Method and apparatus for metal valley installation

A unique method and apparatus for metal valley installation that waterproofs shingled roof applications in valley (e.g., such as “V” or “W” metal valley angled roof) applications. Applicant's invention provides a membrane situated between the metal valley and the shingles with a portion of the membrane being situated and secured to the roof deck between the ice and water shield and the shingles. The membrane creates a dead zone that collects or prevents ice and water from backing up from the roof valley over the metal valley, over the edge of the metal valley, and in between the ice and water shield and the shingles.

II. FIELD OF THE INVENTION

The present invention relates to waterproofing the roof of a dwelling or other structure such as a roof having an open metal valley. More particularly, Applicant's invention is a method for securing and waterproofing valley shingles in shingled roof applications, while allowing freedom of movement between the metal valley and the valley shingles, and, allowing the easy removal of worn shingles without damaging existing valley metal.

III. DESCRIPTION OF THE PRIOR ART

Current common method: The current method of installing a metal valley involves first, applying a layer of “ice and water shield”, which is a commonly used, roll-dispensed membrane, with or without a granulated surface, and a bitumen or similarly functioning tacky layer (which seals around roofing nails) for adhesion to a wood roof deck. A metal valley strip, in a “V” or “W” configuration, with an included angle the same as that of the intersecting roofs, is then laid on the newly applied ice and water shield and secured to the roof deck, through the ice and water shield, with edge clips, or nail heads only. The valley shingles are cut to length and with the corresponding angle of the valley. It is commonly thought that driving water may possibly funnel along the top edge of each shingle, lodging between shingles, or working back past the metal valley strip to the roof deck. To prevent this, the top corner of each shingle, where it meets the valley, is sometimes chamfered so that driving water can be glanced off and directed down the valley. The valley shingles are then laid and the shingles are adhered to the metal valley strip with caulking or roofing cement, typically petroleum base. However, this likewise continues to experience problems.

Accordingly, Applicant has invented a unique method and apparatus to solve this problem. Thus, there is a need and there has never been disclosed Applicant's inventive method and apparatus for metal valley installation.

IV. SUMMARY OF THE INVENTION

The present invention is a unique method and apparatus for metal valley installation that waterproofs shingled roof applications in valley (e.g., such as “V” or “W” metal valley angled roof) applications. Applicant's invention provides a membrane situated between the metal valley and the shingles with a portion of the membrane being situated and secured to the roof deck between the ice and water shield and the shingles. The membrane creates a dead zone that collects or prevents ice and water from backing up from the roof valley over the metal valley, over the edge of the metal valley, and in between the ice and water shield and the shingles.

VI. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIGS.1through3, Applicant's invention for a roof valley of a roof deck10is illustrated. The invention for the roof valley of a roof deck10comprises a roof deck12, an ice and water shield14, a metal valley16, a membrane18, and shingles20.

The roof deck12, preferably made of a plywood or OSB type material, is illustrated in a “V” shape to create a roof valley22having a centerline23(also referred to as a base), and that extends up to an apex or the top of the roof valley22. The roof valley22can be provided with any slope, although the slope is typically more evident in the bent metal (copper) valley16applications. Alternatively, Applicant's invention likewise applies in any other angled roof valley application(s) and/or angled slope(s).

The ice and water shield14is a water protector, sometimes also referred to as “peel and stick”, is a waterproof roof underlayment layer or shield developed to protect vulnerable areas on the roof deck12from ice and water damage. One such ice and water shield14is sold under the Grace Ice & Water Shield® brand. Typically, the ice and water shield14, for example, is made with polymer-modified bitumen. In Applicant's invention, the ice and water shield14, and as described in more detail herein, is situated and covers the roof valley22and is usually confined to, and runs in, the same direction as the roof valley22.

The metal valley16is an exposed metal pan, preferably made of a copper material or any other material known to one skilled in the art, that is positioned at the intersection of the adjoining roof slopes24and26of the roof valley22. The metal valley16has defined edges28and30and also extends over the edge of the eave of the roof deck12with the edges secured by any fastening means known to one skilled in the art such as copper nails. This has long been a common way of coping with the increased volume of water that naturally occurs at these intersections.

The membrane18, and as described in more detail herein, is positioned over portions of both the ice and water shield14and metal valley16and is preferably secured using the adhesion (discussed in more detail below). Additionally, when securing or fastening the shingles20in place, a fastening means such as nails is placed as close as possible to the metal between the shingles20, the ice and water shield14, and the roof deck12.

The membrane18is designed and manufactured for the use of securing and waterproofing the transition of the open metal valley16strip to a roof deck12and the means of bonding valley shingles20to the same membrane18. Some of the characteristics of the membrane18can be similar to commonly used ice and water shields14currently in use in roofing applications with the following additional features.

The membrane18can be of a film surface, or mineral surface, with an adhesive petroleum-based, or similarly functioning backing, which, when pressed against a roof deck12, ice and water shield14, and metal valley16strip, secures and waterproofs the transition. The membrane18can feature one continuous adhesive backing, or alternatively feature (2) adhesive backing zones of differing characteristics, with one adhesive zone34formulated for adhering the membrane18to either: (i) the roof deck12, (ii) the ice and water shield14, or (iii) the combination of the ice and water shield14and the metal valley16, as illustrated inFIGS.2and3, and one adhesive zone36formulated for adhering the membrane18to the underside of the shingles20.

The membrane18can be produced to be dispensed from a roll, or in lengths, with the adhesive backing(s) or zones34and36covered with (2) zones of protective paper or film layers48to facilitate the exposure of each adhesive zone34and36individually. The adhesive zones34and36converge at the centerline38of the membrane18along its length which also coincides with a fold line40, which is manufactured into the membrane18to allow for a naturally occurring fold during installation. The membrane18can also be produced to be dispensed from a roll already in the folded condition. The metal valley16can also be produced with the membrane18pre-attached along its edges and delivered to the site in a ready to apply form.

Inventive method: Applicant's inventive method begins after the metal valley16strip is set in place. At this step, the membrane18is used to secure the metal valley16strip against the ice and water shield14that was previously laid on the roof deck12. In the preferred embodiment, the membrane18simultaneously covers both a portion of the metal valley16and the ice and water shield14and is situated between the metal valley16and ice and water shield14and the shingles20that cover the metal valley16and ice and water shield14.

After installation and during use, this membrane18is formed into a double layer (e.g., with each layer of the double layer preferably of equal lengths) and provides a dead end or dead zone32, as illustrated inFIG.3, that collects or prevents ice and water from backing up from the roof valley22over the metal valley16, over the edge of the metal valley16, and in between the ice and water shield14and shingles20(i.e., in the absence of the membrane18).

The membrane18can be supplied in a roll form and will feature a bitumen or similarly functioning coating. This coating can be continuous across the membrane18, or, can be zones of differing characteristics, with zones meeting at the center of the membrane18and running its longitudinal length. Meeting at the center of its length will be (2) protective paper48peel-and-stick zones, allowing (1) zone to be stripped individually along the membrane18center. Corresponding with this center is a fold line40that will allow the membrane18to be easily folded in half along its center, as illustrated inFIG.2(e.g., left side, where the membrane18is folded in the direction of Arrow A). After it has been cut from the roll, the membrane18is laid flat, or folded, and positioned so that one half of the membrane18(one of the paper covered zones) covers equally, the metal valley16strip and the previously laid ice and water shield14, as further illustrated inFIGS.2and3. After being positioned, the peel-and-stick paper48is removed from this zone and the membrane18is pressed against the metal valley16strip and the previously laid ice and water shield14. This process of removing a piece of membrane18from the roll, positioning, peeling, and pressing it, is repeated for the opposite side of the metal valley16strip. In this manner, the membrane18in the folded state is placed equidistant over and from the edges28and30of the metal valley16. At this point in the process the metal valley16is secured into place and the transition between the metal valley16and the roof deck12has been waterproofed. This process can also be applied if the installer has used metal valley16strip retaining clips.

Alternatively, in an alternate embodiment, another approach to the process can be to leave the paper48on the top half of the membrane18fold until all the valley shingles20are in place and then peel the paper48out from under the shingles20as the last step. This would be the fastest way to do it. The only drawback with this method is the shingles20cannot be nailed as close to the valley. You would have to keep the nails away from the still-papered membrane18, as it would be difficult to remove the paper with nails through it. But if this process is ever implemented, removing the paper last will probably be the most common way to do it. Applicant prefers getting the nails as close to the metal as possible, as can then keep the metal as tight to the roof as possible.

Prior to laying the valley shingles20, if the membrane18has not been folded prior to securing it to the roof deck, it is folded along its centerline38at this point, back onto itself, into a doubled-up condition. This folding process then exposes the adhesive zone or side36of the membrane18in the up position, and is ready, after peeling the protective paper48layer, to receive valley shingles20. After a valley shingle20has been cut to length, at the appropriate angle to meet the metal valley16, the paper48is removed, exposing the adhesive, and the valley shingle is pressed against the roof deck12to secure it into place. This is repeated for each course of shingles20. In this manner, as illustrated inFIGS.2and3, the shingles20cover the entire membrane18.

One of the characteristics of a metal valley16is the large change in length due to temperature variation. For this reason, nailing directly into metal valley16is typically avoided to prevent the contraction and expansion of the metal eventually fatiguing the material and causing stress fractures and subsequent leaking. Thus, in Applicant's invention, and as illustrated inFIGS.2and3, a fastening or securing means42is used to fasten or secure the membrane18to the roof deck12between the ice and water shield14and the shingles20. Preferably, the fastening or securing means42is a nail or any other fastening or securing means known to one skilled in the art. Additionally, it is contemplated that the fastening or securing means42is, as illustrated inFIG.2, inserted through the shingle20, through the membrane18and into the ice and water shield14and roof deck12; or alternatively, the fastening or securing means42is, as illustrated inFIG.3, inserted through an extension46extending outwardly from the fold line40of the membrane18and into the ice and water shield14and roof deck12.

The same movement of metal valley16can also adversely affect the adhesive bond between the metal valley16and the shingles20when using the current typical method of caulking or cementing the shingles20directly to the metal valley16strip. Using the folding membrane18of Applicant's invention isolates the shingles20from the movement of the metal valley16strip, as it expands and contracts separately from the shingles20.

This isolation is also beneficial under conditions of ice buildup as the membrane18and bonded shingles20are able to move together but independently from the metal valley16, where the current typical method of direct adhesion is susceptible to the expansion of ice.

Another advantage of the folding membrane18is the increased area of adhesion between the shingles20and the membrane18which may negate the need to chamfer the tops of the shingles20at the valley. This method minimizes the entry points of water as each shingle20is pressed against the adhesive backing. If water should at any time drive up under the valley shingles20, its ability to drive between shingles20is minimized and any water that drives up behind the membrane18is stopped by the dead end or dead zone32, as illustrated inFIG.4, created when the membrane18was folded back on itself. This can offer an additional advantage when considering the width of metal valley16, as it is often as wide as 20″ or more to prevent water intrusion in the event of ice dam buildup. If for example a metal valley16width of 14″ is used, and each edge of the metal is covered with the folding membrane18which overlaps each metal edge and extends an additional 3″, then the total effective coverage of protection would still be 20″. The material cost savings can be substantial when using metal valley16made from copper.

Another advantage is how the shingle20travels with the membrane18. Though the shingle20is adhered to the roof deck12through the membrane18, the shingle20is still isolated from the heat induced movements of the copper metal valley16. Also, if ice ever accumulated in this area, it would pose no damage, as Applicant's invention allows the structure to flex, thereby protecting the valley shingle structure from the expansive nature of frozen water. In the currently typical process of adhering the shingles to the copper via roofing cement or caulk, the underside of the shingle20would have been adhered into place against the copper metal valley16directly, which makes this adhesion area vulnerable to the expansive quality of freezing water and to the lateral movement of the heat induced copper expansion.

An additional benefit of this method would become apparent during re-roofing where this method had been previously applied. With the current conventional method of applying shingles20to open metal valleys, re-roofing would require the separation of previously cemented shingles20from the metal valley16by prying and cleaning the metal surface, or, replacing the valley metal16entirely. With Applicant's unique method proposed here, the shingle20/membrane18assembly would be pried back to expose the fold of the membrane18adequately to cut through the membrane18, leaving the original layer of membrane18which adheres the metal to the roof deck12(which had been previously covered with ice and water shield14) intact. Because the membrane18has the same semi-permanent nature of ice and water shield14, any section of membrane18that could not be easily removed from the roof deck12or metal valley16, can be left in place, and a new membrane18can be placed directly over.

Therefore, the application of this method would result in minimal damage to existing metal valley16, which is especially advantageous when working with costly metal valley16such as copper.

Thus, there has been provided Applicant's unique invention. While the invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.