Abstract
A roof snow melt system includes a drip edge cover having a drip edge cable platform and a drip edge S-bend; a first plate having a plate attachment strip insertable into the drip edge S-bend and a plate cable containment lip, the plate cable containment lip and drip edge cable platform to house a length of heat cable; a first valley end cap couplable to the at least one plate, the first valley end cap comprising an insertion lip formed at a valley cap C-shaped bend; and a valley plate to be coupled to a valley of a roof, the valley plate having a valley plate C-bend to receive the insertion lip of the first valley end cap to couple the valley end cap to the valley plate wherein the valley plate includes at least one valley plate containment lip to receive the length of heat cable.
Claims
1. A roof snow melt system comprising: a drip edge cover having a drip edge cable platform and a drip edge S-bend; a first plate having: a plate attachment strip insertable into the drip edge S-bend; and a plate cable containment lip, the plate cable containment lip and drip edge cable platform to house a length of heat cable; a first valley end cap couplable to the at least one plate, the first valley end cap comprising an insertion lip formed at a valley cap C-shaped bend; and a valley plate to be coupled to a valley of a roof, the valley plate having a valley plate C-bend to receive the insertion lip of the first valley end cap to couple the valley end cap to the valley plate.
2. The roof snow melt system of claim 1 further comprising: a valley plate vertical ridge formed along a length of the valley plate.
3. The roof snow melt system of claim 1 further comprising: at least one valley plate containment lip formed along the length of the valley plate to receive the length of the heat cable.
4. The roof snow melt system of claim 3, wherein the containment lip is formed along a first vertical edge of the valley plate and a second vertical edge of the valley plate.
5. The roof snow melt system of claim 1, wherein the first valley end cap includes six sides and wherein at least one side of the valley end cap has an edge formed to interlock with the at least one plate at a valley location on the roof.
6. The roof snow melt system of claim 1 further comprising: a second valley end cap having six sides, wherein at least one of the six sides includes an edge to interlock with a second plate placed above and operatively coupled to the first plate, the second valley end cap fitting over the first valley end cap such that an exposed portion of the heat cable is covered.
7. The roof snow melt system of claim 6, wherein the second valley end cap comprises an insertion lip formed at a valley cap C-shaped bend to be inserted into the valley plate C-bend.
8. A roof snow melt system comprising: a drip edge cover having a drip edge cable platform and a drip edge S-bend; a first plate having: a plate attachment strip insertable into the drip edge S-bend; and a plate cable containment lip, the plate cable containment lip and drip edge cable platform to house a length of heat cable; a first valley end cap couplable to the first plate; and a valley plate to be coupled to a valley of a roof, the valley plate having at least one valley plate containment lip to receive the length of heat cable.
9. The roof snow melt system of claim 8, wherein the valley plate containment lip runs along the length of the valley plate along a first edge of the valley plate and a second edge of the valley plate.
10. The roof snow melt system of claim 8, further comprising: a valley plate vertical ridge formed along a length of the valley plate.
11. The roof snow melt system of claim 8, further comprising: the first valley end cap comprising an insertion lip formed at a valley cap C-shaped bend.
12. The roof snow melt system of claim 8, further comprising: a valley plate C-bend formed along a length of the valley plate to receive the insertion lip of the first valley end cap to couple the valley end cap to the valley plate.
13. The roof snow melt system of claim 8, wherein the first valley end cap includes six sides and wherein at least one side of the valley end cap has an edge formed to interlock with the at least one plate at a valley location on the roof.
14. The roof snow melt system of claim 8, further comprising: a second valley end cap having six sides, wherein at least one of the six sides includes an edge to interlock with a second plate placed above and operatively coupled to the first plate, the second valley end cap fitting over the first valley end cap such that an exposed portion of the heat cable is covered.
15. The roof snow melt system of claim 14, wherein the second valley end cap comprises an insertion lip formed at a valley cap C-shaped bend to be inserted into the valley plate C-bend.
16. A snow melting system for a roof and formed into a valley of the roof comprising: a drip edge cover having a drip edge cable platform and a drip edge S-bend; a first plate having: a plate attachment strip insertable into the drip edge S-bend; and a plate cable containment lip, the plate cable containment lip and drip edge cable platform to house a length of heat cable; a first valley end cap couplable to the first plate, the first valley end cap comprising an insertion lip formed at a valley cap C-shaped bend; and a valley plate to be coupled to a valley of a roof, the valley plate having at least one valley plate containment lip to receive the length of heat cable, wherein the valley plate includes at least one valley plate containment lip to receive the length of heat cable.
17. The roof snow melt system of claim 16 further comprising: a valley plate vertical ridge formed along a length of the valley plate.
18. The roof snow melt system of claim 16, wherein the containment lip is formed along a first vertical edge of the valley plate and a second vertical edge of the valley plate.
19. The roof snow melt system of claim 16, wherein the first valley end cap includes six sides and wherein at least one side of the valley end cap has an edge formed to interlock with the at least one plate at a valley location on the roof.
20. The roof snow melt system of claim 16 further comprising: a second valley end cap having six sides, wherein at least one of the six sides includes an edge to interlock with a second plate placed above and operatively coupled to the first plate, the second valley end cap fitting over the first valley end cap such that an exposed portion of the heat cable is covered, wherein the second valley end cap comprises an insertion lip formed at a valley cap C-shaped bend to be inserted into the valley plate C-bend.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] It will be appreciated that for simplicity and clarity of illustration, elements illustrated in the Figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements. Embodiments incorporating teachings of the present disclosure are shown and described with respect to the drawings herein, in which:
[0021] FIG. 1 is a perspective view of a snow-covered roof, with an exemplary snow melt system partially installed according to an embodiment of the present disclosure;
[0022] FIG. 2 is a perspective view of the snow melt system utilized in FIG. 1 according to an embodiment of the present disclosure;
[0023] FIG. 3 is a close-up view of the snow melt system of FIG. 2, taken in circle III according to an embodiment of the present disclosure;
[0024] FIG. 4 is a perspective view of the drip edge cover utilized in the snow melt system of FIG. 1 according to an embodiment of the present disclosure;
[0025] FIG. 5 is a perspective view of the intermediate plate utilized in the snow melt system of FIG. 1 according to an embodiment of the present disclosure;
[0026] FIG. 6 is a side elevation of the drip edge cover of FIG. 4 and intermediate plate of FIG. 5 joined, with a heating cable according to an embodiment of the present disclosure;
[0027] FIG. 7 is a perspective view of the terminal plate utilized in the snow melt system of FIG. 1 according to an embodiment of the present disclosure;
[0028] FIG. 8 is a side elevation of the terminal plate of FIG. 7 and intermediate plate of FIG. 5 joined, with a heating cable according to an embodiment of the present disclosure;
[0029] FIG. 9 is a close-up view of the snow melt system of FIG. 1, taking in circle IX, detailing its interface with the roof shingles according to an embodiment of the present disclosure;
[0030] FIG. 10 is a perspective view of a snow-covered roof, with an alternate snow melt system partially installed according to an embodiment of the present disclosure;
[0031] FIG. 11 is a perspective view of a snow-covered roof, with a further alternate snow melt system partially installed according to an embodiment of the present disclosure;
[0032] FIG. 12 is an aerial view of a roof valley location according to an embodiment of the present disclosure;
[0033] FIG. 13 is a front perspective view of the plate system substantially covering a roof valley location according to an embodiment of the present disclosure;
[0034] FIG. 14 is a top view of the six-sided valley cap plate according to an embodiment of the present disclosure;
[0035] FIG. 15 is a top view of the heated panel system with cable exposed (without plates) according to an embodiment of the present disclosure;
[0036] FIG. 16 is a top view of the valley end cap covering the heat cable on an intermediate plate according to an embodiment of the present disclosure;
[0037] FIG. 17 is a top view of a second valley end cap being attached over the first or previous valley end cap according to an embodiment of the present disclosure;
[0038] FIG. 18 is a top view illustrating a first and second valley end cap being installed and attached to the plates therein concealing and protecting the heat cable according to an embodiment of the present disclosure;
[0039] FIG. 19 is an aerial perspective view of the snow melt system as assembled illustrating the plates and valley ends at a roof valley location with the plates both stacked vertically as well as horizontally abutting/neighboring, showing how the plates may cover an irregular roof valley location;
[0040] FIG. 20 is a perspective view of a valley plate formed to fit within a valley on a roof according to an embodiment of the present disclosure;
[0041] FIG. 21 is a side view of a valley plate formed to fit within a valley on a roof according to an embodiment of the present disclosure;
[0042] FIG. 22 is a side view of a valley plate formed to fit within a valley on a roof according to another embodiment of the present disclosure;
[0043] FIG. 23 is a side view of a portion of a valley plate, taking in circle IVX of FIG. 22 including a valley plate cable containment lip used to house a heat cable according to an embodiment of the present disclosure;
[0044] FIG. 24 is a side view of a valley plate including a valley plate coupling lip used to interface with a valley end cap according to an embodiment of the present disclosure;
[0045] FIG. 25 is a perspective view of a valley plate interfacing with a plurality of valley end caps according to an embodiment of the present disclosure;
[0046] FIG. 26 is a front perspective view of the snow melt system including a valley plate substantially covering a roof valley location according to an embodiment of the present disclosure.
[0047] The use of the same reference symbols in different drawings may indicate similar items.
DETAILED DESCRIPTION OF THE DRAWINGS
[0048] The following description in combination with the Figures is provided to assist in understanding the teachings disclosed herein. The description is focused on specific implementations and embodiments of the teachings and is provided to assist in describing the teachings. This focus should not be interpreted as a limitation on the scope or applicability of the teachings.
[0049] With reference to FIG. 1, a snow-covered roof 10 is depicted. The roof 10 includes a portion of the roof 10 utilizing an embodiment of the snow melt system 20. In an embodiment, a side of the roof 10 without the system remains covered in a layer of snow 5, while the snow melt system 20 effectively melts snow near an edge portion of the roof 10. The depicted snow melt system 20 (shown and described in more detail in, at least, FIGS. 2 and 3) features, at least, four components: a drip edge cover 30, an intermediate plate 40, a terminal plate 50, and a heat cable 60 (not shown in FIG. 1).
[0050] Drip edge cover 30 (shown and described in more detail in, at least, FIG. 4) is a rectangular plate which has been bent to accommodate the edge of the roof 10. It is appreciated that, although the drip edge cover 30 is shown to have a generally rectangle shape, the drip edge cover 30 may be of any dimension in order to accommodate different size roofs 10 and layouts of those roofs 10. A drip edge attachment strip 37 of the drip edge cover 30 may serve as an attachment, or anchor, section and may be attached to the roof 10 by any known or later discovered roof attachment means, including nails 19, staples, or glue and other adhesives. A drip edge S-bend 35 of the drip edge cover 30 is located adjacent to the longitudinal edge 37 of the drip edge cover 30. The drip edge cover 30 is then folded over itself slightly, creating a protrusion, or cable platform 33 of the drip edge cover 30. This drip edge cable platform 33 may engage with an intermediate plate cable containment lip 43 formed on an intermediate plate 40 or a terminal plate cable containment lip 53 of a terminal plate 50 to contain the heat cable 60 between the respective plated. The drip edge cover 30 may continue, at an angle downward (e.g., at an approximately right angle) and terminate at is drip edge cover lower edge 31 of the drip edge cover 30. The cable platform 33 provides a generally flat surface for interacting with the heat cable 60 and next successive plate (e.g., an intermediate plate 40 or terminal plate 50) which, in the depicted embodiment in FIG. 1, includes the intermediate plate 40.
[0051] The intermediate plate 40 (shown and described in more detail in, at least, FIG. 5) may have a rectangular shape with two longitudinal edges in an embodiment. It is appreciated, however, that the dimensions of the intermediate plate 40 (and the terminal plate 50) may be different to fit different roofs surfaces and purposes and the present specification contemplates these different dimensions. Similar to the drip edge cover 30, the intermediate plate upper edge 47 (shown in, at least, FIG. 5) serves as an anchor strip and may be fastened to the roof using a nail 19 or other appropriate fastening device. Proximate the intermediate plate upper edge 47 is an intermediate plate S-bend 45 of the intermediate plate 40 similar to that of the drip edge cover 30. The lower edge of the intermediate plate 40 may be folded over itself and bent in a slight V-bend to form an intermediate plate cable containment lip 43 of the intermediate plate 40 while the intermediate plate attachment strip 41 itself becomes an insert for the drip edge cover's S-bend 35. The interaction of these pieces is shown in FIG. 6 in an example embodiment. The intermediate plate attachment strip 41 of the intermediate plate 40 is fitted into the S-bend 35 of the drip edge cover 30. The intermediate plate cable containment lip 43 and cable platform 33 of the drip edge cover 30 combine to form a heat cable chamber 25 in which heat cable 60 may reside. In an embodiment, the gauge or size of the heat cable 60 may be selected such that the heat cable 60 is wedged into the cable chamber 25 in order to maximize contact between the heat cable 60 and both the drip edge cover 30 and intermediate cover 40 to promote thermal conduction throughout the snow melt system 20. The intermediate plate 40 then covers the remainder of the drip edge cover 30, including the attachment strip 37 in order to properly shed water from melted snow and ice from off of the roof 10. This arrangement prevents water from interacting with the roof attachment means so that the homeowner's roof and internal structures are not water damaged.
[0052] The terminal plate 50 features a similar containment lip structure as that of the intermediate plate 40 referred to herein as the terminal plate cable containment lip 53. As the intermediate plate 40 interfaces with the terminal plate 50, the terminal plate 50, with its lower end folded over to form a terminal plate attachment strip 51, may be operatively coupled together in order to secure the terminal plate 50 to the intermediate plate 40 (e.g., as seen in, at least, FIG. 7). It is appreciated that, because the terminal plate 50 does not interface with another plate further up slope of the roof 10, the terminal plate 50 does not feature an S-bend, but instead terminates at its terminal plate upper edge 57. In an embodiment, the terminal plate 50 interfaces with the intermediate plate in exactly the same manner as the intermediate plate 40 interfaces with the drip edge cover 30 (e.g., as seen in, for example, FIGS. 2, 3, and 8). That is to say that the terminal plate attachment strip 51 is positioned into the intermediate plate S-bend 45 and the terminal plate cable containment lip 53, in combination and in the coupled state, forms a cable chamber 25 for the heat cable 60. In an embodiment, a significant portion of the anchor strip 47 of the intermediate plate 40 is covered. This allows the terminal plate 50 to also be fastened to the roof at its upper edge 57. In an embodiment, the terminal plate upper edge 57 may have its edge covered by shingles 15 (e.g., as seen in, for example, FIG. 9), circle IX). In so doing, each successive upper layer to the system protects the lower layers' attachment to the roof 10. It is appreciated that multiple layers of intermediate plates 40 may be placed up the slop of the roof 10 and, in some example embodiments, may cover the entire surface of the roof 10 with a terminal plate 50 being the penultimate layer of plates and below a roof peak cap (e.g., a metal cap or other shingle cap material). Again, the terminal plate 50 may be coupled to the surface of the roof 10 using a nail 19 similar to the nail 19 shown in FIG. 8 being used to secure the intermediate plate 40 to the surface of the roof 10.
[0053] It is appreciated that variations to the snow melt system 20 are possible and contemplated by the present specification. As can be seen in FIG. 10, for example, the terminal plate 50 may be attached directly to the drip edge cover 30 or. Alternatively, as shown in FIG. 11 for example, at least one additional layer of intermediate plates 40 may be added to the snow melt system 20. Since the attachment methodology is uniform with each plate (e.g., 30, 40, 50), any number of intermediate plates 40 may be utilized.
[0054] In an embodiment, each of the drip edge cover 30, the intermediate plates 40, and the terminal plate 50 may be made of a heat-conductive metal. It is appreciated that metal alloys may also be used as material from which the plate (e.g., 30, 40, 50) 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 e.g., 35 and 45) and the containment lips (e.g., 43 and 53), may be easily and permanently formed while the structure of the plates (e.g., 30, 40, 50) may retain enough elasticity so that the pieces may be locked together and hold the heat cables 60. In an embodiment, dimensions of the individual plates (e.g., 30, 40, 50) may vary depending upon the actual material from which they are made and the intended roofing material that may accompany them on the surface of the roof 10. A length between 3-4 feet (0.9-1.2 meters) may provide for good coverage while also being manageable for installation. It is also true that smaller length plates (e.g., 30, 40, 50) may be utilized as caps for even coverage over the roof 10 without cutting the plates (e.g., 30, 40, 50).
[0055] In an embodiment, the plates (e.g., 30, 40, 50) may have enough width to cover at least one exposed shingle face (typically 6 inches) or a roofing tile (typically 12 inches) with some overlap to fit underneath the next higher row of roofing material used to finish the roof 10. The width of the plates (e.g., 30, 40, 50) 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. In an embodiment, a maximum width of the plates (e.g., 30, 40, 50) may be selected such that the plate will conduct heat throughout its entire width and length. Therefore, a width of 12 to 14 inches (0.30 to 0.35 meters) may provide effective heat distribution through the plates (e.g., 40, 50), but a width of as little as 6 inches (0.15 meters) may also be utilized.
[0056] In an embodiment, the heat cables 60 may be threaded through the space formed by the containment lips (e.g., 43 and 53) or may be positioned as each plate is installed. They may also be slipped under each of the containment lips (e.g., 43 and 53), using the elasticity of the material used to form the plates (e.g., 30, 40, 50) (e.g., a metal such as aluminum) to harmlessly create enough space for installation. Removal and replacement of the heat cable 60 may be accomplished by either pulling it out horizontally from within the containment lips (e.g., 43 and 53) or by slipping it under the containment lips (e.g., 43 and 53). The elasticity of the metal forming the containment lips (e.g., 43 and 53) allows the containment lips (e.g., 43 and 53) to contain heat cable 60 in one position in the snow melt system 20, allowing for uniform operation. The containment lips (e.g., 43 and 53) may also accommodate various sizes of heat cable 60, including heat cable 60 slightly larger than the cable chamber 25 formed by the containment lips' (e.g., 43 and 53) construction. Agan, at least some contact to be made between the heat cable 60 and the plates and further contact between the heat cable 60 and plates (e.g., 30, 40, 50) will create relatively more efficient heat transfer from the heat cable 60 to the plates (e.g., 30, 40, 50) thereby increasing the snow and ice melting capabilities of the snow melt system 20.
[0057] In an embodiment, the snow melt system 20 may further include a valley end cap 300-1 (and also 300-2) that comprises a formed cap plate that integrates with the heated plates (e.g., 30, 40, 50). Once the heat cable 60 is installed into the snow melt system 20, valley end caps 300-1 will be used to fill or cover cavities formed by and finish off the ends of the plates (e.g., 30, 40, 50). The process of the installation of these valley end caps 300-1 may involve working from the bottom of the snow melt system 20 and working to the top installing subsequent valley end caps 300-1. Thus, a second valley end cap 300-2 may be installed on top of a first valley end cap 300-1. The snow melt system 20 can accommodate multiple rows and/or plates to conceal the heat cable 60 appropriately.
[0058] In an embodiment, the valley end cap 300-1 may be engineered, positioned, and designed to mount to the terminated cut end of a plate (e.g., 30, 40, 50) at a valley 470 location and conceal the heat cable 60 under the valley end cap 300. The valley end caps' 300-1 positioning, engineering and design accommodates the heat cable 60 in a structural transition from, for example, a drip edge cover 30 to an intermediate plate 40 or an intermediate plate 40 to a terminal plate 50. In the process of concealing the existing heat cable 60, this valley end cap 300-1 may also account for snow and ice that may slide down the roof 10 allowing that snow or ice to flow over the top of the snow melt system 20. Previously, these locations exposed the heat cable 60 and made it vulnerable to ice and snow damaging the heat cable 60. The described methods and systems that include the valley end cap 300-1 address these issues.
[0059] In some embodiments, after the plates (e.g., 30, 40, 50) for the roof 10 are installed, the heat cable 60 is then inserted into the plates (e.g., 30, 40, 50) as described herein with portions of the heat cable 60 extending out from each of the plates (e.g., 30, 40, 50) and towards the various locations of valleys 470 on the roof 10. The heat cable 60 therefore transitions from one horizontal cable chamber 25 to another horizontal cable chamber 25 as described herein with the heat cable 60 passing up the slop of the roof 10 in a serpentine manner from one level of plates (e.g., 30, 40, 50) to a next vertically available level of plates (e.g., 30, 40, 50).
[0060] At the transition point(s) between the drip edge cover 30 and the intermediate plate 40 as well as between the intermediate plate 40 and the terminal plate 50, the valley end cap 300-1 is then placed over the top of the heat cable's 60 transition position. In some embodiments, the top side of the valley end cap 300-1 slides into the cavity of the cable chamber 25 used for containing the heat cable 60 as described herein. The side of the valley end cap 300-1 that intersects with a valley plate 480 at the valley 470 has a that hooks into a C-fold formed into the valley plate 480, in an embodiment, to hold the valley end cap 300-1 at the valley 470. As described herein, a valley plate 480 may be used to not only secure these valley end caps 300-1 in place but also hold its own or the same heat cable 60 in place such that a heat cable 60 is made to run up and down the length of the valley plate 480.
[0061] In an embodiment, a small fold on the bottom side of the valley end cap 300-1 may be used to hook to a lower edge of a plate (e.g., 30, 40, 50). At this position-point, optional screws are placed to secure the valley end cap 300 to the roof 10. An optional additional valley end cap 300-2 is then placed over the first valley end cap 300-1, therein integrating the edges of the valley end cap 300-1 to the plates (e.g., 30, 40, 50) and valley plate 480 (similar to the first valley end cap 300-1 position).
[0062] Some advantages to the valley end caps 300-1 include, but are not limited to, containment of the heat cable 60, thereby preventing the heat cable 60 from being exposed to the elements and preventing additional damage from wind, snow, ice, or other factors that could damage the heat cable 60. Additionally, the valley end caps 300-1 cover the heat cable 60 thereby visually hiding the heat cable 60 and increasing the athletics of the roof as viewed by the public from a street or other visual advantage location. Additionally, the valley end caps 300-1 are formed and positioned in such a way that they allow for the sliding of snow off the roof 10 to pass over the top of it and not catch any exposed edges of the plates (e.g., 30, 40, 50) and other physical elements of the snow melt system 20. This design and fabrication technique may further prevent snow and ice from pulling on or dragging any parts of the snow melt system 20 and ripping them off the roof 10.
[0063] Still further, the positioning, engineering and design of the valley end cap(s) 300-1 create(s) a low visual profile. Bare heat cables 60 and other heat cable products are unduly bulky. The presently described snow melt system 20 with the valley end caps 300-1 are low-profile to elegantly conceal into the snow melt system 20. The end result of the presently-described snow melt system 20 is a professional, clean looking roof 10. Even further, the valley end caps 300-1 may be comprised of standard sheet metal, any appropriate metallic, or composite material in a substantially sheet-form. Examples may include copper, steel, aluminum, alloys of various metals, or alternate appropriate materials/composites. Again, it is appreciated that, because the heat cable 60 may come in physical contact with the valley end caps 300-1 as well as the other plates (e.g., 30, 40, 50), the material used to form the valley end caps 300-1 and the plates (e.g., 30, 40, 50) may be thermally conductive such that snow and ice may be melted off from the surface of the snow melt system 20 as described herein.
[0064] In an embodiment, the valley end caps 300-1 (and the plates (e.g., 30, 40, 50)) may be made of Kynar-clad sheet metal. Kynar designed to be integrated into the snow melt system 20 (by, inter alia, Wasatch Heat Cable). The integration of the valley end caps 300-1, 300-2 conceals and protects the heat cable 60 within the snow melt system 20. Applying the valley end caps 300-1, 300-2 protects for the heat cable 60 and the plates (e.g., 30, 40, 50) of the roof 10 by providing a smooth surface for anything sliding from the top of the roof 10 to the bottom of the roof 10 to flow over the top of the components without catching any edges. The valley end caps 300-1 are low-profile, therefore being aesthetically appealing to higher-end snow melt systems 20.
[0065] FIG. 12 shows a roof valley location 470 which implements the valley end caps 300-1, 300-2 described herein. The positioning of the adjacent shingles 15 at this location 470 requires the special feature (infra) which can cover this location while housing the heat cable 60. It is appreciated that the other elements of the snow melt system 20 described in connection with, for example, FIGS. 1 through 11 may be used in connection with the valley end caps 300-1, 300-2 and valley plate 480 as described herein.
[0066] FIG. 13 is a front perspective view of the valley end cap 300-1, 300-2 and valley plate 480 substantially covering a valley 470 location of a roof, illustrating substantially abutting/neighboring plates (e.g., 30, 40, 50) interconnected in-and-around a valley 470 that may or may not include gutters placed near the valley 470. In an embodiment, the heat cable 60 is shown running into the base of the valley plate 480 allowing the heat cable 60 to be run up and down the length or a portion of the length of the valley 470 of the roof 10 in order to melt snow 5 and ice within the valley 470. The valley plate 480 runs between the valley end cap 300-1, 300-2 running vertically up each side of the valley 470 of the roof 10. The valley plate 480 may be made to cover the intermediate valley 470 between these valley end cap 300-1, 300-2 (which cover their associated shingles and plates where applicable).
[0067] This intermediate structure, the valley plate 480 of the valley 470, is a special valley plate positioned in the roof's groove/valley. The valley plate 480 comprises parallel channels running vertically (longways, as shown) such that that the cable 60 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 an embodiment, the valley plate 480 is positioned in a roof valley 470, running substantially from the roof's 10 top to its bottom. The valley plate 480 comprises at least two substantially parallel cable chambers 25, each cable chamber 25 having at least one entry/exit point for accommodating the heat cable 60.
[0068] In an embodiment, the heat cable 60 runs inside the valley plate 480 at the roof valley 470 location, and then the heat cable 60 exits the valley plate 480 to enter another plate (e.g., 30, 40, 50) in a series/stacking fashion as shown in, at least, FIG. 13 and in FIG. 19. The cable may alternatively exit the flashing plate 480 and then run away from the roof's 10 plates (e.g., 30, 40, 50) to ground or into a parapet or a rain gutter or another position.
[0069] FIG. 14 is a top view of a six-sided valley end cap 300-1 (similarly valley end cap 300-2) according to an embodiment of the present disclosure. The valley end cap 300-1 features six irregular sides designed to cover the heat cable 60 at the valley 470 location of a roof 10. The valley end cap 300-1 features a valley cap C-shaped bend 430 at the outer edge of the valley end cap 300. The valley cap C-shaped bend 430 therein forms an interlocking-capable edge wherein the valley cap edge height 440 is substantially the same as the height differential 400 between plates (e.g., 30, 40, 50) (e.g., an intermediate plate 40 and a terminal plate 50, shown in FIG. 14). The elasticity of the sheet metal comprising the intermediate plate 40 and the terminal plate 50 allows the necessary requisite slope bending to bridge this vertical height differential 400. Copper-based plate material, or common sheet metal, or a composite thereof, allows for this elasticity.
[0070] In an embodiment shown in FIG. 14, side one 301 of the valley end cap 300 features a clean cut with a vertical direction relative to the plane of the roof 10. This side one 301 of the valley end cap 300-1 overlaps atop the intermediate plate 40 or terminal plate 50, therein allowing the snow melt system 20 to jump over the valley 470 (not shown in FIG. 14), as well as allow the heat cable 60 to snake underneath the snow melt system 20 unencumbered by weather.
[0071] In an embodiment, side two 302 of the valley end cap 300-1 includes an inner surface of side two's 302 valley cap C-bend 430 that includes an insertion lip 330. The insertion lip 330 of the valley cap C-shaped bend 430 of the first valley end cap 300-1 may hook into or otherwise interface with a corresponding C-bend 430 of a second valley end cap 300-2, therein fitting into and covering, at least, a portion of the valley 470. In an embodiment, the valley cap C-bend 330 may have a valley cap edge height 440 that matches the height differential 400 such that the insertion lip 330 may interface with other valley end caps such as the second valley end cap 300-2 and the valley plate 480 described herein.
[0072] In an embodiment, side three 303 of the first valley end cap 300-1 includes a diagonal transition that assists in physically covering the heat cable 60 when installed and transitions on top of the previous/next valley end cap such as the second valley end cap 300-2 (e.g., illustrated in, for example, FIGS. 17 and 18). The diagonal transition of side three 303 allows one plate to sufficiently bend over another plate to bridge the height gap 400 between the instant planes.
[0073] In an embodiment, edge four 304 of the valley end cap 300-1 comprises an under-fold that hooks the bottom lip of the plate (e.g., 30, 40, 50) (not shown), keeping the valley end cap 300-1 secure to the plate (e.g., 30, 40, 50) as shown in FIG. 16. Additionally, a fifth side 305 of the valley end cap 300-1 herein shows the top side of the plate 300 that inserts between (and partially covers) the plate (e.g., 30, 40, 50) (not shown) and underneath the heat cable 60 which is also covered by the second valley end cap 300-2 (not shown in FIG. 14). In an embodiment, side six 306 of the valley end cap 300-1 is a diagonal notch that allows the heat cable 60 to transition/jump from underneath the valley end cap 300-1 and transition/jump to the top of the valley end cap 300-1 towards its own side one 301 and into the plate (e.g., 30, 40, 50) (not shown) system.
[0074] FIG. 15 is a top view of the heated panel system with cable exposed (without plates) according to an embodiment of the present disclosure. FIG. 15 shows two plates (e.g., 30, 40, 50) (in this case an intermediate plate 40 and a terminal plate 50) with the heat cable 60 being slightly exposed next to a valley 470 formed on a roof 10. FIG. 15 further shows the intermediate plate 40 and the terminal plate 50 being connected together with a joint as described herein. Indeed, at this point of installation, the intermediate plate 40 and terminal plate 50 may have been affixed to the roof 10 using a nail 19 or other coupling device. There is a length of heat cable 60 that transitions from the cable chamber 25 of the intermediate plate 40 up to the heat cable chamber 25 of the terminal plate 50 proximate to the valley location 470.
[0075] FIG. 16 is a top view of the valley end cap 300-1 covering the heat cable 60 on an intermediate plate 40 according to an embodiment of the present disclosure. FIG. 16 shows a first valley end cap 300-1 installed with the heat cable 60 transitioning from within the cable chamber 25 of the terminal plate 50 placed above the intermediate plate 40, underneath the valley end cap 300-1, and into the cable chamber 25 of the intermediate plate 40 thereby running/jumping into the cavity 470 between the intermediate plate 40 and the terminal plate 50. As described herein, the valley end cap 300-1 includes a number of edges that interface with the intermediate plate 40 and terminal plate 50 such that the valley end cap 300-1 is secured to, at least, the intermediate plate 40 such that the valley end cap 300-1, when installed, will not be moved via movement of snow or ice as it melts within the valley 470.
[0076] FIG. 17 is a top view of a second valley end cap 300-2 being attached over the first or previous valley end cap 300-2-1 according to an embodiment of the present disclosure. FIG. 17 shows that the second valley end cap 300-2 is arranged to be installed over the top of the first valley end cap 300-1 and coupled to the terminal plate 50. In this process, the second valley end cap 300-2 will completely cover any exposed portion of the heat cable 60 that transitions from the cable chamber 25 formed into the terminal plate 50 and routed into the cable chamber 25 of the intermediate plate 40. It is appreciated that the second valley end cap 300-2 may include similar securing features along the sides (e.g., 301, 302, 303, 304, 305, 306) of the valley end cap 300-2 as those described in connection with the valley end cap 300-1 in FIG. 14 that secures the second valley end cap 300-2 to, at least, the terminal plate 50 in order to prevent the second valley end cap 300-2 from being dislodged as snow and ice is flowing down the valley 470 and is being melted by the snow melt system 20 described herein.
[0077] FIG. 18 is a top view illustrating a first valley end cap 300-1 and second valley end cap 300-2 being installed and attached to their respective plates (e.g., 40, 50) therein concealing and protecting the heat cable 60 according to an embodiment of the present disclosure. FIG. 18 shows that the first cap plate 300-1 is fully installed, as well as the second cap plate 300-2. FIG. 18 shows 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).
[0078] During installation of the snow melt system 20 and after the intermediate plate 40 and terminal plate 50 have been installed, the heat cable 60 may be placed or run through the cable chamber 25 with a portion of the heat cable 60 being exposed as shown in, for example, FIG. 15, the snow melt system 20 will then be ready to have the valley end cap 300-1, 300-2 installed. In an embodiment, installing a valley end cap 300-1, 300-2 may be accomplished according to the following steps. In an embodiment, side five 305 of the first valley end cap 300-1 may be inserted between the connecting joints of the intermediate plate 40 and terminal plate 50 and underneath the cable chamber 25 that runs between the joints of the intermediate plate 40 and terminal plate 50. In an embodiment, side four 304 of the first valley end cap 300-1 may be hooked onto the bottom of the intermediate plate 40. At this point, side two 302 may be inserted into the valley plate C-bend 482 of the valley plate 480 placed and secured into the valley 470 of the roof 10. Side three 503 of the first valley end cap 300-1 covers the transition location of any previous intermediate plate 40 (where applicable). At this point, the terminal plate 50 also features a terminal plate attachment strip 51 at the outer edge of the terminal plate 50. The terminal plate attachment strip 51 therein forms an interlocking-capable edge wherein the edge height is substantially the same as the valley cap edge height 440 of the first valley end cap 300-1. It is appreciated that the height differential 400 between plates (e.g., 40, 50, shown in FIG. 18 as height differential 400) is covered by the elasticity of the sheet metal type material comprising the intermediate plate 40 and the terminal plate 50. The material of the terminal plate 50 therefore allows the requisite bend to bridge this vertical slope plane height differential 400.
[0079] At this point the terminal plate cable containment lip 53 of the terminal plate 50 overlaps atop the intermediate plate 40 therein allowing the system to jump over the valley 470, thereby allowing the heat cable 60 to snake underneath the intermediate plate 40, the terminal plate 50, the first valley end cap 300-1, and second valley end cap 300-2 (unencumbered by weather). In an embodiment, a second edge of the terminal plate 50 similarly features an insertion lip 330 (inner surface of C-bend, herein not shown as it resides on the underside of the terminal plate 50). The inner surface of the terminal plate's 50 insertion lip 330 hooks into the corresponding insertion lip 330 of the intermediate plate 40, therein fitting into and covering, at least, a portion of the valley 470.
[0080] FIG. 19 is an aerial perspective view of the snow melt system 20 as assembled illustrating the plates (e.g., 40, 50) and valley end caps 300-1, 300-2 at a valley 470 on the roof 10 with the plates (e.g., 40, 50) both stacked vertically as well as horizontally abutting/neighboring plates (e.g., 40, 50), showing how the plates (e.g., 40, 50) may cover an irregular roof valley 470 location.
[0081] FIG. 20 is a perspective view of a valley plate formed to fit within a valley (e.g., 470, FIG. 13) on a roof 10 according to an embodiment of the present disclosure. As described herein, this valley plate 480 may interface with the valley end caps 300-1, 300-2 described herein on both sides of the valley 470. Thus, those valley end caps 300-1, 300-2 described in connection with FIGS. 13 through 19 show the use of right-handed valley end caps 300-1 where mirror-image versions of those valley end caps 300-1, 300-2 may be used as left-handed valley end caps 300-1, 300-2 such that both sides of the valley plate 480 may interface with a valley end cap 300-1, 300-2 as described herein. It is, however, anticipated that only one side of the valley plate 480 may interface with one or more valley end caps 300-1, 300-2 in those situations where ice or snow may not accumulate to a significant degree on that slop of the roof 10 where plates (e.g., 40, 50) and a heat cable 60 (not shown in FIG. 20) are not placed.
[0082] As described herein, the valley plate 480 may include at least one valley plate C-bend 482-1, 482-2. FIG. 20 shows that the valley plate 480 includes two valley plate C-bends 482-1, 482-2 for coupling to one or more valley end caps 300-1, 300-2 along both sides, right and left sides, of the valley plate 480 formed within the valley 470. It is appreciated that each of the valley plate C-bends 482-1, 482-2 may run the entire length of the valley plate 480 so that any number of valley end caps 300-1, 300-2 may be operatively coupled to the valley plate 480. By coupling the valley end caps 300-1, 300-2 to the valley plate 480, additional structural support may be imparted onto the valley end caps 300-1, 300-2 such that any snow or ice that slides down the valley 470 are not able to dislodge the valley end caps 300-1, 300-2 from their installed locations as described herein. It is appreciated that, in some embodiments, the valley plate 480 may not implement a valley plate C-bend 482-1, 482-2 allowing the valley end caps 300-1, 300-2 physical coupling to each of the plates (e.g., 40, 50) for structural support as described herein. It is appreciated that a portion of the valley plate C-bend 482-1, 482-2 may extend a distance from the center of the valley plate 480 so that the valley plate 480 may be secured to the roof 10 via nailing one or more nails into the extended portion of the valley plate 480 and into the subsurface of the roof 10.
[0083] As shown in FIG. 20, the valley plate 480 also includes, in an embodiment, a valley plate vertical ridge 483. The valley plate vertical ridge 483 may be in the form of a ridge that extends the entire length of the valley plate 480. In an embodiment, the valley plate vertical ridge 483 may be used to impart additional structural support to the valley plate 480. In an alternative embodiment, the valley plate vertical ridge 483 may be used to bifurcate the melting snow and ice in order to better melt the ice and snow as well as drain the resulting water from off of the roof 10. It in embodiment, the valley plate 480 may not include a valley plate vertical ridge 483.
[0084] The dimensions of the valley plate 480 may promote the transmission of heat from the heat cable 60 such that snow and ice within the valley 470 can be effectively melted and the resulting water may run effectively down the valley plate 480 and to a gutter system where available. FIG. 21 is a side view of a valley plate 480 formed to fit within a valley 470 on a roof 10 according to an embodiment of the present disclosure. FIG. 21 shows the valley plate 480 conforming to a surface of the roof 10 within a valley 470. The valley plate vertical ridge 483 may be aligned with the lowest part of the valley 470, in an embodiment. Again, the pliability of the material that the valley plate 480 is made of such as copper or aluminum allows for the installer to generally cause the valley plate 480 to conform to the surface of the roof 10 at the valley 470. Indeed, because the pitches of different roof surfaces that meet at this valley 470 may vary from house to house and even from valley 470 to valley 470 on a single roof 10, the pliability of the valley plate 480 allows for a single product to be manufactured that can be used in a variety of situations.
[0085] Again, FIG. 21 shows a middle cross-sectional portion of the valley plate 480 that includes the valley plate cable containment lips 484-1, 484-2. As described herein, these valley plate cable containment lip 484-1, 484-2 may be used to secure a heat cable 60 along the length of the valley plate 480. As shown, the heat cable 60 may be passed up a first side of the valley plate 480 and down a second side of the valley plate 480 so as to provide heat to both sides of the valley plate 480. The heat cable 60 placed within the valley plate cable containment lips 484-1, 484-2 of the valley plate 480 may prevent ice and snow accumulation within the valley 470 as well as continue the heating of the snow and ice between different sets of plates (e.g., 30, 40, 50) formed on the slopes of the roof 10.
[0086] FIG. 21 also depicts certain dimensions of the valley plate 480 being called out and highlighted. For example, section A depicts a length of a valley plate cable containment lip 484-1, 484-2 which may be the same for both valley plate cable containment lips 484-1, 484-2. As described herein, the valley plate cable containment lip 484-1, 484-2 is used to house the heat cable 60 and, as such may be sized to hold the heat cable 60 against the under-surfaces of the valley plate cable containment lip 484-1, 484-2. In an embodiment, the length A of the valley plate cable containment lip 484-1, 484-2 may be 3 inches. In an embodiment, the length A may be between 2 and 4 inches. It is appreciated that other lengths may be used, and the present specification contemplates these other lengths. The valley plate cable containment lip 484-1, 484-2 also includes a first finger length B of about 0.5 inches. In an embodiment, the first finger length B is between 0.3 and 0.7 inches. It is appreciated that other lengths for the first finger length B may be used, and the present specification contemplates these other lengths. Indeed, the lengths of A and B may vary depending on an anticipated gauge or size of the heat cable 60 and may be selected such that the inner surfaces of the valley plate cable containment lip 484-1, 484-2 come into maximum contact with the heat cable 60 while the first finger of the valley plate cable containment lip 484-1, 484-2 is still in contact with the surface of the valley plate 480. This maximum contact with the heat cable 60 allows a maximum amount of heat to be conducted into the material of the valley plate 480 thereby increasing the ability for the snow melt system 20 to melt ice and snow and prevent ice dams from forming on the roof 10.
[0087] As described herein, the valley plate 480 may also include a flashing edge 485. The flashing edge 485 may be an extended portion of the valley plate 480 that is meant to receive a nail 19 or other fastening device that secures the valley plate 480 to the surface of the roof 10. In an embodiment, a length D of the flashing edge 485 may be between to 10 inches. It is appreciated that the nails 19 and the flashing edge 485 may be covered by the terminal plate 50, the intermediate plate 40, and/or the valley end caps 300-1, 300-2 described herein so that the waterproofing of the roof 10 may be maintained. In an embodiment, a layer of flashing tape, roofing cement, or other roofing sealing may be used along the flashing edge 485 in order to provide an additional layer of waterproofing along the sides of the valley plate 480.
[0088] The valley plate 480 may also include a gutter dimension C that is the length of the valley plate 480 from a center line 486 to an end of the valley plate cable containment lip 484-1, 484-2. In an embodiment, this length of the gutter dimension C may be 1 to 3 inches. Agan, it is appreciated that other lengths may be used, and the present specification contemplates these other lengths. The length of the gutter dimension C may be selected based on, for example, the heat conductive properties of material that the valley plate 480 is made of. Where the heat conductive properties of the material that the valley plate 480 is made of is relatively high, the length of the gutter dimension C may be increased. Where the heat conductivity of the material that the valley plate 480 is made of is relatively lower, the length of the gutter dimension C may be reduced so that heat may be evenly distributed within the lower portions of the valley plate 480.
[0089] FIG. 22 is a side view of a valley plate 480 formed to fit within a valley 470 on a roof 10 according to another embodiment of the present disclosure. Similar to FIG. 21, FIG. 22 shows those dimensions (e.g., A, B, C, and D) that describes the size of the valley plate 480 in some embodiments. Additionally, the valley plate 480 is shown to be secured to the roof 10 using one or more nails 19.
[0090] A difference between FIG. 21 and FIG. 22 is the absence of a valley plate vertical ridge 483 in FIG. 22. As described herein, the valley plate 480 may not include a valley plate vertical ridge 483 and may include a gutter dimension C that is measured from a center line 486 to an edge of the valley plate cable containment lip 484-1, 484-2.
[0091] Both FIGS. 21 and 22 include circle IVX that focuses on the right hand valley plate cable containment lip 484-1, 484-2. FIG. 23, therefor, is a side view of a portion of a valley plate 480, taking in circle IVX of FIGS. 21 and 22 including a valley plate cable containment lip 484-1, 484-2 used to house a heat cable 60 (not shown) according to an embodiment of the present disclosure. FIG. 23 includes a number of angles that further define the orientation of the metal surfaces of the valley plate cable containment lip 484-1, 484-2 of the valley plate 480. For example, a first angle 0 may define a pocket angle where the heat cable is placed. In an embodiment, this first angle 0 may be 150. In an embodiment, this first angle 0 may be between 100 to 200. This first angle 0 may allow for the pocket to be formed such that the heat cable may sit, be secured within, and come into maximum contact with the material of the valley plate 480 in order to best conduct heat into the valley plate 480.
[0092] FIG. 23 also shows a second angle that is formed as the valley plate 480 is double backed towards the valley plate cable containment lip 484-1, 484-2. In an embodiment, during manufacturing, the second angle may be formed into a 0. However, as the valley plate cable containment lip 484-1, 484-2 is formed this may change to increase to between 0 and 15. However, because the second angle is created as a 0 angle, the material of the valley plate 480 is biased such that the valley plate cable containment lip 484-1, 484-2 is forced against the valley plate 480 to create the valley plate cable containment lip 484-1, 484-2 used to house the heat cable 60. This bias, spring force created by the second angle causes the heat cable 60 to be pressed against the interior surfaces of the valley plate cable containment lip 484-1, 484-2 for maximum heat conductivity.
[0093] FIG. 24 is a side view of a valley plate 480 including a valley plate C-bend 482-1, 482-2 used to interface with a valley end cap 300-1, 300-2 according to an embodiment of the present disclosure. The valley plate 480 shown in FIG. 24 may include those elements similar to FIG. 21, for example, such as the valley plate vertical ridge 483, valley plate cable containment lip 484-1, 484-2, and flashing edge 485 as described herein.
[0094] In an embodiment, the flashing edge 485 may include a valley plate C-bend 482-1, 482-2 that is formed at the end of the flashing edge 485. The valley plate C-bend 482-1, 482-2 may be a portion of the flashing edge 485 that is doubled back and configured to receive an insertion lip 330 of each of the valley end caps 300-1, 300-2. The insertion lip 330 is part of the second side 302 of the valley end cap 300-1, 300-2 and is used to better secure the valley end caps 300-1, 300-2 in place along the length of the valley plate 480. Indeed, FIG. 25 shows such an assembly.
[0095] FIG. 25 is a perspective view of a valley plate 480 interfacing with a plurality of valley end caps 300-1, 300-2 according to an embodiment of the present disclosure. FIG. 25 shows only a portion of the valley plate 480 that interfaces with the valley end caps 300-1, 300-2 which includes the valley plate C-bend 482-1, 482-2 shown, at least, in FIG. 24. Indeed, FIG. 25 shows that the insertion lips 330 of each of the valley end caps 300-1, 300-2 are and can be inserted into the valley plate C-bend 482-1, 482-2 during installation of the snow melt system 20. The inclusion of the insertion lip 330 on the valley end caps 300-1, 300-2 and the valley plate C-bends 482-1, 482-2 formed to receive the insertion lips 330 allows for a better secured valley end caps 300-1, 300-2 along the length of the valley plate 480. Indeed, as snow, ice, and water flow down the valley plate 480, the rigidity of the coupling of the valley end caps 300-1, 300-2 to the valley plate 480 prevent damage to the snow melt system 20 and the heat cable 60 housed underneath the valley end caps 300-1, 300-2.
[0096] FIG. 26 is a front perspective view of the snow melt system 20 including a valley plate 480 substantially covering a roof valley 470 location according to an embodiment of the present disclosure. As shown, the valley plate 480 may interface with valley end caps 300-1, 300-2 along both sides of the valley plate 480 such that the entire valley 470 is both heated using the heat cable 60 and the valley end caps 300-1, 300-2 are secured such that the snow, ice, and water cannot dislodge the valley end caps 300-1, 300-2 should they flow down the valley 470 and valley plate 480. Again, the heat cable 60 may be run up and back down a valley plate cable containment lip 484-1, 484-2 formed into the valley plate 480 such that both sides of the valley plate 480 are heated along with the serpentine heat cable 60 placed within the plate cable containment lips 43, 53 of the intermediate plates 40 and terminal plate 50.
[0097] Although only a few exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the embodiments of the present disclosure. Accordingly, all such modifications are intended to be included within the scope of the embodiments of the present disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
[0098] The subject matter described herein is to be considered illustrative, and not restrictive, and the appended claims are intended to cover any and all such modifications, enhancements, and other embodiments that fall within the scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents and shall not be restricted or limited by the foregoing detailed description.
