RIDGE VENT SCREEN SYSTEM

Description

BACKGROUND OF THE INVENTION

The present invention relates to ridge vents for attic ventilation systems, and more particularly to the prevention of unwanted pests from entering an attic through the ridge vent.

A common method for venting an attic space is the use of a continuous vent at the soffit combined with a continuous ridge vent. To form the ridge vent, a slot is cut out of the roof sheathing along the ridge. The slot forms a vent that enables air flowing in through the soffit vent to exit the attic. In some cases, an underlayment layer is positioned on the roof sheathing, and the ridge vent will include cutting a slot in the underlayment that is aligned with the slot in the roof sheathing. Shingles may be placed over the underlayment and adjacent to the ridge vent without covering or blocking the ridge vent. A vent cap is typically mounted over the ridge vent. These vent caps come in various formats, and typically include a pair of vented upright sidewalls supporting a non-porous cap section. The sidewalls are a mounted on either side of the ridge vent, and enable air to exit the ridge vent through the sidewalls. The sidewalls may be slotted in such a way that they prevent pests such as rodents from entering the attic space. In some cases, fibrous material is installed under the vent cap between the sidewalls to additionally prevent smaller pests such as insects from entering the attic space.

Unfortunately, conventional ridge caps often fail to keep pests such as rodents and insects from entering the attic space through the ridge vent. Over time, the fibrous material may deteriorate and shift to enable insects to pass through the ridge vent, and the slotted sidewalls may break or warp, unwantedly letting rodents through or under the cap and into the attic space. As such, there continues to be a need for a system that more reliably prevents pests from entering the ridge vent.

SUMMARY OF THE INVENTION

The present invention provides an effective, long lasting ridge vent screen system that includes a screen layer positioned between an underlayment layer and a ridge vent cap. The screen layer includes a screen material positioned between and attached to two sections of a second material. The screen material is aligned over the ridge and the slots in the sheathing and underlayment to enable air flow.

In one embodiment, the screen layer is positioned on the underlayment layer, the screen layer including screen material and a second material, the screen material aligned at least partially over the underlayment slot and having a first side edge and a second side edge, the second material having a first section and a second section, the first section attached to the first side edge of the mesh and extending over the underlayment on one side of the underlayment slot, the second section attached to the second side edge and extending over the underlayment on the other side of the underlayment slot.

In one embodiment, the screen material is heat welded or sewn to the second material, and the second material is formed of the same material as the underlayment. A layer of shingles may be positioned underneath the ridge vent cap, with the layer of shingles positioned to enable air flow through the ridge vent and vent cap.

In one embodiment, the screen material may additionally include a durable coating, such as a durable water repellent. The durable coating may be added to the screen material aligned over the underlayment slot and under the ridge vent cap. This treated, or coated screen material can redirect moisture, prevent saturation, and preserve airflow through the screen material.

The present invention also includes a method for installing a ridge vent system, including the steps of: (a) attaching the sheathing layer over the roof supports by fasteners or another attachment method, (b) creating a sheathing slot by cutting the slot in the sheathing layer aligned with the ridge, or by positioning the sheathing in a manner that is spaced apart at the ridge; (c) rolling out or otherwise placing the underlayment layer over the sheathing layer; (d) forming the underlayment slot in alignment with the sheathing slot; (e) positioning the screen layer with the screen material in alignment with the underlayment slot; (f) attaching and the second material of the screen layer on either side of the ridge to secure the screen layer in place; and (g) attaching the ridge vent cap over the screen layer or a shingle layer.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a ridge vent system according to one embodiment of the present invention.

FIG. 2 is a side cross sectional view thereof taken along line II-II in FIG. 1.

FIG. 3 is an exploded view of the components of a ridge vent system according to one embodiment.

FIG. 4 is a top view of a screen layer according to one embodiment.

FIG. 5 is a close up view of the portion of the screen layer in circle V in FIG. 4.

DESCRIPTION OF THE CURRENT EMBODIMENT

I. Overview

A ridge vent system according to one embodiment of the present invention is shown in FIG. 1 and generally designated 10. The ridge vent system 10 generally includes a roof 12 formed with a layer of roof sheathing 14, a layer of underlayment 16, a screen layer 18, a layer of shingles 20, and a vent cap 22. A slot 24 is formed in the roof sheathing 14 at the ridge 26 of the roof 12. An underlayment slot 28 is formed in the underlayment layer 16 and at least partially aligned over the sheathing slot 24. The screen layer 18 includes a mesh portion 30 that is aligned over the underlayment slot 28, and the vent cap 22 is positioned to cover the mesh portion 30 to enable air flow through the ridge vent system 10.

II. Structure

The roof 12 and roof sheathing 14 are generally conventional, and therefore will not be described in detail herein. Suffice it to say that the roof 12 is generally formed from a series of structure members including trusses 32, which are covered with sheathing 14 that may be plywood, fiberboard, oriented strand board (OSB) or another cover layer material. The sheathing 14 is connected to the structural members by conventional fasteners. The roof 12 includes a ridge 26, which is generally at an apex portion of the roof 12, and in one embodiment, the sheathing 14 is cut or positioned to define a ridge vent opening or sheathing slot 24, which may be a continuous opening across the ridge 26, or a series of openings spaced apart from one another. The sheathing slot 24 forms an opening that enables air flow from the attic space beneath the roof 12 to the atmosphere.

The underlayment 16 is typically applied over the sheathing 14 as a water barrier layer, and is formed from a waterproof or water resistant membrane material. It acts as a barrier to protect the roof sheathing 14 from leaks and the effects of harsh weather. The underlayment material may be an asphalt-saturated felt, rubberized asphalt, or most commonly, a synthetic polymer such as polypropylene, polyethylene or polyvinylchloride (PVC). In one embodiment, the underlayment 16 includes an upper surface 34 and a lower surface 36. The underlayment 16 may be positioned to cover the entire extent of the roof sheathing 14 and the lower surface 36 may be attached to the sheathing 14 by fasteners, an adhesive, or a combination of fasteners and adhesive. In one embodiment, the underlayment is cut to form an underlayment slot 28 that aligns with the ridge 26 and the sheathing slot 24 to enable air flow therethrough. Alternatively, separate sections of underlayment material may be attached on either side of the ridge 26 to form the underlayment slot 28 between the two sections of underlayment 16.

In one embodiment, the screen layer 18 is positioned over the upper surface 34 of the layer of underlayment 16. FIGS. 4 and 5 illustrate the screen layer 18 in greater detail. As seen in these Figs., in one embodiment, the screen layer 18 includes two materials, including an air-permeable mesh or screen material 30, and a second material 40 attached to the screen material 30. The second material 40 may be a variety of materials capable of attaching over the underlayment layer 16, and in one embodiment the second material 40 is the same material as the underlayment layer 16, such as a synthetic polymer material. The screen material 30 may be a metal, fiberglass, or plastic wire material constructed into a mesh pattern, such as a PVC mesh. In the illustrated embodiment, the screen material 30 includes an upper surface 42, a lower surface 44 opposite the upper surface 42, a first side edge 46, a second side edge 48, and first and second ends 50. The second material 40 may include a first section 54 and a second section 56. In one embodiment, the first section 54 includes a side edge 58 that is attached to the first side edge 46 of the screen 30, and the second section 56 includes a side edge 60 that is attached to the second side edge 48 of the screen 30. In this configuration, the side edges 58 and 60 of the two sections of the second material 40 are spaced apart and parallel with each other with the screen material 40 positioned in between. Portions of the screen material 40 may overlap the sections 54, 56 of the second material 40.

In one embodiment, the screen material 30 is coated with a durable coating 200. The coating 200 may cover all or a portion of the screen material 30, and may be one of a variety of coating materials that can enhance one or more performance characteristics of the screen material. In one embodiment, the durable coating 200 is a durable water repellent (DWR) that can redirect wind-driven rain, reduce water saturation of the screen material 30, and maintain airflow (i.e., maintain the porosity of the mesh pattern of the screen material 30) while adding long-term durability to the screen material 30. The coating 200 may also help prevent biological growth on the mesh in high-moisture environments and release dust and particle build up. In one embodiment, the DWR includes one or more of a fluorine-free water-based repellent (such as AME 2500 or similar), a silane or siloxane based coating, a wax-emulsion or paraffin based coating, or a fluoropolymer-based coating (such as C6 or C8). These coatings 200 may be formulated with or without cross linkers or binders, depending on the application method and the desired properties. Alternative. DWR's may include silicone based hydrophobic sprays, fluorine-free textile guards such as those used in outdoor fabrics, or nanotechnology coatings such as plasma treatments that modify surface energy. In another embodiment, the coating 200 may be, or may additionally include another durable coating 200, such as a fire retardant, an acrylic or polyurethane that can improve UV stability, a strengthening coating such as an elastomeric or epoxy-based coating, or a pest resistant coating such as a capsaicin infused coating or a bitterant such as denatonium benzoate.

With reference to FIG. 5, the durable coating 200 may be applied to all or any portion of the screen layer 30, and in one embodiment the coating 200 is applied to at least a portion of the air-permeable mesh/screen material 30. The coating 200 may be applied by one of a variety of application methods, including airless spray, roller or immersion. The coating 200 may be applied at any step during the assembly of the ridge vent system 10, and may include an ambient or heat-assisted curing process such as infrared or forced air. The coating 200 may be applied to the outer surface of the screen material 30 (either one or both sides), but is applied in such a way that it does not significantly reduce the porosity of the mesh and still enables air flow through the screen material 30, preserving breathability while adding moisture control. In one embodiment, the coated screen material maintains porosity that is fine enough to block pests, but large enough to allow airflow.

In one embodiment, the screen material 30 is attached to the second material 40 by stitching the materials together along a first stitch line 70 and a second stich line 72. The materials may be stitched together with a conventional yarn 75, according to conventional methods wherein the yarn 75 passes through the screen material 40 and the second material 40 along the stitch lines 70, 72. As illustrated, the stitch lines 70, 72 are generally parallel to one another and extend continuously along the screen material 30 from the first end 50 to the second end 50. In another embodiment, sections of screen material 30 may alternate with sections of the second material 40 and in this embodiment, the stitch lines may be intermittent. In another embodiment, the screen material 30 may be attached to the second material 40 by an adhesive, a series of fasteners, a heat weld, heat stake, an ultrasonic weld, or another attachment method. In one embodiment, both materials are thermoplastics selected to be materially compatible with one another for joining via heat welding. In one such example, the screen material 30 is a PVC fiberglass screen and the second material 40 is a PVC fabric that efficaciously heat welds (or “PVC welds”) to the PVC fiberglass screen for attachment of the screen material 30 to the second material 40 either as a standalone attachment or in combination with another attachment method such as stitching. In another embodiment, the screen material 30 is a stainless steel mesh and is heat staked to the second material 40, which may be a PVC fabric.

Referring now to FIGS. 1-3, the screen layer 18 is attached over the underlayment 16 with the screen material 30 aligned over the underlayment slot 28 and the sheathing slot 24 to enable air flow through all three layers. The side edge 58 of the first section 54 of the second material 40 is positioned on one side of the ridge 26, and the side edge 60 of the second section 56 is positioned on the opposite side of the ridge 26. The screen layer 18 may be attached over the underlayment by one of a variety of attachment methods, including a series of fasteners, an adhesive, or both. In one embodiment, the screen layer 18 is attached to the underlayment 16 in the same manner as the attachment of the underlayment 16 to the sheathing 14. The second material sections 54, 56 may extend a desired distance over the underlayment 16 to overlap a portion of the underlayment 16 and form an attachment portion for the screen layer 18.

In one embodiment, a layer of shingles 20 is positioned over the screen layer 18, and over the underlayment layer 16 in areas beyond the extend of the screen layer 18. The shingle layer 20 may be generally conventional, and therefore will not be described in detail. In short, the shingles 20 provide a further barrier layer for waterproofing the roof system, and the shingle layer 20 may be one of a variety of known shingle systems for attaching over a roof. In the illustrated embodiment, the shingles 20 are positioned on the roof such that they form a gap 80 at the ridge 26 aligned with the screen material 30 of the screen layer 18, the underlayment slot 28 and the sheathing slot 24 to enable air flow through all layers.

The roof vent cap 22 is positioned over the ridge 26. A variety of roof vent cap styles may be used for the external covering of the ridge. One example of such a roof vent cap 22 is shown in the Figs. With reference to FIGS. 1 and 2, the roof vent cap 22 includes a cap housing 82 having a pair of sidewalls 84, an upper wall 85 and a spacer 87. The sidewalls 84 each have a lower edge 86 and an upper edge 88. The spacer 87 may extend between the shingle layer 20 and the upper wall 85. In one embodiment, and the sidewalls 84 may define one or more slotted vent openings (not shown) enabling air flow through the sidewalls 84 and through the layers of the system 10. As illustrated, the vent cap 22 additionally includes cap shingles 100 that are positioned over the upper wall 85 of the housing 82. A series of fasteners 102 may extend through the cap shingles 100, the housing 82, and the remaining layers of the system 10 to attach the roof vent cap 22 to the roof 12. In one embodiment, a layer of air-permeable fabric or fiber 104 may be positioned within the roof vent cap 22 between the lower edges 86 of the sidewalls 84 and the shingle layer 20 to form a vent cap pest barrier.

III. Installation

Installation of the ridge vent system 10 according to one embodiment of the present invention involves the steps of sequentially positioning and attaching the various layers of the system 10. The sheathing layer 14 is attached over the roof supports 32 by fasteners or another attachment method. The sheathing slot 24 is created by cutting the slot in the sheathing layer 14 aligned with the ridge 26, or by positioning the sheathing 14 in a manner that is spaced apart at the ridge 26. The underlayment layer 16 is rolled out or otherwise placed over the sheathing layer 14 and attached over the sheathing layer 14. The underlayment slot 28 is cut into the underlayment 16 in alignment with the sheathing slot 24, or alternatively the slot 28 is formed in the positioning of the underlayment 16 on the roof 12. The screen layer 18 is then positioned on the roof 12 with the screen material 30 in alignment with the underlayment slot 28, and the second material 40 of the screen layer 18 is attached on either side of the ridge 26 to secure the screen layer 18 in place. In an embodiment where the screen material 30 includes a durable coating 200, the coating 200 may be applied such that it is positioned underneath the ridge vent cap, and over the underlayment slot 28. The shingle 20 and ridge vent cap 22 are then attached over the screen layer. The final system 10 is one that provides the advantages of a ridge vent system with vent cap 22, while increasing the ability of the system to prevent the entrance of pests over time.

Throughout this description, directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” may be used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.