ROLLABLE RIDGE VENT

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to ridge vents for covering an opening at a roof ridge. More specifically, the present disclosure relates to a rollable ridge vent assembly.

BACKGROUND

In the winter, household activities such as cooking, showering, and doing laundry, generate moisture that can migrate to the attic and damage insulation and building materials of a house's roof. In the summer, attic temperatures can rise to over 150° F., which can cause premature aging and cracking of wood and roofing materials. These elevated temperatures can also increase cooling costs for the home owner. In the construction of rooves, therefore, it is often desirable to provide a ventilation opening at the roof ridge and cover it with a vent. Ridge vents are passive ventilation systems that provide openings through which air can convectively flow to and from under the roof structure to provide attic ventilation.

Roof ridge ventilators typically cover over an elongated opening that is formed in a roof and that extends along the peak of the roof, with the opening typically being in the range of approximately 1.5-3 inches in width and running along a substantial portion of the roof peak. Such openings typically do not extend to the ends of the peak for various structural and functional reasons, as well as other reasons. Such roof ridge ventilators typically function in cooperation with air inlet openings that are typically formed in a lower region of the roof that is generally protected from precipitation, such as the eaves or soffits.

Many ridge vents have been developed that are made of polymeric materials that are flexible along a longitudinal axis in order to permit the ridge vent to conform to the sloped sides of a roof to cover the ridge opening. These ridge vents typically include a plurality of vent openings or projections and supporting structures that extend from a common panel and that serve the functions of resisting entry of precipitation, insects, and foreign matter, and providing supportive structures that space the panel away from the roof to allow air flow and provide crush resistance. It is further desirable that ridge vents are designed to create a “Venturi effect” or air draft to draw hot air outwardly from the underlying attic.

Prior art roof ridge vents are known that can be rolled for compact packaging and transport to an installation site. However, to make these ridge vents rollable requires some sacrificing in their features and resulting thermal efficiency in drawing hot air from the underlying attic, or costly modifications to the baffle structure in order to allow the ridge vent to be rolled in a spiral form.

Accordingly, there remains a need for a ridge vent, and particularly a rollable ridge vent that can be made cost-effectively, and that efficiently assists convection of heat and moisture laden air from beneath a roof.

SUMMARY

To overcome the problems described above, in an embodiment of the present disclosure a ridge vent, includes an elongated flexible member having a central panel defined between a pair of lateral edges, a first end, and a second end, the central panel having top and bottom major surfaces; a pair of vent openings defining openings through the central panel with one each located inward of a corresponding lateral edge; and a plurality of flow projections extending from a central portion of the central panel to at least one of the pair of lateral edges.

The ridge vent can further include an end internal gusset extending from the bottom major surface along the first end to support the central panel above a roof.

In an aspect, each of the plurality of flow projections has a convex cross-sectional shape.

In an aspect, the end gusset includes a corrugated portion.

In an aspect, each of the plurality of flow projections is thicker than the central panel.

In an aspect, the second end includes a pair of tabs extending perpendicularly from the central panel with one each located adjacent to a corresponding one of the pair of vent openings.

In an aspect, some of the plurality of flow projections extend from the central portion of the central panel to a first one of the pair of lateral edges.

In an aspect, some of the plurality of flow projections extend from the central portion of the central panel to a second one of the pair of lateral edges.

In another embodiment, a ridge vent includes an elongated flexible member having a central panel defined between a pair of lateral edges, a first end, and a second end, the central panel having top and bottom major surfaces; a pair of vent openings defining openings through the central panel with one each located inward of a corresponding lateral edge; and a plurality of joining buttons of resin material protruding from the bottom major surface and aligned and spaced along the second end, wherein the second end has a sinusoidal-shaped portion and one of the plurality of joining buttons is located adjacent to a corresponding peak of the sinusoidal-shaped portion.

The ridge vent can further include a plurality of flow projections extending from a central portion of the central panel to at least one of the pair of lateral edges.

In an aspect, the second end includes a pair of tabs extending perpendicularly from the central panel with one each located adjacent to a corresponding one of the pair of vent openings.

In an aspect, each of the pair of tabs is located between a corresponding lateral edge and the sinusoidal-shaped portion.

The ridge vent can further include an end gusset extending along the first end to support the central panel above a roof.

In an aspect, each of the plurality of flow projections has a convex cross-sectional shape.

In another embodiment, a ridge vent system includes a plurality of ridge vents, wherein each of the plurality of ridge vents includes: an elongated flexible member having a central panel defined between a pair of lateral edges, a first end, and a second end, the central panel having top and bottom major surfaces; a pair of vent openings defining openings through the central panel with one each located inward of a corresponding lateral edge; a plurality of joining holes aligned and spaced along the first end; a plurality of joining buttons of resin material protruding from the central panel and aligned and spaced along the second end, wherein each of the plurality of ridge vents is bondable with another of the plurality of ridge vents such that the resin material of each of the joining buttons of each of the ridge vents is deformable to fit into a corresponding one of the plurality of joining holes of the another of the plurality of ridge vents to define a joint when the resin material is solidified.

In an aspect, each of the plurality of ridge vents further includes an end gusset extending along the first end to support the central panel above a roof.

In an aspect, each of the plurality of ridge vents further includes a plurality of flow projections extending from a central portion of the central panel to at least one of the pair of lateral edges.

In an aspect, each of the plurality of flow projections is thicker than the central panel.

In an aspect, each of the plurality of ridge vents further includes a pair of tabs extending perpendicularly from the central panel with one each located adjacent to a corresponding vent, and each of the plurality of ridge vents is bondable with another of the plurality of ridge vents such that resin material of each of the tabs of each of the ridge vents is deformable to fit into a corresponding one of the plurality of side holes of the another of the plurality of ridge vents to define a joint when the resin material is solidified.

As described, ridge vent features are configured to balance intake and exhaust of attic air, reduce debris and weather ingress, ease installation, and decrease job site waste while providing structural integrity. Manufacturability features provide increased production rate and robust joints between molded sections.

The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a ridge vent according to an embodiment.

FIG. 2 is a bottom perspective view of a ridge vent.

FIG. 3 is a side view of a ridge vent.

FIG. 4 is a bottom view of a portion of a second end of a ridge vent.

FIG. 5 and FIG. 6 are perspective views of a ridge vent roll according to embodiments.

FIG. 7 is a perspective view of a ridge vent resiliently deformed to define a roll and being unrolled at the peak of a roof during installation of a ridge.

FIG. 8 is a sectional view of a roof with a ridge vent in a relaxed position.

FIG. 9 shows a ridge vent in an installed position on a roof.

FIG. 10 is a bottom view of a portion of a first end of a ridge vent.

FIG. 11 is a cross section view of a flow projection of a ridge vent.

FIG. 12 is a top perspective view of a portion of a first end of a ridge vent.

FIG. 13 is a bottom perspective view of a portion of a second end of a ridge vent.

FIG. 14 is a top perspective view of a portion of a first end of a ridge vent.

FIG. 15 is a bottom view of a portion of two ridge vents joined together.

FIG. 16 and FIG. 17 are bottom perspective views of a portion of two ridge vents joined together.

FIG. 18 is a bottom view of a portion of two ridge vents joined together.

FIG. 19 is a top perspective view of a portion of two ridge vents joined together.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

Directional terms as used herein—for example up, down, right, left, front, back, top, bottom, vertical, horizontal—are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

As used herein, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components, unless the context clearly indicates otherwise.

In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustrating specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed herein, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense.

This disclosure describes a ridge vent and rollable ridge vent system that can be used in shingle-over roof vent applications, roll-out shingle over roof ridge vent applications, and in applications where shingles are not used over the ridge vent. The rollable ridge vents of this disclosure can be designed for ridge and hip roof applications, they can have a low profile for a minimum accented ridge line. The vent openings or louver openings in the ridge vent are designed to keep out insects and weather infiltration, and the side baffles are structured to deflect wind and rain and create negative air pressure (i.e., a Venturi effect). The side baffles are desirably molded into the roof vent in such a way that they can be readily rolled into a coil, laid out over an opening in a roof vent, and positioned in their final form easily, and without significant additional cost to the installer.

FIGS. 1-4 show a ridge vent 101 to cover an opening at a roof ridge. The ridge vent 101 can be molded and combined with other ridge vents 101 into a lengthened structure that can be rolled into a spiral coil as a rollable ridge vent 1010, as shown in a representative FIG. 5, but can also be provided in a straight or rigid form.

The ridge vent 101 can include an elongated flexible member having a generally planar central panel portion 10 defined between lateral edges 16, a pair of lateral side portions defining a pair of side baffles 18, and a pair of transverse ends, a first end and a second end. The central panel portion 10, which is preferably bi-axially flexible, can include a plurality of support ribs 12 for supporting and spacing the central panel portion 10 when installed above a roof. The ridge vent 101 can include a pair of air vents with one each extending along a corresponding lateral edge 16. Each air vent can include a plurality of slotted vent openings 14 (best seen in FIG. 4) defined therethrough and separated by slats 24, along the lateral edges 16 of the central panel portion 10. The slats 24 define a portion of, and can be planar with at least one of the major surfaces of the central panel portion 10. For example, the slats 24 can be planar with the rear major surface of the central panel portion 10 shown in FIG. 1 but can be thicker than the major surface 10 such that a thickness of the slats 24 extends above the bottom or underside major surface the central panel portion 10 shown in FIG. 2. The added thickness of the slats 24 can increase structural integrity of the vent openings 14.

The ridge vent 101 can include side baffles 18 defined integrally with and extending from the bottom of the central panel portion 10 proximate to the lateral edges 16 and between a corresponding lateral edge 16 and the air vent openings 14 on that side. The side baffles 18 can extend substantially perpendicular (90°±30°) from the bottom major surface of the central panel portion 10 (shown in FIGS. 2 and 4) and can be substantially sinusoidal shaped. The side baffles 18 can extend an entire length of the lateral edge 16.

As shown in FIGS. 2 and 4, the ridge vent 101 can include support ribs 12 that extend from the bottom major surface of the central panel portion 10 and can connect with a side baffle 18. These support ribs 12 extend inboard beyond the air vent openings and help to prevent insects, debris, water, and other undesirable materials from entering through the lateral portions of the ridge vent 101.

An internal baffle 13 can be located at an interior end of each support rib 12. The internal baffle 13 can be arch shaped and used to manage airflow from the opening in the roof ridge to the vent openings 14. Additional, internal baffles 13 can be included that extend from the bottom major surface of the central panel portion 10 but are not connected to a support rib 12.

The ridge vent 101 can also include internal gussets 20 that extends from the bottom major surface of the central panel portion 10 to provide strength to and support for the central region of the central panel portion 10. At least one of the internal gussets 20 can extend across the width of the central panel portion 10 between the two side baffles 18. An end gusset 21 located at a first end of the ridge vent 101 can also extend across the width of the central panel portion 10 between the two side baffles 18. A central portion of the internal gussets 20 and end gusset 21 can be corrugated or have an accordion or triangular shaped structure to allow the central portion of the ridge vent 101 to bend over the opening in a roof ridge while providing spacing from the roof and structural support. Once the ridge vent 101 is installed, internal gussets 20 will allow the ridge vent 101 to form and retain a curved or peak shape and not flatten, for example, as shown in FIG. 9. In some embodiments, the ridge vent 101 can include an end gusset 21 at both ends.

The ridge vent 101 can also include reinforced nail holes 19. The nail holes 19 can be openings located at periodic intervals extending along the two lateral edges 16. The nails holes 19 can have a diameter that approximates a diameter of a roofing nail 191 (shown in FIG. 9) that extends through the ridge vent 101 and meant to be used to nail the ridge vent 101 to a roof. The nail holes 19 can be reinforced with a boss that can be included and extend from the underside of the central panel portion 10 to define a corresponding nail hole 19. An internal baffle 13 can also be defined with the boss to add air deflection and structural support. In some embodiments, the rollable ridge vent 1010 can be included with nails that have been force fit and retained into the nail holes 19 to speed installation.

The ridge vent 101 can be injection molded as one piece and constructed from a polymer material, such as polypropylene, polyvinylchloride, polyethylene, thermoplastic polyolefin, and a high impact copolymer polypropylene. The ridge vent 101 can be made in a three-foot long section and indexed or slid in one direction and then overmolded with another subsequently molded ridge vent 101 to join the two ridge vents 101. The length of the ridge vent 101 can be a function of or limited by a molding machine. This overmolding joining process can be repeated to create a one-piece, for example 30-foot long, strip that can be rolled for storage, shipment, and handling at a work site, e.g., like the rollable ridge vent 1010 shown in representative FIGS. 5 and 6.

In application, the ridge vent 101 can be laid over or unrolled over the opening in a roof ridge and is supported by the ribs 12, the edge baffles 18, the internal gussets 20, and the end gusset 21. The ridge vent 101 can be tacked into place by nails through any of the nail holes 19. In a shingle-over ridge vent installation method, a plurality of shingles can be laid over a portion of the ridge vent 101 and both the ridge vent 101 and the shingles can be simultaneously nailed to a roof substrate, such as plywood, studs, tongue and groove planks, or the like, to secure both the ridge vent 101 and shingles in place. The shingles can be layered over the fasteners of the adjacent shingle, to minimize water penetration. The shingles are preferably layered to leave the vent openings 14 open. This arrangement should also not interfere with the Venturi action of air flow from the attic through the vents. After installation, the edge baffles 18 can be seated generally perpendicular to (±30°) or upright in relation to the roof when the ridge vent 101 is installed. The ridge vent 101 can provide a net free area of 12 square-inches per linear foot.

As mentioned, the ridge vent 101 is configured to be mounted over an opening 52 that is formed in the peak of a roof 12 of a building, as shown in FIG. 7. The ridge vent 101 can be configured to be resiliently deformed or rolled lengthwise into a roll 1010, which facilitates handling, transportation, and installation of the ridge vent 101 on the roof 12. The ability of the ridge vent 101 to be resiliently deformed or flexed is due both to the advantageous design thereof as well as the selection of the material out of which the ridge vent 101 is manufactured. Moreover, the ability of the ridge vent 101 to be resiliently deformed or rolled lengthwise into the roll 1010 results from the specific material of the ridge vent 101, but also advantageously results from configuring the ridge vent 101 such that a plurality of projections that extend from a panel of the ridge vent 101 each extend only a short longitudinal distance along the panel, and thus do not resist lengthwise resilient deformation of the ridge vent 101 to as great an extent as would smaller numbers of projections that each extend a relatively greater longitudinal distance along the ridge vent 101. The ridge vent 101 can be resiliently deformed or flexed about a longitudinal axis thereof between a relaxed position (shown in FIG. 8) in which the ridge vent 101 is substantially flat across an axis transverse to the longitudinal axis and an installed position (shown in FIG. 9) in which the ridge vent 101 is angled to conform substantially to the sloped sides of the roof 50.

In some embodiments, a foam insert or another end cap (not shown) can be used to close an end of the ridge vent 101 prior to completion of the installation. More preferably, a length of the ridge vent 101 can be cut and joined with an adjacent piece on the roof such that one of the internal gussets 20 or end gusset 21 that extends the width of the ridge vent 101, which are located at intervals across the ridge vent 101, can be located at an end of the ridge to close an end of the ridge vent spanning the opening of the roof. In some embodiments, any combination of the internal gussets 20 and the end gussets 21 can be located at 6 inch intervals across the ridge vent 101. This provides for a more efficient installation as no additional inserts, end caps, or separate pieces are needed to close off the ends, thereby reducing jobsite waste.

In some embodiments, an internal filter 60 can be coupled to the rollable ridge vent 1010, as shown in representative FIG. 6. An exemplary filter 60 can be made of an untreated, unwoven fiberglass mesh. The filter 60 can be attached to the rollable ridge vent 1010 using an adhesive or by a heat staking process by which the support ribs 12 are melted into the filter material along the full length of the product. The filter, of fiberglass mesh construction or the like, can be provided beneath the central panel portion 10 for filtering out insects, snow, rain, debris, etc., while allowing sufficient air flow therethrough to accomplish the purposes of the rollable ridge vent 1010.

The ridge vent 101 can further include manufacturability features that increase production rate, facilitate joining of two ridge vents 101 during molding, and create strong and robust joints between two ridge vents 101. FIGS. 10 to 19 are used to describe such manufacturability features.

FIG. 10 is a bottom or underside view of a portion of the ridge vent 101 that shows features provided to increase manufacturability. One feature is a series of flow projections 70. The flow projections 70 protrude from and are raised above other portions of the central panel portion 10. As such, the thickness differences of the flow projections 70 are visible. As shown, a grouping of the flow projections 70 can extend from a central location 72 such that the grouping defines a spider like-shaped pattern where the central location 72 corresponds to a spider body and the flow projections 70 correspond to spider legs connected at one end to the body. FIG. 11 shows that a cross section of the flow projections 70 can be convex such that a center of a flow projection 70 is the thickest portion and a thickness of the flow projection 70 tapers away from the center until the cross section of the flow projection 70 terminates at an edge 71 having a thickness of the central panel portion 10. The cross section of each of the flow projections 70 can be substantially uniform throughout their length.

The flow projections 70 in the ridge vent 101 result from a specific corresponding mold flow channel shape provided to allow better resin distribution and complete fill throughout the molded part during the injection molding process. Including the flow channels in a mold resulting in the flow projections 70 increases the efficiency of molding the ridge vent 101. A larger molding machine would be required to push the resin to the outer edges of the mold to fabricate a comparable ridge vent that does not include the flow projections 70. Providing the flow projections 70 optimizes the molding process to use the least amount of resin at a desired viscosity to flow to the outer edges in a uniform manner to minimize the time needed to mold a ridge vent 101. Flow projections 70 allow for better resin distribution throughout the molded part during the injection molding process. With flow projections 70, resin travels easier through the mold tool, thus reducing the flow time and increases the roll production. The variance in the thickness from the flow projections 70 allows for a reduction of the material and reduced injection tonnage needed to manufacture the rolls, improve rollback, and maintain structural integrity when nail gun applicators are used to install the ridge vent 101.

During injection molding, resin can be provided via valve gates to the central locations 72 as the resin flows and is distributed to outer portions of the mold. After the resin sufficiently cools, the ridge vent 101 can be ejected from the mold as one piece that is about three feet long. A robotic arm can slide the ejected ridge vent 101 to a side in indexing. The ejected ridge vent 101 can be joined with a subsequently molded ridge vent 101. These steps can be repeated until ten ridge vents 101 are produced and joined together to define a length of a strip, e.g., a 30-foot strip, which can then be rolled into a product like 1010.

The ridge vent 101 can be manufactured in any of a wide variety of fashions such as various types of molding, casting, and other methodologies. The ridge vent 101 is particularly appropriately manufactured via injection molding, although other and additional manufacturing processes may be employed without departing from the concept of the present invention. This disclosure contemplates an efficient manufacturing process for making ridge vents 101 including a forming operation employing polymeric materials. The forming operation can include injection molding, extrusion or compression molding, for example. In an embodiment, the ridge vent 101 is made by index injection molding. In such an embodiment, a mold having upper and lower mold sections is provided for forming a mold cavity. A quantity of polymeric material is injected into the mold cavity and a first ridge vent section 101 is formed in the mold cavity. Next, the first ridge vent section 101 is indexed so that it is substantially moved beyond the mold cavity but remains in contact with the mold. A small stepped extension can remain in the mold. A second quantity of polymer is injected between the mold sections of mold and a second ridge vent 101 section is formed which is connected to the first ridge vent section 101. The cooled first ridge vent section 101 can then be rolled up in lengths containing about 20-50 feet of vent material, which is then packaged for storage and shipping. For example, a rolled length can be about 30 feet.

The ridge vent 101 can include additional manufacturability features that increase production rate such as overmolding features at the ends of the ridge vent 101 that facilitate joining with another ridge vent 101 with a robust bond. For example, FIG. 10 shows that the ridge vent 101 can include a step or flange 74 extending across a first end. The flange 74 can include a strip of resin material with increased thickness than the central panel portion 10 and that extends a width of the ridge vent 101 between the slats 24 along both edges of the ridge vent 101. The flange 74 can include a series of joining holes 76 that are through flange 74 and aligned and spaced periodically along the flange 74.

FIG. 12 is a perspective view of an opposite side of a portion of the ridge vent 101 at the first end that includes the joining holes 76. This side of the ridge vent 101 can include recesses 80 with one each around a corresponding joining hole 76. The thickness of the recesses 80 is reduced compared to the central panel portion 10. As shown, the recesses 80 defined at most of the joining holes 76 create a sinusoidal or scalloped pattern whereas recesses 80 at outermost joining holes 76 can have a different shape. The joining holes 76 and the recesses 80 are defined and oriented to mate with corresponding features on the opposite (second) end of another ridge vent 101.

FIG. 13 is a perspective bottom or underside view of a portion of the ridge vent 101 at the second end opposite to the first end shown in FIGS. 10 and 12. As shown in FIG. 13 and also FIG. 4, the second end of the ridge vent 101 can include features that are configured to join with corresponding features at the first end of another ridge vent 101. The second end can include a series of joining buttons 96 that are defined of resin material protruding from the central panel portion 10 and are aligned and spaced periodically along the second end. As shown, most of the joining buttons 96 are adjacent to an edge 90 having a sinusoidal or scalloped pattern whereas the edge 90 at the outermost joining buttons 96 can have a different shape. The second end also can include tabs 110, one at each end used for joining.

During joining of two ridge vents 101 to define a strip, the first end of one ridge vent 101 is aligned with the second end of another ridge vent 101 such that the two ridge vents 101 fit together. The sinusoidal pattern of the edge 90 along the second end can fit into the sinusoidal recesses 80 along the first end. The locations of the joining buttons 96 along the second end align with corresponding joining holes 76 along the first end. The resin defining the joining buttons 96 can flow through the joining holes 76 and the resin at the edge 90 can flow with the resin in the recesses 80 to define a robust seam 1400, as shown in FIGS. 18 and 19.

The ridge vent 101 can include additional manufacturability features that facilitate joining with another ridge vent 101 with a robust bond. FIG. 14 is a perspective view of a portion of the first end showing that the end gusset 21 that extends across the width of the ridge vent 101 can include side holes 100 (also visible in FIG. 12) through the end gusset 21. As shown, the side holes 100 can be located on the end gusset 21 adjacent to the edges 16. When two ridge vents 101 are joined, the side holes 100 adjacent to one edge 16 are aligned with a tab 110 on the other ridge vent 101. While being joined, resin material flows from the tab 110 and through the side holes 100 to create a side joint 1100 shown in FIG. 15. The side joint 1100 provides bonding forces in a direction perpendicular to the bonding forces of the joining buttons 96 with the joining holes 76 to add strength to the bonded portion. FIGS. 16 and 17 provide alternative views of the side joint 1100.

It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the appended claims.