FIELD OF THE INVENTION

[0001] The present invention relates to a preventative roofing system. More specifically, a roofing system which prevents damage to roofs, eaves, and the structures below caused by ice backing.

BACKGROUND OF THE INVENTION

[0002] It is well known that both ice damming and ice backing can cause significant damage to homes, particularly roofs, in the United States.

[0003] The present invention relates to inhibiting and preventing ice backing, the process by which ice grows upward from an existing ice dam and works its way into the gap between the fascia and upper surface or sheathing of the roof, or underneath the roof eaves, shingles/tiles, and fascia of roofs, causing them to separate and crack. When temperatures rise above freezing, ice melt water begins to seep underneath the protective outer layers of the roof. Consequently, once temperatures reach freezing again, the ice continues to grow into the cracks it formed causing water damage, leaks and mold. This process can repeat daily, or several times a day, depending on the weather conditions and/or sun exposure to the roof.

[0004] Aside from the physical damage, there are significant costs associated with ice backing. According to an article published on telegram.com in February 2015, titled“How Much Will Snow Damage Cost?,” winter roof damage costs insurance companies a minimum of one billion dollars per year, a cost which has been steadily on the rise since 2013. Most of the damage to roofs from snow results from ice dams.

[0005] Some solutions to this problem have been envisioned, such as electrically heated warming panels. For example, U.S. Patent No. 4,769,526 to Taouil discloses a de-icing panel that contains a plurality of channels through which electrical heating elements are dispersed. Although this solution can prevent ice damage to roofs, it is costly, not user-friendly, requires electrical components and wiring, and still requires the separate installation of heating elements to be functional.

[0006] Additionally, the existing products, while intended towards the prevention of ice formation, they are not intended to protect damage resultant from ice buildup and ice backing.

SUMMARY OF THE INVENTION

[0007] Therefore, it is an object of the present invention to provide a simple and cost- effective roofing system which inhibits ice backing and associated damage to the roofing structure. It is yet another object of the invention to provide a roofing system which prevents ice damage (i.e., ice backing) from occurring without utilizing an electrical framework.

[0008] These and other objects are achieved by providing an Ice Backing Flashing system (hereinafter, the“IBF system”) which is comprised of an IBF layer to prevent ice backflow, the process where ice grows underneath the eaves and into the underside of the roof. As such, this system effectively eliminates the ability for ice to work its way back into the roof through the shingles/tiles, eaves and fascia.

[0009] In one aspect of the invention, the IBF layer includes an upper portion attachable to an upper surface or sheathing of a roof, a lower portion attachable to a fascia portion of the roof, and a bend between the upper and lower portions attachable over an edge of the roof. The IBF layer may be provided by itself or layered together with a plurality of underlayment layers. For example, in one aspect of the invention, a roofing system is provided including a first underlayment layer and the IBF layer adjacent to and above the first underlayment layer, the ice back flashing layer including an upper portion attachable to an upper surface of a roof, a lower portion attachable to a fascia portion of the roof, and a bend between the upper and lower portions attachable over an edge of the roof. In some embodiments, the system includes a second underlayment layer adjacent to and above the upper portion of the ice back flashing layer, a drip edge layer adjacent to and above the second underlayment layer, and/or a third underlayment layer adjacent to and above the drip edge.

[0010] In some embodiments, an adhesive underlayment is already attached to the IBF layer, thereby simplifying installation of the roofing system. In other embodiments, the adhesive underlayment is separate from the IBF layer, providing more flexibility and control in the installation process and choice of materials.

[0011] In some embodiments, it is preferable that at least some of the underlayment layers are heat resistant and can withstand various weather conditions/the changing seasons, otherwise the underlayment layers are prone to melting in the heat and cracking in the cold.

[0012] In some embodiments, the upper portion of the ice backing flashing layer has at least one fold defining an edge extending at least partially toward the bend between the upper and lower portions. The fold or folds provide additional ice protection and, in some

embodiments, may engage or interlock with other layers of the system. The fold may be positioned at a top distal end of the upper portion or one or a plurality of folds may be positioned between the top distal end and the bend between the upper and lower portions. In some embodiments, the bend between the upper and lower portions includes a first bend and a second bend forming a nose portion extending at least partially away from the roof.

[0013] In some embodiments, the system includes a gutter secured to the lower portion of the ice backing flashing layer. The lower portion of the ice backing flashing layer may extend below the gutter. In some embodiments, the lower portion of the ice backing flashing layer includes a lip extending outward from the fascia portion of the roof below the gutter.

[0014] Further provided is a method of preventing ice backing, including the steps of securing a first underlayment layer to an upper surface of a roof, and securing an ice backing flashing layer to the roof adjacent to and above the first underlayment layer, the ice backing flashing layer including an upper portion, a lower portion, and a bend between the upper and lower portions, wherein the upper portion is secured to the upper surface of the roof and the lower portion is secured to a fascia portion of the roof. In some embodiments, the method includes securing a second underlayment layer adjacent to and above the upper portion of the ice backing flashing layer, securing a drip edge layer adjacent to and above the second underlayment layer, and/or securing a third underlayment layer adjacent to and above the drip edge.

[0015] Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

[0017] FIG. 1A is a perspective view of an IBF system according to an exemplary embodiment of the present disclosure that is attached to the fascia and roof base of a pitched roof, and FIGS. IB through 1H are perspective views of each layer in the IBF system;

[0018] FIG. 2A is a perspective view of an IBF system according to an exemplary embodiment of the present disclosure with a first layer of underlayment adhesively attached to a lower surface of an IBF layer, the underlayment being a high- temperature underlayment attached to both the fascia and roof base;

[0019] FIG. 2B is a perspective view of the IBF system of FIG. 2A without an underlayment layer;

[0020] FIG. 3A is a perspective view of an IBF system according to an exemplary embodiment of the present disclosure with a first layer of underlayment adhesively attached to a lower surface of the IBF layer, the IBF layer containing a protruding nose at its bottom end and sized to accommodate wider fascia;

[0021] FIG. 3B is a perspective view of the IBF system of FIG. 3 A without an underlayment layer;

[0022] FIG. 4 is a side view of the IBF system on a pitched roof with the first layer of underlayment adhesively attached to the lower surface of the IBF layer, a second layer of underlayment attached to an upper surface of the first layer, a third drip edge layer attached to an upper surface of the second layer, a fourth layer of underlayment attached to an upper surface of the third layer, and the roof shingles attached to an upper surface of the fourth layer;

[0023] FIG. 5 is a side view of an IBF system according to an exemplary embodiment of the present disclosure that is on a flat roof with a first EPDM membrane which attaches to the trim of the building, a second layer of IBF attached to an upper surface of the EPDM membrane, a third layer of silicone attached to an upper surface of the IBF layer, a fourth drip edge layer attached to an upper surface of the third silicone layer, and a fifth cover strip layer attached to an upper surface of the drip edge;

[0024] FIG. 6 is a side view of an IBF system on a pitched roof with a first underlayment layer, a second layer of IBF adhesively attached to an upper surface of the underlayment, a third layer of underlayment attached to an upper surface of the IBF layer, a fourth drip edge layer attached to an upper surface of the third layer, a fifth layer underlayment attached to an upper surface of the drip edge, and a final layer of synthetic underlayment covering the entire IBF system;

[0025] FIG. 7 is a side view of an IBF system according to an exemplary embodiment of the present disclosure on a flat roof;

[0026] FIG. 8 is a side view of the IBF system of FIG. 7 on a pitched roof;

[0027] FIGS. 9A and 9B are side views of an IBF system according to an exemplary embodiment of the present disclosure on a flat roof;

[0028] FIGS. 10A and 10B are side views of the IBF system of FIGS. 9A and 9B on a pitched roof;

[0029] FIG. 11 is a side view of an IBF system according to an exemplary embodiment of the present disclosure on a flat roof;

[0030] FIG. 12 is a side view of the IBF system of FIG. 11 on a pitched roof;

[0031] FIG. 13 is a perspective view of a customizable IBF system;

[0032] FIG. 14 illustrates embodiments of a bottom end of an IBF layer according to an exemplary embodiment of the present disclosure;

[0033] FIG. 15 illustrates embodiments of an upper portion of an IBF layer according to an exemplary embodiment of the present disclosure;

[0034] FIG. 16 illustrates embodiments of a top end of an IBF layer according to an exemplary embodiment of the present disclosure; and

[0035] FIG. 17 illustrates embodiments of a nose bend portion of an IBF layer according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0036] Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views. The following examples are presented to further illustrate and explain the present invention. The following examples and materials can be modified based on an individual consumer’s specific project, roof, and/or needs and should not be taken as limiting in any regard.

[0037] It is to be understood that the disclosure of the invention in this specification does not include all possible combinations of such particular features; rather, it discloses the most common embodiments of such features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.

[0038] The IBF system 10 according to the present embodiments includes a plurality of layers of material on a roof 20 to prevent ice backflow. The layers generally include an IBF layer 30 situated between other layers of roofing materials such as a drip edge 40 and layers of underlayment described below. In a preferred embodiment, the IBF layer 30 is a metal flashing.

[0039] FIG. 1A shows one version of the IBF system 10 according to an exemplary embodiment of the present disclosure, an IBF system. All of the versions disclosed herein can be used in conjunction with both pitched roofs and flat roofs 20. The figures show only portions of the various layers of the IBF system 10 for illustration purposes but one skilled in the art will understand that each of the layers may extend across an entire width of the roof. For example, the IBF layer 30 may be produced in various lengths, including commonly used 1 to 10-foot lengths and custom lengths depending on the need. [0040] As shown in FIG. 1A, and in more detail in FIG. 1C, the IBF layer 30 has a lower portion 32 (along the fascia 22) and an upper portion 34 (along the plywood/roof surface 24), the lower portion 32 and the upper portion 34 generally extending farther down the fascia 22 and up the roof surface 24, respectively, as compared to the drip edge 40. In some embodiments, the IBF layer 30 extends down the fascia 22 at least twice as far as the drip edge 40 extends down.

Further, the upper portion 34 of the IBF layer 30 which extends up the roof/plywood 24 towards the top of the roof 20 also extends farther than the drip edge 40, such as at least 1.5 times the length of the drip edge 40 in that direction. In one exemplary embodiment, the lower portion 32 has a height (a) of about 3 inches and the upper portion 34 has a length (d) of about 4 inches. In another exemplary embodiment, the lower portion 32 has a height (a) of about 6 to 7 inches. These dimensions are only exemplary.

[0041] Between the lower and upper portions 32/34 of the IBF layer 30 is an intermediate bend in the structure which extends around the edge of the roof to assist in inhibiting ice backing. The bend may be a simple bend with an interior angle of at least about 90 degrees, a more complex bend to create a nose or protrusion on the edge of the roof, and/or a series of preformed bend lines to provide different installation options. In preferred embodiments, for the IBF system 10 to work most effectively, like-metal should be used with like-metal; e.g., a copper IBF system should be used with a copper drip edge and copper gutters, similarly an aluminum IBF system should be used with an aluminum drip edge and aluminum gutters. However, in other embodiments, different metals and even different material types may be used.

[0042] The upper portion 34 of the IBF layer 30 may, in some embodiments, turn back on itself in the sense that the structure extends in one direction and then is bent at approximately (or slightly less than) 180 degrees and onto itself to create a generally“C” or“V” shaped end 36. The return portion of this“C” or“V” shape created by the bend returns a distance of approximately 0.5 inches, particularly about at least 5% (more particularly at least 10% or more particularly approximately 12.5%) of the length (d) of the IBF layer 30 between the intermediate bend and end of the IBF where the“C” or“V” shape is found. However, in other embodiments, the upper end 36 is flat without a bend back.

[0043] The upper end 36 of the IBF layer 30 is opposite to a lower end 38 which, in the exemplary embodiment shown in FIGS. 1A through 1H, is an outwardly extending portion 38 of the IBF layer 30 which is designed to extend outwardly below a gutter, e.g., by a distance (b) of about 1 inch. It is also understood that in certain embodiments, the portion of the IBF whose end is adjacent the fascia (opposite end to“C” or“V” return) may not extend outwardly, see, e.g., FIGS. 2A-2B. The lower end 38 may in either case include a return portion 39 having a length or height (c) of about 0.5 inch. These dimensions are only exemplary.

[0044] As shown in FIGS. 1A through 1H, an IBF system 10 generally comprises a first high-temperature underlayment 50 (e.g., an underlayment that is stable up to at least about 250°F) against the roof 22/24 and the IBF layer 30 secured at least partially over the first underlayment 50 with fasteners 60 such as nails 62 and/or clips 64. A second underlayment 52 may be placed over the IBF layer 30 and below a drip edge 40. The second underlayment 52 may be a high-temperature underlayer or an ice protection underlayment (e.g., an 18-inch MFM IB-3 Ice Buster or WIP underlayment). A third underlayment 54 (e.g., an 18-inch MFM IB-3 Ice Buster or WIP underlayment) and a top underlayment 56 (e.g., any underlayment) may be above the drip edge 40. The IBF system 10 is attached to the fascia 22 and plywood 24 of a pitched or flat roof 20.

[0045] In some embodiments, Carlisle WIP Products’ underlayments are used. For example, WIP 300 (i.e., a high-tensile- strength rubberized asphalt underlayment designed to withstand temperatures up to 250°F) or equivalent is a preferred high-temperature underlayment due to its flexibility and heat resistant properties, while WIP 100 (i.e., a 55-mil flexible rubberized asphalt, fiberglass-reinforced membrane) or equivalent is the preferred ice protection underlayment. In some embodiments, the WIP 100 underlayment can be replaced with the WIP 300 high-temperature underlayment.

[0046] The first high-temperature underlayment 50 is the first layer of the IBF system 10 involved in the protection against roof damage and ice backing. The high temperature properties are desired to avoid cracking or degradation of the underlayment 50 over time which can contribute to ice damage.

[0047] Roofs often have a gap or space between the fascia 22 and upper surface or sheathing of the roof 24. In a preferred embodiment, the IBF layer 30 is an overhanging stmcture that seals over the spaces between the fascia 22 and roof 24 and extends down behind the gutter, thereby preventing ice from growing up and into the underside of or between layers of the roof 24.

[0048] As shown in FIG. IE, the IBF layer 30 is secured between two layers of underlayment: a first high-temperature underlayment 50 below, and a second high-temperature or ice protection underlayment 52 above. In the exemplary embodiment, the IBF layer 30 is sheet metal made from non-ferrous or alloy metals that are 16 gauge or lower. In preferred

embodiments, the sheet metal of the IBF layer 30 is made from copper or aluminum that is 16 gauge or lower. In some other embodiments, the IBF layer 30 is comprised of other materials such as composite materials.

[0049] As seen in FIGS. 1C through 1H, in certain embodiments, the IBF layer 30 has, at its bottom end, a bent end 38 which helps prevent ice from working its way into the roofing layers in this IBF version. As noted above, the bent end 38 may extend out by a distance (b) of about 1 inch or more.

[0050] As shown in FIG. ID, fasteners 60 can be used to secure the IBF layer 30 to the roof. For example, nails 62 may be used in the upper portion 34 and/or lower portion 32 and clips 64 may be used along the edges, such as along the end 36.

[0051] As shown in FIG. IE, a second layer of underlayment, either a high-temperature underlayment or an ice protection underlayment 52, is placed on the top surface of the IBF layer 30.

[0052] As shown in FIG. IF, the drip edge 40 is added to the top surface of the high- temperature or ice protection underlayment 52. The drip edge 40 is a bent piece of sheet metal that acts as support for the gutters 80. The drip edge 40 at least partially extends outward from the roof edge. In some embodiments, the IBF layer 30 also extends out from the roof edge within the drip edge (see, e.g., FIGS. 5-6.)

[0053] As shown in FIG. 1G, a third layer of underlayment 54 is attached to the top surface of the drip edge 40. This third underlayment 54 can be an ice protection underlayment, or a cold weather-proof underlayment of similar quality. A top underlayment 56 is attached to the top surface of the third underlayment 54.

[0054] FIG. 2A shows another version of the IBF system 10 according to an exemplary embodiment of the present disclosure. This IBF system comprises an IBF layer 30 that comes with a first high-temperature underlayment 50 already adhesively attached to its bottom surface. This version allows for easy installation and can be used on flat or pitched roofs. In the exemplary embodiment, the upper portion of the underlayment 50 extends farther up the roof than the IBF layer 30. For example, dimension (d) may be about 4 inches while dimension (g) is about 9 inches. FIG. 2B shows another version without the underlayment 50 attached.

[0055] As shown in FIGS. 2A to 3B, the IBF system 10 can include a nose/bridge or lip 38 on the IBF layer 30 that is bent backwards or protruding at its bottom end 39.

[0056] As shown in FIG. 4, the IBF system 10 is compatible with pitched roofs with shingles 70 and comprises an IBF layer 30 attached to a high-temperature underlayment 50, to which a second high-temperature or protection underlayment 52 is attached. A drip edge 40 is attached to the top surface of the second underlayment 52 and holds up the gutter 80 while directing water into it. A third underlayment 54 is placed between the drip edge 40 and the shingles 70 of the roof. As can be seen, the bottom outward directed portion of the IBF is positioned below the gutter 80 whereas the outward directed portion of the drip edge 40 is positioned above the gutter.

[0057] FIGS. 5, 7, 9A-9B, and 11 show that all versions of the IBF system 10 are compatible on flat roof styles, such as those usually seen on buildings. The IBF system may comprise an EPDM membrane 51 which covers the trim of a building, an IBF layer 30 which is attached to the top side of the EPDM membrane 51, a silicone layer 53 attached to the top side of the IBF layer 30 which acts as a sealant, and a drip edge 40 attached to the top side of the silicone layer 53 with nails 62. In some embodiments, a gutter 80 may attach to the drip edge 40 and a cover strip 72 seals the entire IBF system 10.

[0058] FIGS. 6, 8, 10A-10B, and 12 show that all versions of the IBF system 10 are also compatible with pitched roofs. These IBF systems comprise a first layer consisting of either an EPDM underlayment 51 or a high-temperature underlayment 50, an IBF layer 30 is adhered to the top surface of the first EPDM 51 or high-temperature underlayment 50 layer, a second high- temperature or ice protection underlayment 52 is attached to the top surface of the IBF layer 30, a drip edge 40 is attached to the top surface of the second underlayment 52, a third ice protection underlayment 54 is attached to the top surface of the drip edge and a synthetic underlayment 58 covers the entire IBF system 10.

[0059] FIG. 13 shows one example of one way a custom IBF system 10 can be constructed. In the exemplary embodiment, the IBF system 10 includes two bend lines which can be used depending on the desired height of the lower portion. For example, bending at the lower bend line can result in a lower portion having a height (a) of about 5 inches while bending at the upper bend line can result in a lower portion having a height (j) of about 6.5 inches. In another embodiment, height (a) is only 2-3 inches. In the exemplary embodiment, dimension (d) is about 4 inches and dimension (k) is about 5 inches. These dimensions are only exemplary. The custom IBF system can be made in various other ways and with various other lengths depending on the need of the job.

[0060] FIG. 14 illustrates different embodiments of the bottom end 38 of the IBF layer 30. Each differs at least in the way that they direct water off the bottom. Ends 38c to 38f direct water off the flashing when they extend down below a gutter while ends 38a to 38b can be used behind a gutter.

[0061] FIG. 15 illustrates different embodiments of the upper portion 34 of the IBF layer 30. Upper portion 34a is the simplest design. Upper portion 34b includes one intermediate bend or fold back portion to help stop ice from working its way up. The bend can be pressed down on the edge of an underlayerment or the drip edge 40 and/or the bend may engage or interlock with an edge of the underlayment or drip edge. Upper portions 34c to 34d have additional intermediate bends to provide additional ice protection. The bends can similarly be pressed down onto and/or engage with edges of underlayments and/or the drip edge 40. The bends generally are greater than ninety degrees and preferably greater than one-hundred and thirty-five degrees.

[0062] FIG. 16 illustrates different embodiments of the top end 36. Top end 36a is the simplest. Top end 36b provides a bend back to help stop ice from working its way over the top of and past the IBF layer 30. Top end 36c is an alternative with a bend back on the lower surface which avoids the exposure of cut sheet metal.

[0063] FIG. 17 illustrates different embodiments of a nose bend portion 33 of the IBF layer. Nose bends 33a and 33b may be used with any drip edge. Nose bend 33a is the simplest design. Nose bend 33b has a bend that is at least partially flush against the lower portion 32 to help prevent ice from working its way over the edge behind the drip edge 40. Nose bends 33c to 33e have a nose that the drip edge 40 receives and/or clamps onto to help stop ice from working its way over the drip edge 40 or behind it.

[0064] The present invention satisfies the need for a simple, cost- effective, non electrical way to prevent ice backing and associated roof damage. The layering of the various underlayments with the IBF layer 30 creates an effective sealing system which prevents ice from building up and growing into the roof through the fascia, eaves and roofing layers. Additionally, the IBF system 10 can be tailored to fit various roof angles and fascia heights.

[0065] As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Thus, the present disclosure is not to be considered as limited by the foregoing description.