Heating system and method of making and use

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Solution Overview

Problem

Existing heating systems for roofs, such as zig-zag heat cables and hat-channel systems, are ineffective in preventing ice dam formations, as they are exposed to the elements, prone to damage, and require maintenance, leading to leaks and unsightly installations.

Innovation Solution

A heating system comprising a heating panel with a cover or cap that conceals the heating element, providing comprehensive heat transfer while protecting it from environmental factors, and includes interlocking elements to secure the system to the roof, preventing water ingress and enhancing aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If zig-zag heat cable is exposed on the roof, then it can provide heating to prevent ice dams, but it is exposed to ultraviolet degradation and environmental damage

Engineering Contradiction:

Improveheating effectivenessVSAvoidultraviolet degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a roofing panel as an intermediary component that conceals the heat cable while allowing thermal energy to pass through. The panel acts as a mediator between the heat cable and the external environment, protecting the cable from UV radiation and environmental damage while maintaining heating effectiveness.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat cable is nested within channels formed in the roofing panel. The panel structure contains the cable within its body, similar to nested dolls, where the inner component (cable) is protected by the outer structure (panel) while still functioning.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If hat-channel system is used with exposed fasteners, then it can be installed on existing roofs, but the fasteners may loosen and leak

Engineering Contradiction:

Improveretrofit capabilityVSAvoidleak prevention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent removes the exposed fastener attachment method from the system. Instead of using exposed fasteners that penetrate the roofing panel, the system uses concealed attachment methods where fasteners are hidden within the panel structure or attached to the underside, eliminating the leak path through exposed penetrations.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If heating panel conceals the heating element, then it protects from environmental factors and improves aesthetics, but it may reduce heat transfer efficiency

Engineering Contradiction:

Improveprotection from elementsVSAvoidheat transfer efficiency

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The roofing panel is designed with varying thermal properties in different regions. The portions in contact with the heat cable have high thermal conductivity to efficiently transfer heat, while other portions may have different properties to protect against environmental factors. This local differentiation optimizes both protection and heat transfer.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The roofing panel is constructed from composite materials that combine properties of both protection and heat transfer. The composite structure allows the panel to conceal and protect the heating element while maintaining effective thermal energy transmission to the roof surface.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively prevents ice dam formations by providing consistent heat along the roof edges, reducing maintenance needs, and ensuring the heating elements remain functional and aesthetically pleasing, while being lightweight and adaptable for retrofitting existing roofs.

Implementation Method 1

providing comprehensive heat transfer while protecting it from environmental factors

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

providing consistent heat along the roof edges

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS10604937B2Heating system and method of making and use

Publication Date: 2020.03.31 CASEY BRIAN

AI summary

Heating systems including heating elements and fastener materials covered and protected from the environment by a heating cap structure. The heating cap structure can interlock mating ribs or other structure in adjacent heating panels. Additional heating cap, transition, or flashing sections may further cover and protect heating system components. One or more heating elements may include heating cable or heating fluids or materials penetrating heating element bodies. The heating element bodies and heating cap panels and covers can include extruded or otherwise formed sections having a wide variety of shapes that can be varied to provide desired objectives, such as for example supporting strength, increased heat transfer, component cost minimization, component life, heating system weight, and ease of assembly, use, maintenance, expansion, contraction, and adaptability. The outer and other surfaces of the heating system may be painted, including to improve aesthetics. Sealing films and materials may be included.