the roof. 102.

(22) The heating element 100 flange-support end 130 of the heating element 106 and upper end support section 132 are substantially thicker than (i) the relatively substantially thinner intermediate section 134 extending from the flange-support end 130 to the upper end support section 132, and (ii) the relatively substantially thinner upper end 136 extending upwardly along the roof from the upper end support section 132.

(23) With reference now to FIG. 4, the heating element 100 has a generally planar upper surface 138 extending from its upper end 136 to the lower peak edge 140 of the lower flange-support end 130. The heating element flange 111 extends downwardly from upper surface 138 to provide a planar side flange surface 142 at an acute angle to the plane of the upper surface 138. The downward extension of the flange 111 provides a lip 144 extending below, and spaced from, a flange mounting corner 146 that sealingly mounts about the upper edge 148 of the roof 102. The lip 144 has an interior radiused side 150 extending from the lowermost end 152 of the lip 144 to the mounting corner 146 while maintaining separation from the adjacent roof edge 104. The mounting corner 146 is provided by a thin wall section 158 extending transversely downwardly from the adjacent planar base 154 of the flange-support end 130. The U-shaped heating cable channel 110 extends upwardly above the mounting corner 146 between side flange surface 142 and a radiused or curved interior side 156 of the flange-support end 130.

(24) The upper end support section 132 of the heating element 100 includes a fastener passage 160 through which the fastener 126 secures the heating element 100 to the roof surfaces 102 and also to provide a tight seal between the roof upper edge 148 and mounting corner 146. The lower surfaces 154, 164, 166 of the flange-support end 130, thickened upper end support section 132, and upper end 136 of the heating element 100 abut, and support the heating element 100 on, the roof support surface 102. The fastener passage 126 is countersunk into the upper end support section so that the fastener end 160 is seated entirely within the periphery of the fastener passage 126.

(25) The heating cable 108 is mounted within heating cable channel 110 so that the cable tightly abuts the mating interior side wall of the channel 110. The heating cable 108 and heating element 100 thus transfer heat to mating abutting interior surface or underside 116 of the heating element cover 106. In contrast, the lower surfaces 154, 164, and 166 provide relatively little supporting contact with the roof surface 102 and thus relatively less area for heat transfer loss through those surfaces 154, 164, 166. In addition, the relatively thinner intermediate section 132 and upper end 136 of the heating element 100 are spaced from the opposed portions of the roof support surface 102, creating insulating air spaces 101, 103 or providing areas in which other types of insulating materials can be injected or otherwise placed. Further, insulating material can also be injected or placed in the space 105 between upper section 176 of the heating element cover 106 and the adjacent roof surface 102 below the upper section 176.

(26) The heating element cover 106 has a lower gripping lip edge 168 abutting the lower end of the flange lip 144 and from there surrounds the mating outer planar upper surfaces 170, 172, 174 of the heating element 100. The upper section 176 of the heating element cover 106 extends upwardly to abut the roof surface 102 and at that contact point 180 extends in roof mounting section 178 angularly upwardly along the roof surface 102 under the roof shingle (or other roof structure) 50 abutting the top surface of roof mounting section 178. A corrosion resistant nail 182 is nailed through the roof mounting section 178 to underlie the roof shingle 50. The heating element cover 106 thus surrounds, and helps protect from the elements and debris, the entire otherwise exposed portions of the heating element 100, the heater cable 108 mounted in the heating element 100, and the screw fasteners, e.g., 126.

(27) In the embodiment of FIG. 4, the heating element 100 is extruded (and thus unitary) and has a width HEW of 3.885 inches and a thickness T2 of 1.05 inches, and the heating element cover has width W2 of 11 inches and a thickness T3 of 1.27 inches. The weight of the FIG. 4 embodiment of the heating element 100 is as follows: the weight of the heating element cover or panel 106 is 0.59 lbs (if 6063 aluminum) or 1 to 1.25 lbs. (if copper) per linear foot; the weight of the heating element 100 is 3.85 lbs. per lineal foot if made of copper; the weight of the heating cable 108 is 0.09 lbs. per lineal foot; and the weight of the fasteners, e.g., 126, and nails, e.g., 182, is 0.01 ounces per lineal foot. The sizing and weight of these components may be adjusted in this embodiment just as described above for the FIG. 1 embodiment.

(28) As compared to the Bylin RIM panel prior art system explained above, the particular dimensioned embodiment of FIGS. 3 and 4 provides: (i) 96% more heating top surface area on the cover panel 36; and (ii) 91% less convective contact area between the heating element and supporting roof structure. Lesser percentages may also be achieved by differing designs; greater percentages may be achieved too, such as, for example, by deletion of a central heater cable passage structure.

(29) In the particular dimensioned embodiment of FIGS. 3 and 4 described above, the heating element's top surface is 3.27″ wide. The applicant's prior Radiant Edge system has a Radiant Edge top surface cover panel that is 4.63″ wide. This FIG. 1 embodiment thus has 30% LESS top surface area than Radiant Edge system.

(30) In that FIG. 1 embodiment, the heating element's bottom surface in contact with the supporting roof is 0.108″ wide. The Radiant Edge system's bottom surface in contact with the supporting roof is 0.645″ wide. This particular FIG. 1 embodiment thus has 83% less contact area (heat transfer contact area with the supporting structure, such as roof upper surface and roof edge) than the Radiant Edge system.

(31) In that Figure embodiment, heating element's cable/consumption utilizing a Self-regulating heater cable is 12 watts per foot of heating system as installed on a roof edge. The Radiant Edge system's cable/consumption is 24 watt per foot of heating system as installed on a roof edge. This particular FIG. 1 embodiment thus uses approximately 50% LESS energy to operate than Radiant Edge system.

(32) The embodiments shown in the accompanying Figures also mitigate ice dam conditions by providing a downwardly extending water flow surface along the upper surface of the heating element (in the case of FIGS. 1 and 2) or heating element cover (in the case of FIGS. 3 and 4) and nearly vertical lower side edge, terminating in an upwardly extending lower side of the heating element or heating element cover as applicable.

(33) As noted above, insulation may be utilized in conjunction with the heating systems. Certain types of insulation can also provide further support to the heating element 100 and, in turn, the cover 106. In some embodiments, the insulation may be preformed and mounted in or secured to the associated heating element portions.

(34) Insulating sealants, plastic liners, paint, or other layering (not shown) may be mounted, inserted, or sprayed on one or more surfaces of the heating apparatus. For example, such insulating layers can be located between one or more mating sections of, e.g., a copper heating element cover 38 and, e.g., aluminum heating element 100, or between any other structures made of disparate metals or otherwise benefitting for any such liner or layer. Use of an insulating layer can reduce corrosion as well as help seal interior heating apparatus structure from exposure to humidity, water, debris, etc.

(35) The heating apparatus can be utilized with other heating structure(s). For example, multiple heating elements and cover panels may be utilized as necessary to facilitate given objectives, such as size concerns in shipping. Additional heater cable section may be included to extend the heating cable into other structures, such as gutters and along roof valleys. Additional covers may be utilized such as copper cover panels of varying shapes such as might be utilized to cover a heating cable in a given location, such as a roof valley.

(36) With regard to the embodiment of FIGS. 1 and 3, the heater cable channel and fastener support channel may be placed in differing locations while maintaining the objective of relatively maximizing heat transfer contact between the cover panel and heating element and relatively minimizing heat transfer contact between the heating element and supporting structure like an upper roof surface.

(37) Differing cover panel shapes may be utilized. For example, the cover panel may be larger to extend further upward on a roof from its lower edge. The lateral ends of the cover panel, at one or both ends of the heating element may include extension portions that can be bent in position to surround and seal from the elements the heating element and/or associated heater cabling. In the alternative or in addition, other metal sheeting or cap structure may be mounted to or surrounding exposed or unsealed portions of either of the opposed lateral ends of the heating panel to seal the heating element or associated heater cable from the elements or debris.

(38) In the embodiments described above, heat is distributed to the heating element by a heating cable. For example, a heating fluid may be utilized to distribute heat in heating channels or conduits in the heating element.

(39) In one exemplary embodiment, the heating apparatus may be assembled as follows: 1. mounting and securing the heating element to a roof either to a roof deck or over existing roofing such as roof shingles, in some instances adjacent and surrounding somewhat a roof edge; 2. when applicable, mounting the heating cable in the heating cable channel in the heating element; 3. mounting and securing a cover panel to generally surround the heating element, and in some embodiments, extend over and/or under portions of the roof structure or otherwise beyond contact with the heating element. 4. if the heat source structure is electrical, connecting the heating cable structure to a power supply.

(40) In some embodiments, the methods of installing disclosed herein may include adding an insulating layer at desired locations on the heating element or to the underside of the cover panel. The insulating layer(s) may be mounted to the heating element locations either before mounting the heating element or during or after such mounting. The insulating layer(s) may be added to the underside of the heating element cover at any point prior to mounting the cover to generally surround the heating element, depending on the nature of the insulating layer.

(41) In some embodiments, the step of securing the heating element and/or cover panel to the roof may include inserting or otherwise utilizing an insulating washer or other insulating layer to be located between a metal fastener head and underlying structure on the heating element or heating element cover with which the head will be in contact. Further, in some embodiments, fastener components or materials other than or in addition to screws or nails may be used. For example, construction adhesive may be utilized in certain applications to fasten one structure or component to another abutting the structure or component.

(42) Paint may be applied to exposed surfaces of the heating apparatus, such as the upper surface of the cover panel, to achieve desired aesthetics. Metallic paint may be used to improve heat transfer through the paint.

(43) It can thus be seen that some heating apparatus embodiments of the type shown in the accompanying Figures can thus provide more efficient, reliable, and easily manufactured, mounted, used, and maintained heating system than prior art systems for applicable environments. Some heating element embodiments can provide substantially more heat transfer to the cover panel and substantially less heat transfer to the supporting roofing structure.

(44) As used herein, spatial or directional terms, such as upwardly, downwardly, lower, and the like, relate to the subject matter as it is shown in the drawing figures. However, it is to be understood that the subject matter described herein may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting or requiring and orientation in space. Furthermore, as used herein (i.e., in the claims and the specification), articles such as “the,” “a,” and “an” can connote the singular or plural. Also, as used herein, the word “or” when used without a preceding “either” (or other similar language indicating that “or” is unequivocally meant to be exclusive—e.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., “x or y” means one or both x or y). Likewise, as used herein, the term “and/or” shall also be interpreted to be inclusive (e.g., “x and/or y” means one or both x or y). In situations where “and/or” or “or” are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all of the items together, or any combination or number of the items. Moreover, terms used in the specification and claims such as have, having, include, and including should be construed to be synonymous with the terms comprise and comprising.

(45) The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries (e.g., definition of “plane” as a carpenter's tool would not be relevant to the use of the term “plane” when used to refer to an airplane, etc.) in dictionaries (e.g., widely used general reference dictionaries and/or relevant technical dictionaries), commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used herein in a manner more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase “as used herein shall mean” or similar language (e.g., “herein this term means,” “as defined herein,” “for the purposes of this disclosure [the term] shall mean,” etc.). References to specific examples, use of “i.e.,” use of the word “invention” or similar terms are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained herein should be considered a disclaimer or disavowal of claim scope. The subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any particular embodiment, feature, or combination of features shown herein. This is true even if only a single embodiment of the particular feature or combination of features is illustrated and described herein. Thus, the appended claims should be read to be given their broadest interpretation in view of the prior art and the ordinary meaning of the claim terms.