Roof valley plug

US20260250953A1Pending Publication Date: 2026-08-27VALLEY PLUG LLC
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Patent Information

Application Number
US19/062337
Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
Filing Date
2025-02-25
Publication Date
2026-08-27

AI Technical Summary

Technical Problem

Through the passage of time and with temperature changes, this moisture can break down even the best roofing materials.

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Abstract

A roofing seal for the valley portion of roofing flashing includes a diamond shaped cross sectional face that is elongated in length to approximnately two to three inches and the cross section includes a first pair of equal length sides fortning an interior angle of about sixty degrees and a second pair of sides that are also equal in length to one another but shorter than the first pair of sides, and the seal formis a plug for insertion into an opening in the roofing valley flashing to effectively keep out water and debris.
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Description

BACKGROUND OF THE INVENTION

[0001] Roofing is all about the prevention of the elements and debris from entering a structure. The roof receives the brunt of the force dealt by nature as it is the first line of defense for the structure. It is imperative that every possible mitigation detail be addressed to extend the life of the roof. One thing that gets overlooked is the prevention of the accumulation and infiltration of debris. Insects, animals, and wind can compact debris into any opening. As debris accumulates, moisture is permitted to collect and linger in a single spot. Through the passage of time and with temperature changes, this moisture can break down even the best roofing materials.

[0002] One known area on a roof that is known to be problematic is called the valley. A roof valley is the V-shaped area where two roof slopes meet, prior to reaching the gutter. The valley allows water to collect where the slopes meet and continues to flow off the roof. Roof valleys are essential for managing heavy rainfall and directing water toward gutters and downspouts. Roof valleys also collect debris such as leaves and help funnel them downwards off the roof.

[0003] The valley is commonly constructed using pre-formed sheet metal flashing that forms a "W" shaped cross section. This sheet metal forms a gutter that guides water and debris through the valley where the two roof slopes meet into the proper gutter located on the eve. After the sheet metal is placed, shingles are affixed to the roof, but the central "W" section of the valley is left exposed. This is done as shingles are designed to lay flat and cannot conform to the change of slope that the two meeting slopes create.

[0004] Traditional practice is to overlap shingles with the flashing where possible. Since the shingles are designed to lay flat, the peak of the "W" section cannot be overlapped. As long as the sheet metal remains intact that does not present any issues. When the valley ends so does the flashing and an opening is typically left exposed at the bottom of the valley on the peak of the "W" section. As gravity directs water and debris downwards, this is typically not considered a problem. Unfortunately wind, animals, and insects defy gravity and are known to collect under the valley flashing by entering through this opening.

[0005] What is therefore needed is a way to seal the opening at the bottom of a roof valley. What is also needed is a seal that conforms to different slopes. Another need is for a cost- effective solution that does not require special tools or fabrication of new flashing. Finally, what is needed is an improved method of sealing the bottom of roof valley flashing.BRIEF STATEMENT OF THE INVENTION

[0006] In accordance with one aspect of the invention, a roofing flashing seal includes an elongated body having a length formed with a closed cell, polyurethane foam; a uniform, cross- sectional shape formed into the body throughout the length of the body. The cross-sectional shape includes four sides, wherein a first and second side of the cross-sectional shape are equal length. The third and fourth sides are equal length and shorter than the first and second side thereby forming a diamond shape cross section.

[0007] The foam is elastically deformable such that when compressed to at least half thickness the foam rebounds back to its original shape. While the foam is preferably closed cell polyurethane, it may be any other material that is similarly elastic and non-absorbent.

[0008] The elongated body may be between two to four inches long with either an adhesive pre-applied to any number of the sides and protected with a removable strip or applied in the field with a caulking tube or the like.

[0009] In another aspect of the invention, the roofing flashing seal may include an elongated body formed out of a foam material having a uniform, diamond cross-sectional shape. The cross-sectional shape may be determined by analyzing a section of the body perpendicular to an outer surface of the body and where the cross-sectional shape is consistent throughout a length of the body. The cross-sectional shape includes two sides of equal length and a third and fourth side that are each smaller but also equal in length. The foam material may be a closed cell polyurethane foam with an elasticity such that it rebounds back to original shape when compressed and does not absorb water.

[0010] In yet another aspect of the invention, a method of sealing an opening in roof flashing may include the steps of forming an elongated body with a length using an impermeable, non- absorbent material. The elongated body may be shaped such that a cross-sectional portion of the body forms a first pair of equal-length sides and second pair of equal length sides wherein each one of the sides in the second pair is smaller than the first pair. The cross-sectional shape of the body is uniform and maintained throughout the entire length of the body.

[0011] During installation, the body is inserted into an opening formed in a roofing valley underneath valley flashing. The body may be compressed between the flashing and the roof surface. The opening in which the body is inserted is in a central location of the flashing proximate a lowest point of the valley. An adhesive may be applied to the body such that the body is retained within the opening. The flashing includes a "W" profile and the cross-sectional shape of the body nests within the profile such that the first pair of sides nest against a portion of the flashing.

[0012] Various other features and advantages will be made apparent from the following detailed description and the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The drawings illustrate preferred embodiments presently contemplated for carrying out the invention.

[0014] In the drawings:

[0015] FIG. 1 is a perspective view from the front side of a roofing flashing seal, according to an embodiment of the invention.

[0016] FIG. 2 is a perspective view from the top side of the roofing flashing seal of FIG. 1, according to an embodiment of the invention.

[0017] FIG. 3 is a front view of the roofing flashing seal of FIG. 1, according to an embodiment of the invention.

[0018] FIG. 4 is a side view of the roofing flashing seal of FIG. 1, according to an embodiment of the invention.

[0019] FIG. 5 is a bottom view of the roofing flashing seal of FIG. 1, according to an embodiment of the invention.

[0020] FIG. 6 is a close-up, perspective view of the roofing flashing seal of FIG. 1, as it is being installed into roofing valley flashing, according to an embodiment of the invention.

[0021] FIG. 7 is a close-up, perspective view of the roofing flashing seal of FIG. 1, after it has been installed into roofing valley flashing, according to an embodiment of the invention.

[0022] FIG. 8 is a perspective view of the roofing flashing seal of FIG. 1, after it has been installed into roofing valley flashing, according to an embodiment of the invention.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Referring generally to FIGS. 1-5, a roofing flashing seal in the form of a plug 10 is shown. The plug 10 is formed with a diamond-shaped cross section having four sides. The diamond-shaped cross section includes a top peak 22 with an interior angle of approximately sixty degrees. The exact interior angle is not critical, but preferably the interior angle matches the geometry of roof valley flashing, as shown with respect to FIGS. 6 and 7.

[0024] The diamond shape is formed by a total of 4 sides. A first side 18 joins a second side 20 thereby forming the 60-degree interior angled peak 22. A third side 16 and fourth side 18 join to form the base 24 of the diamond. The interior angle of the base 24 is larger than that of the peak 22. The exact angle is not important but is preferably a larger angle than that of the peak 22, which allows valley flashing to rest flush on a roof, as shown with respect to FIG. 8. The four sides of the plug 10 form the diamond-shaped face 12.

[0025] The face 12 is flat and planar. To manufacture the plug, any conventional process may be used such as extrusion or drawing. For example, an extrusion process may be used with a die matching the diamond-shaped face 12 to create an elongated body. Additionally, the elongated body may be cut from a sheet of foam. This process may be used to produce the elongated body into a plug 10 of any desired length. Ideally, the plug 10 includes a length of approximately two to three inches. The preferred length of the plug 10 should provide sufficient contact with flashing where a water and debris tight joint is possible.

[0026] The material in which the plug 10 is constructed is preferably a soft and elastic material which can withstand wide temperature variations and frost cycles. One example of a suitable material would be closed-cell urethane foam. Using closed-cell foam would prevent the plug from absorbing water and allow it to be slightly compressed providing an optimal seal.

[0027] Application of the plug 10 to valley flashing 30 is shown in FIGS. 6-10. An exemplary piece of valley flashing 30 is shown which comes pre-formed with a valley 32. As shown in

[0028] FIG. 6, the plug 10 is oriented such that the peak 22 is vertical. The peak 22, left surface 28, and right surface 26 of the plug 10 are designed to nest within valley flashing 30 and fill in the valley 32. When inserting the plug 10 into the valley 32, the plug 10 is slightly compressed. After insertion, the plug 10 can elastically expand to help fill in any small grooves or crevices. Ideally, the plug 10 may be compressed to half its thickness and still rebound back to its original shape. This helps ensure that all four sides of the plug 10 sufficiently contact surrounding material to form a proper seal.

[0029] To help ensure the plug 10 remains in place, an elastomeric sealant is preferably used. One example of such a sealant is silicone caulking, but other caulk formulations may be used as well. It is also envisioned that any compound that is sufficiently viscous to be dispensed on the field, conform to the proper shape, cure yet remain flexible may be used. The sealant used should be able to withstand many freeze / thaw cycles as well as temperature swings from the changes in weather. The sealant helps ensure the plug 10 bonds to the valley flashing and does not move. It also prevents water and debris from wicking past it.

[0030] Once the proper sealant is dispensed onto the right surface 26, left surface 28, and peak 22 of the plug 10, the plug 10 may be set into place within the valley as shown in FIG. 7. Excess sealant may be forced out during insertion of the plug 10, but it may be wiped away. It is foreseen that including a sealant pre-applied to the plug 10 may be beneficial. In such an example, there could be a peel and stick adhesive pre-applied to the plug. This would allow a user to simply peel away a protective cover and discard it. The plug 10 would then be pressed into place. The pressure of inserting the plug 10 into the valley 32 may activate the adhesive and cause it to lock in place. One benefit, however, of dispensing a sealant on site is that it is less likely to prematurely dry or lose effectiveness as pre-applied sealants sometimes do.

[0031] Following insertion of the plug 10 into the valley 32 with proper sealant, the valley flashing 30 may be installed on a roof as is customarily done. FIG. 8 shows the valley flashing 30 abutting roofing shingles 40 in an installed application. The plug 10 prevents liquid and debris such as rain or leaves from getting trapped under the valley flashing 30. Even with strong winds, where water is known to be forced under shingles and flashing, the sealant glues the plug 10 in place and prevents the accumulation of debris and water. Insects and animals are also kept out of the opening by the plug 10.

[0032] In retrofit applications the plug may be simply compressed by pushing it into place into the valley 32 opening. Sealant may be dispensed directly into the valley 32 or to the plug 10 prior to insertion. Ideally, a plug 10 is inserted into the valley 32 opening prior to affixing the valley flashing 30 to the roof.

[0033] This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Examples

Embodiment Construction

[0023]Referring generally to FIGS. 1-5, a roofing flashing seal in the form of a plug 10 is shown. The plug 10 is formed with a diamond-shaped cross section having four sides. The diamond-shaped cross section includes a top peak 22 with an interior angle of approximately sixty degrees. The exact interior angle is not critical, but preferably the interior angle matches the geometry of roof valley flashing, as shown with respect to FIGS. 6 and 7.

[0024]The diamond shape is formed by a total of 4 sides. A first side 18 joins a second side 20 thereby forming the 60-degree interior angled peak 22. A third side 16 and fourth side 18 join to form the base 24 of the diamond. The interior angle of the base 24 is larger than that of the peak 22. The exact angle is not important but is preferably a larger angle than that of the peak 22, which allows valley flashing to rest flush on a roof, as shown with respect to FIG. 8. The four sides of the plug 10 form the diamond-shaped face 12.

[0025]The f...

Claims

1. A roofing flashing seal comprising:an elongated body having a length formed with a closed cell, polyurethane foam;a uniform, cross-sectional shape formed into the body throughout the length of the body, wherein the cross-sectional shape includes four sides, wherein a first and second side of the cross-sectional shape are equal length and the third and fourth sides are equal length and shorter than the first and second side thereby forming a diamond shape cross section; andwherein the foam is elastically deformable such that when compressed to at least half thickness the foam rebounds back to original, cross-sectional shape.

2. The roofing flashing seal of claim 1, wherein the elongated body is between two to three inches long.

3. The roofing flashing seal of claim 1, wherein the elongated body includes an adhesive applied to at least two of the four sides.

4. The roofing flashing seal of claim 3, wherein the adhesive is a contact adhesive with a removable, protective strip.

5. The roofing flashing seal of claim 3, wherein the adhesive is manually dispensed during installation of the flashing seal.

6. A roofing flashing seal comprising:an elongated body formed out of a foam material having a uniform, diamond cross-sectional shape; andwherein the cross-sectional shape is determined by analyzing a section of the body perpendicular to an outer surface of the body and where the cross-sectional shape is consistent throughout a length of the body.

7. The roofing flashing seal of claim 6, wherein the foam material is a closed cell polyurethane foam with an elasticity such that it rebounds back to original shape when compressed.

8. The roofing flashing seal of claim 6, wherein the cross-sectional shape includes a first and second side of equal length and a third and fourth side are each shorter than the lengths of the first and second side but are also equal in length.

9. The roofing flashing seal of claim 8, further comprising an adhesive applied to at least two of the four sides.

10. The roofing flashing seal of claim 9, wherein the adhesive is manually dispensed during an installation of the seal.

11. A method of sealing an opening in roof flashing comprising the steps of:forming an elongated body with a length using an impermeable, non-absorbent material;shaping the elongated body such that a cross-sectional portion of the elongated body forms a first pair of equal-length sides and second pair of equal length sides wherein each one of the sides of the second pair is shorter than the sides of the first pair;maintaining the cross-sectional shape of the body throughout the entire length of the elongated body;inserting the elongated body into an opening formed in a roof valley underneath a valley flashing in a central location of the valley flashing proximate a lowest point of the roof valley; andapplying an adhesive to the elongated body such that the elongated body is retained within the opening.

12. The method of sealing an opening in roof flashing according to claim 11, wherein the adhesive is applied manually from a dispenser.

13. The method of sealing an opening in roof flashing according to claim 11, wherein the adhesive is pre-applied to the elongated body and is exposed by peeling off a protective strip.

14. Themethod of sealing an opening in roof flashing according to claim 11, wherein the valley flashing is a "W" profile flashing and the cross-sectional shape of the elongated body nests within the profile such that the first pair of sides nest against a portion of the valley flashing.

15. The method of sealing an opening in roof flashing according to claim 11, wherein the valley flashing is secured to a roof surface compressing the elongated body between the roof surface and the valley flashing.