GB2495005A

GB2495005A - End closure for a valley trough in a roof.

Info

Publication number: GB2495005A
Application number: GB1217181.5A
Authority: GB
Inventors: Ron Allen
Original assignee: FILON PRODUCTS Ltd
Current assignee: FILON PRODUCTS Ltd
Priority date: 2011-09-26
Filing date: 2012-09-26
Publication date: 2013-03-27
Also published as: GB201116544D0; GB201217181D0

Abstract

The end closure 40 is suitable for use with a valley trough 20 with a raised central portion. The end closure is made from a waterproof material and comprises a base portion and a shaped portion constructed to closely match the profile of the raised central portion, the base portion being flexible. The end closure may be made from a continuous sheet of 3mm thick polyurethane material. The closure may have the strength to maintain the shape on its own or incorporate a glass reinforced plastic former. Also claimed is a method of constructing a roof having a valley trough comprising the steps of installing the valley trough to the roof; fitting the end closure to the valley trough by placing it underneath the valley trough and cutting or deforming the base portion of the closure to match the shape of the underlying roof portion adjacent to the end cover or cap.

Description

END CLOSURE FOR A VALLEY TROUGH

AND METHOD OF USE

FIELD OF THE INVENTION

This invention relates to end closures for a valley trough and to a method of using the end closures.

BACKGROUND TO THE INVENTION

The construction of a pitched roof of a building typically comprises the erection of a number of inclined rafters defining the overall shape of the roof. A waterproofing layer is typically laid over the rafters, the waterproofing layer often comprising a layer of felt. A number of substantially horizontal battens or the like are fixed to the rafters through the waterproofing layer, and the roof covering comprising tiles or slates for example are laid upon the battens.

Some pitched roofs comprise two substantially flat roof sections which meet at the apex of the roof. Many roofs, however, are of more complex shape having a number of roof sections which meet at inclined valleys or inclined peaks depending upon whether the junction between the adjacent roof sections is concave or convex.

The present invention relates to a roof having a valley trough, which is a component which lies along a valley between two adjacent roof sections and is located between the waterproofing layer and the roof covering. A valley trough (sometimes called a valley strip) is described in GB 2 211 867 and GB 2 234 980

for example.

Most valley troughs are made of glass reinforced plastic material, and are made in modular lengths which can be fitted and cut on site to match the length of the valley. Because the valley trough is flexible it is usual for the builder to mount a supporting (typically timber) valley board upon the rafters along the length of the valley, underneath the waterproofing layer. The valley trough is therefore supported along its length by the valley board. The valley trough will also typically have a raised lip or step along its peripheral edges, the raised steps being supported by respective timber battens along their length.

The valley troughs of GB 2 211 867 and GB 2 234 980 have a raised central s portion which is designed to project upwardly by a distance similar to the thickness of the roof covering. In this way, the tiles, slates or other roof covering can be fitted up to the raised central portion of the valley trough, facilitating easier construction of the roof. Between the raised central portion and each of the peripheral raised steps the valley trough provides channels to carry rainwater io along the valley trough to the bottom of the roof, reducing the likelihood that the rainwater will flow underneath the roof covering. The features of a raised central portion with peripheral steps providing a channel to either side of the raised central portion are typical features of valley troughs.

The present invention provides end closures for a valley trough, i.e. components which can substantially close off the ends of the valley trough so as to reduce or avoid the ingress of water underneath the valley trough.

An end closure can be fitted to the top end of the valley trough, but that will not always be required. Thus, the top of the valley often lies adjacent to the apex of the roof which carries a set of ridge tiles. As above indicated, the raised central portion typically projects by a distance similar to the thickness of the roof covering, so that the top of the raised central portion typically lies close to the level of the ridge tiles. There may therefore be only a small gap between the valley trough and the ridge tiles at the top of the roof, which can usually be easily filled with mortar or other sealing material.

In cases where the top of the valley lies below the apex of the roof, e.g. on a roof having a dormer window, an end closure can be fitted to the top end of the valley trough. It will be understood that in the case of a dormer window the valleys to either side of the dormer window meet above the dormer window, and a double end closure can be used as a saddle closing the top of both valley troughs.

Nevertheless, it is expected that the end closure of the present invention will most commonly be used at the bottom end of the valley trough, where the profile of the valley trough, and in particular the raised central portion, would otherwise present a relatively large opening for the ingress of water, snow and the like. The following description will therefore relate primarily to an end closure for the bottom end of a valley trough.

In the present construction of a roof it is usual for the builder to fill the bottom end s of the valley trough with mortar or a suitable sealant.

The inventor has appreciated that the method of filling the bottom end of the valley board with mortar is problematic. The valley board is flexible and the mortar may not provide an effective and long-lasting seal against water ingress.

io The use of a suitable sealant such as silicone avoids this problem but has its own problems in that the injection of the large volume of sealant required to fill the end of the valley trough is usually a messy exercise, and seldom results in a tidy closure.

The present invention seeks to reduce or avoid the problems with the known methods of closing the end of a valley trough.

SUMMARY OF THE INVENTION

According to the invention there is provided an end closure for a valley trough, the end closure being made of a flexible waterproof material and comprising a base portion and a shaped portion, the shaped portion being shaped to closely match the profile of the raised central portion of the valley trough.

Desirably, the base portion is substantially planar in the rest condition of the end closure. It will be understood, however, that the flexibility of the base portion permits it to be readily deformed to match the contours of the adjacent parts of the roof structure.

Preferably, the shaped portion comprises an upstand projecting from the base portion. Preferably also the end closure includes raised portions to closely match the raised peripheral portions or steps of the valley trough.

Desirably, the end closure is manufactured from polyurethane. Desirably also, the base portion of the end closure is approximately 3mm thick.

It will be understood that a 3mm thick layer of polyurethane is relatively flexible, and can readily be deformed to match the shape required. Preferably, however, the end closure is supported by at least one former to better define the shape required. Preferably, the former lies below the shaped portion. Preferably also, the former is a layer of glass reinforced plastic suitably fixed to the underlying battens prior to fitment of the end closure.

It will also be understood that a 3mm thick layer of polyurethane is relatively easy to cut, for example with a craft knife or snips, permitting the end closure to be cut on site to match the shape required of the particular roof. It will therefore be understood that the bottom end of the valley trough typically lies close to the is eaves and gutter of the roof, and it will usually be necessary to cut the end closure (and in particular the base portion) to fit the particular roof so that the base portion overlies the gutter line.

An alternative (but less preferred) end closure is made of a more rigid material whereby the shaped portion can be self-supporting. The thickness of the material from which the end closure is manufactured can be varied if desired, with relatively thick regions providing less flexibility and being provided at the shaped portion, and with relatively thin regions providing greater flexibility (and permitting easier cutting) and being provided at the base portion.

There is also provided a method of constructing a roof having a valley trough, comprising the following steps: {i} fitting the valley trough to the roof, the valley trough having a raised central portion; {ii} fitting an end closure underneath the bottom end of the valley trough, the end closure being made of a flexible waterproof material and comprising a base portion and a shaped portion, the shaped portion being shaped to closely match the profile of the iaised central portion of the valley trough; {Hi} cutting the base portion to match the shape of the roof adjacent to the bottom of the valley trough.

The closely matching profile of the end closure to the valley trough, and the s fitment of the end closure underneath the valley trough can, with a sufficient overlap, substantially prevent water ingress between the end closure and the valley trough. However, if desired there could be the additional step of sealing the gap between the valley trough and the end closure.

io Even if it is required to include the additional step of sealing the gap, it will be understood that the gap is very small, and ideally suited to the injection of silicone or another suitable sealing material.

In cases where the end closure is to be fitted to the top of a valley, it will be is understood that the end closure overlies the top of the valley trough. In the case of a double end closure used for a dormer window, the end closure overlies the top of both of the valley troughs to either side of the dormer window.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention will now be described in more detail, by way of example, with reference to the accompanying drawings, in which: Fig.1 shows a schematic representation of a part of a roof having a valley trough; Fig.2 shows a photograph of an end closure according to the invention; Fig.3 shows a photograph of the end closure and the end of the valley trough; Fig.4 shows another photograph of the end closure and the end of the valley trough; Fig.5 shows a photograph of the end of the valley trough overlying the end closure; and Fig.6 shows another photograph of the end of the valley trough overlying the end closure.

DETAILED DESCRIPTION

The roof 10 with which the invention is intended to be used has a valley 12 formed at the junction of two substantially planar roof sections 14 and 16. It will be understood that the junction is concave so that it forms a valley 12.

is In known fashion, a valley trough 20 has been fitted to the valley, and is located on top of the waterproof layer (not shown) which is in turn located on top of a valley board and rafters (also not shown). The roof covering comprises a number of tiles or slates 22 which are mounted upon the roof in a typical staggered fashion.

As better seen in Figs. 3-6, the valley trough 20 comprises a raised central portion 24, to either side of which is a channel 26. In this particular embodiment a step is located between the raised central portion 24 and each of the channels 26, the steps 30 being provided to support the edge of the tiles or slates 22 which lie adjacent to the valley trough 20. During the construction of the roof the valley trough 20 is fitted to the valley before the tiles or slates 22, and the tiles or slates which lie adjacent the valley are cut so as to lie upon the step 30 close to the raised central portion 24.

The longitudinal edges of the valley trough also have a step 32, of a similar height to the step 30. The step 32 in use overlies the end of the battens and also supports the roof covering. The steps 30 and 32 together border the channel 26 and additionally serve to retain water within the channel 26, i.e. encouraging water to flow down towards the bottom of the valley rather than underneath the roof covering 22.

The raised central portion 24 of the valley trough 20 is of a height similar to the thickness of the roof covering, and so is visible between the edges of the adjacent tiles or slates 22 in Fig.1.

Fig.1 shows the bottom (eaves) end of the valley 14, but the gutter, fascia and soffit which will typically lie at the bottom end of the roof 10 are omitted as they do io not form part of the present invention, and will be readily apparent to a skilled person.

It will be understood from Fig.1 that in the absence of an end closure the profile of the valley board 20, and in particular the raised central portion 24, presents a is large opening 34 which can permit the ingress of water, snow and the like.

Notwithstanding that the opening 34 lies above the waterproofing iayer, it is necessary to close the end of the valley trough 20 so as to prevent (or at least minimise) the ingress of water and moisture underneath the roof covering. The end closure 40 is designed to close the bottom end of the valley trough 20.

As seen in Figs. 2-6, the end closure 40 comprises a substantially planar base portion 42 and a shaped portion 44, the shaped portion 44 being shaped to closely match the profile, and in particular the raised central portion 24 and the steps 30, of the valley trough 20. Thus, the shaped portion 44 is designed to substantially fill the opening 34 in the bottom end of the valley trough 20.

The end closure 40 is made from a flexible waterproof material, in this embodiment a layer of polyurethane. The base portion 42 is approximately 3mm thick and the shaped portion 44 is approximately 5mm thick, the greater thickness enabling the shaped portion 44 to include a former 46 of glass reinforced plastic, the edge of which is visible in Fig.2. In an alternative and preferred embodiment the former 46 is not embedded within the material of the end closure, but is instead provided as a separate component which is secured to the roof before the end closure is fitted thereover.

The former 46 defines the shape of the shaped portion 44, and in particular closely matches the profile of the raised central portion 24 and steps 30 of the valley trough 20. In addition, the end closure 40 has peripheral raised portions 50, which are configured to closely match the steps 32. Thus, whilst it is not necessary for the end closure 40 to be of the same width as the valley trough 20 (nor therefore to include the steps 50), in this embodiment the widths are similar.

As seen in Fig.6 in particular, when the end of the valley trough 20 overlies the end closure 40, there is substantially no gap therebetween. Whilst Figs. 2-6 show the components on a substantially horizontal surface, in practice the valley trough is inclined, and the end closure 40 will therefore be similarly inclined, so that is with sufficient overlap there may be no requirement to seal the gap between the valiey trough 20 and the end closure 40. in practice, however, the roof builder will typically require a suitable sealant (such as silicone or the like) to be used between the valley trough 20 and the end closure 40.

As shown in FigS, the valley trough 20 is also flexible (though in practice not as ftexible as the end closure 40), and this is typical of valtey troughs made of glass reinforced plastic. The flexible nature of the valley trough 20 facilitates the injection of sealant between the end closure 40 and the valley trough 20, if that is required.

It will be seen that the shaped portion 44 occupies only a small part of the end closure, and terminates at a relatively steep surface 48. The area of the end closure 40 which cannot be cut to match the form of the roof is therefore minimised, which is useful in those roofs where the valley trough terminates close to the eaves.

Claims

<claim-text>CLAIMS1. An end closure for a valley trough having a raised central portion, the end closure being made of a waterproof material and comprising a base portion and a shaped portion, the shaped portion being shaped to closely match the profile of the raised central portion of the valley trough, the base portion being flexible.</claim-text> <claim-text>2. An end closure according to claim 1 comprising a continuous sheet of io waterproof material providing the shaped portion and the base portion.</claim-text> <claim-text>3. An end closure according to claim 1 or claim 2 in which the base portion is formed substantially planar but is deformable into a non-planar shape.is 4. An end closure according to any one of claims 1-3 in which the shaped portion comprises an upstand projecting from the base portion.5. An end closure according to any one of claims 1-4 for a valley trough having raised peripheral portions, in which the end closure includes raised portions to closely match the raised peripheral portions.6. An end closure according to any one of claims 1-5 in which the end closure comprises a layer of polyurethane.7. An end closure according to any one of claims 1-6 in which the base portion is approximately 3mm thick.8. An end closure according to any one of claims 1-7 which includes at least one former to add rigidity to the shaped portion.9. An end closure according to claim 8 in which the former is a layer of glass reinforced plastic.10. An end closure according to any one of claims 1-7 in which the waterproof material is sufficiently rigid so that the shaped portion is self-supporting.11. A method of constructing a roof having a valley trough with a raised central portion, comprising the following steps: {i} fitting the valley trough to the roof; {H} fitting an end closure underneath the bottom end of the valley trough, the end closure being made of a waterproof material and comprising a io base portion and a shaped portion, the shaped portion being shaped to closely match the profile of the raised central portion of the valley trough, the base portion being flexible; {Di} cutting and/or deforming the base portion to match the shape of the roof adjacent to the bottom of the valley trough.12. A method according to ciaim 11 inciuding the additional step of sealing the gap between the valley trough and the end closure.13. A method according to claim 11 or claim 12 including the additional step of securing a former adjacent to the end of the valley, the end closure being fitted over the former.14. An end closure for a valley trough having a raised central portion, the end closure being constructed and arranged substantially as described in relation to Figs. 2-6 of the accompanying drawings.</claim-text>