Note: Descriptions are shown in the official language in which they were submitted.
CA 02717405 2010-10-14
PREFORMED ROOF VENTILATION SYSTEM
FIELD
[00021 This patent application relates generally to a roof ventilation system.
In particular, the
present patent application is directed to a roof ventilation system that
incorporates an eave
component and optional continuation components, each component for mounting
between roof
framing members and roof sheathing.
BACKGROUND
[00031 Residential and commercial buildings with sloped roofs typically
include an open,
unheated attic. The proper use of insulation and ventilation within the attic
space can provide
both energy conservation and help reduce common adverse conditions associated
with moisture
build up and extreme temperature variations. For example, during the summer
extreme heat in
the attic can degrade the roofing materials and increase cooling costs for the
space below the
attic. Insulation is normally placed in the ceiling/attic floor assembly to
insulate the occupied
levels of the building from the heat that builds up in the attic. A
ventilation system is usually
incorporated to reduce heat build-up and remove moisture from the attic. The
ventilation
system requires a combination of soffit vents that bring air into the attic
and a ridge vent that
allows air to vent out of the attic. In general, the air is moved along the
underside of the roof
sheathing by thermal convection. Where the soffit vents are located below the
eaves of the
roof, it is important to provide an air pathway between the soffit vent and
the underside of the
roof sheathing to allow for this air movement. This air pathway will allow
cool air to enter
through the soffit vent, run along the underside of the roof and exit through
the ridge vent to
cool the roof and allow moisture to escape. In cold climates, inadequate
insulation and
ventilation at the eaves often results in repeated freezing and thawing of
snow which produces
ice dams at the roof eaves. These dams can cause water to creep up under the
shingles and leak
into the building. Lack of ventilation will also cause moisture to condense on
the underside of
the roof and within the insulation. This moisture will degrade both the roof
sheathing and
reduce the effectiveness of the insulation. Prolonged moisture can also result
in mold growth
in the attic space. This condition can again be mitigated by providing a
continuous and clear
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CA 02717405 2010-10-14
air pathway from the soffit vent along the underside of the roof to the ridge
vent. Cool air
entering from the soffit vent will flow through this pathway to cool the
underside of the roof
reducing snow melt higher up the roof that would then flow down the roof and
freeze near the
eaves creating an ice dam. The thermal convection of air will also remove
airborne moisture
that would otherwise condense on the underside of the roof or in the
insulation.
[0004] It is therefore common in the building industry, and required by most
building codes, to
install some form of roof ventilation system that will provide a vent channel
(air pathway) on
the underside of the roof running from the eave space to an upper portion of
the roof. It is also
common to install some type of baffle that fits between roof framing members
at the exterior
wall plane to prevent insulation materials from getting into the eave space
and thereby blocking
the soffit vents. Most prior art roof ventilation baffles are designed to be
installed after the roof
has been completely sheathed with plywood or some other substrate. The process
of installing
and fitting "vent chutes" and baffles into the narrow, sloped areas where the
eave portion of the
roof intersects the exterior wall structure of the building can be tedious and
time consuming.
This process can lead to both ineffective vent formation and increased labor
costs when
constructing a building. It is apparent to those skilled in the art that
opportunity exists for
providing new and improved ventilation structures that can create an air
passage between the
soffit vents and the attic ridge vent. Such a structure should be one that is
pre-formed, easy to
align, does not have to be cut, and can adjust to any angle roof.
SUMMARY
[0005] One aspect of the present patent application is directed to a roof
ventilation system
comprising a panel that includes a middle section and flanged lateral edges.
The middle section
and flanged lateral edges creating a vent trough. At least one flanged lateral
edge has a
registration tab for registering with an adjacent panel. When the flanged
lateral edges are
secured between the top of roof framing members and the roof sheathing, a vent
channel is
created between the roof and the panel.
[0006] Another aspect is directed to a method of forming a roof vent channel
comprising the
steps of providing a framed roof with exposed roof framing members and a panel
including a
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middle section and flanged lateral edges. The middle section and flanged
lateral edges forming
a vent trough. At least one of the flanged lateral edges has a registration
tab for registering
with an adjacent panel. The method then includes registering the panel to the
adjacent panel on
the roof framing members and securing the panel to the roof framing members.
Roof sheathing
is installed over the roof framing members and the panel to create the roof
vent channel.
[00071 Yet another aspect is directed to a roof ventilation system for
mounting between roof
framing members and roof sheathing comprising a panel. The panel includes a
roof side, an
attic side, a first end and a second end. The panel further includes a vent
trough formed from a
first flanged lateral edge, a middle section and a second flanged lateral
edge. The panel still
further includes a reinforcing ventilation element spanning between the first
and second flanged
lateral edges, the reinforcing ventilation element containing at least one
ventilation opening to
allow moisture to travel between the roof side and attic side of the panel.
100081 Still another aspect is directed to a roof ventilation system for
mounting between roof
framing members and roof sheathing comprising a panel. The panel includes a
roof side, an
attic side, a first end and a second end. The panel includes a vent trough
formed from a first
flanged lateral edge a middle section and a second flanged lateral edge, each
flanged lateral
edge having a canted section and a flat edge section extending outward
parallel to the middle
section. The panel further includes an array of vent channel supports
dimensioned to extend
from the middle section to a plane defined by the flat edge sections of the
first and second
flanged lateral edges. The panel still further includes a plurality of
reinforcing elements
spanning between and perpendicular to the first and second flanged lateral
edges.
[00091 Still another aspect is directed to a roof ventilation system for
mounting between roof
framing members and roof sheathing comprising a panel. The panel includes a
roof side, an
attic side, a first end and a second end. The panel further includes a vent
trough formed from a
first flanged lateral edge, a middle section and a second flanged lateral
edge, each flanged
lateral edge having a canted section and a flat edge section extending outward
parallel to the
middle section. The panel still further including an array of vent channel
supports dimensioned
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to extend from the middle section to a plane defined by the flat edge sections
of the first and
second flanged lateral edges, each vent channel support intersecting the plane
a single apex.
[0010] Still yet another aspect is directed to an insulation dam for creating
a barrier between
attic space and eave space, the attic and eave space bounded by roof framing
members and roof
sheathing. The insulation dam comprises a flat and rectangular top panel
having a top edge, a
bottom edge, a first panel edge and second panel edge. The top panel has a
width that spans
greater than the width between the roof framing members. The insulation dam
further
comprise a baffle flap that has a top blocking edge and opposite framing
edges. The blocking
panel is attached at the top blocking edge by a hinge to the bottom edge of
the top panel. The
blocking panel spans the width of the roof framing members. Baffle flap tabs
extend from each
of the opposite frame edges of the baffle flap. Each baffle flap tab has a
fold line where it
meets each of the opposite frame edges. Whereby when the insulation dam is
installed, each
baffle flap tab bends toward the eave space and orients to attach
substantially parallel to the
inside of the roof framing members. A baffle flap gap exists between the top
panel and each of
the baffle flap tabs. The baffle flap tabs are dimensioned so that the baffle
flap tabs do not stick
into the plane of the roof sheathing when secured to the roof framing members.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The foregoing and other aspects and advantages of the invention will be
apparent from
the following detailed description as illustrated in the accompanying
drawings, in which:
[0012] FIG. 1 a is a cut away, perspective view of one embodiment of the roof
ventilation
system showing eave components secured adjacent to each other on roof framing
members
with registration tabs aligned to registration gaps and a hinged baffle flap
oriented to stop
insulation from getting into the eave space;
[0013] FIG. lb is a sectional, partial cut away, side view of the roof
ventilation system in FIG.
1 a, showing the baffle flap, the formation of the vent channel and how air
flows from the soffit
vent through the vent channel and out the ridge vent;
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[0014] FIG. 2 is a perspective view of two eave components in FIG. 1 a,
comprising panels
laying adjacent to each other and secured to the roof framing members;
[0015] FIG. 3 is a sectional view perpendicular to roof framing members in
FIG. lb, just
interior the attic from the eave space showing the formation of the vent
channel and its location
relative to insulation;
[0016] FIG. 4a is a perspective view of a first registration structure in
accordance with the
embodiments shown in FIGS. 1-22;
[0017] FIG. 4b is a perspective view of a second registration structure in
accordance with the
embodiments shown in FIGS. 1-22;
[0018] FIG. 4c is a perspective view of a third registration structure in
accordance with the
embodiments shown in FIGS. 1-22;
[0019] FIG. 4d is a perspective view of a fourth registration structure in
accordance with the
embodiments shown in FIGS. 1-22;
[0020] FIG. 4e is a perspective view of a fifth registration structure in
accordance with the
embodiments shown in FIGS. 1-22;
[0021] FIG. 5 is a perspective view showing key features of the eave component
of FIGS. la,
1 b and 2, and how multiple eave components may be compactly stacked for
shipping;
[0022] FIG. 6a is a perspective view showing how the incorporation of a living
hinge as part of
the eave component of FIGS. la, lb and 2, and how this living hinge allows the
user to adjust
the baffle flap for any slope roof;
[0023] FIG. 6b is a perspective view showing the structure of a living hinge
for panels shown
in FIGS. 1-2, 5, 6a, 9a-11, 15, 17a, 18a, 18b and 22-24;
CA 02717405 2010-10-14
[0024] FIG. 6c is a perspective view of the living hinge of FIG. 6b with the
baffle flap now
angled to fit the slope of a roof;
[0025] FIG. 7 is a perspective view showing key features of a continuation
component that
would be used as shown in FIGS. 9a, 9b and 10;
[0026] FIG. 8 is a perspective view of the continuation component of FIG. 7,
but now with
perforations that allow for additional ventilation of insulation;
[0027] FIG. 9a is a perspective view showing the use of the eave components of
FIG. 5 and the
continuation components of FIG. 7 when the building has a cathedral ceiling;
[0028] FIG. 9b is a perspective view showing the use of the eave components of
FIG. 5 and the
continuation components of FIG. 7 when the building has a finished attic;
[0029] FIG. 10 is a perspective view showing how a continuation component of
FIG. 7 may be
installed in a framing bay in conjunction with an eave component of FIG. 5 to
extend the length
of a vent channel;
[0030] FIG. 11 is a perspective view showing how a user can hold the eave
components of
FIG. 5 and continuation components of FIG. 7 during installation of the self-
registering roof
ventilation system;
100311 FIG. 12a is a perspective view of a portion of a panel in one
embodiment showing a
first structure of an integral reinforcing ventilation element integrated with
a panel, the panel
may be that of an eave component or a continuation component;
[0032] FIG. 12b is a perspective view of a portion of a panel in one
embodiment showing a
second structure of an integral reinforcing ventilation element integrated
with a panel, the panel
may be that of an eave component or a continuation component;
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[0033] FIG. 12c is a perspective view of a portion of a panel in one
embodiment showing a
third structure of an integral reinforcing ventilation element integrated with
a panel, the panel
may be that of an eave component or a continuation component;
[0034] FIG. 13a is a perspective view of one embodiment showing a mountable
reinforcing
ventilation element;
[0035] FIG. 13b is a sectional view along line A-A of FIG. 13a showing the
cross-sectional
shape of the mountable reinforcing ventilation element;
[0036] FIG. 14a is an exploded, perspective view of a portion of a panel
showing how the
mountable reinforcing ventilation element of FIGS. 13a and 13b is mounted over
a ventilation
slot in the panel;
[0037] FIG. 14b is a sectional view along line B-B of FIG. 14a showing how
when the
mountable reinforcing ventilation element is mounted moisture can move from
the attic side to
the eave side of the panel;
[0038] FIG. 15 is a perspective view showing how the reinforcing ventilation
elements
depicted in FIGS. 12-14 maybe added and spaced along the length of an eave
component of
FIG. 5;
[0039] FIG. 16 is a perspective view showing how the reinforcing ventilation
elements
depicted in FIGS. 12-14 may be added and spaced along the length of an
extension component
of FIG. 7;
[0040] FIG. 17a is a perspective view showing key features of a reinforced
eave component in
FIG. 15 and how multiple eave components may be compactly stacked for
shipping;
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[0041] FIG. 17b is a perspective view along line C-C of FIG. 17a showing how
mountable
reinforcing ventilation elements fit within each other for compact stacking;
[0042] FIG. 18a is a perspective view of one embodiment of the eave component
where the
panel includes reinforcing elements, vent channel supports, a formed grid
pattern and
interlocking elements;
[0043] FIG. 18b is a perspective view of the eave component in FIG. 18a,
further including
registration tabs and registration gaps;
[0044] FIG. 19a is a perspective view of one embodiment of the continuation
component where
the panel includes reinforcing elements, vent channel supports, a formed grid
pattern and
interlocking elements;
[0045] FIG. 19b is a perspective view of the continuation component in FIG.
19a, further
including registration tabs and registration gaps;
[0046] FIG. 20a is a perspective view of a portion of the panel in FIGS. 18a-
19b, showing key
features of the reinforcing element and vent channel support;
[0047] FIG. 20b is a perspective view of a portion of the panel in FIGS. 18a-
19b, showing
details of the vent channel supports, and the formed grid pattern within the
middle section and
canted sections;
[0048] FIG. 20c is a perspective view of a portion of the panel in FIGS. 18a-
19b, showing key
features of the interlocking element;
[0049] FIG. 21 a is a sectional view perpendicular to roof framing members for
an eave
component of FIG. 18a after installation, the section through a reinforcing
element just interior
the attic from the eave space showing the formation of the vent channel and
its location relative
to insulation;
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[0050] FIG. 21 b is a sectional view perpendicular to roof framing members for
an eave
component of FIG. 18a after installation, the section through a vent channel
supports just
interior the attic from the eave space showing the formation of the vent
channel and its location
relative to insulation;
[0051] FIG. 21c is a sectional view perpendicular to roof framing members for
an eave
component of FIG. 18a after installation, the section through a interlocking
component interior
the attic showing the formation of the vent channel and its location relative
to insulation;
[0052] FIG. 22 is a perspective view showing how a continuation component of
FIG. 19a may
be installed in a framing bay in conjunction with an eave component of FIG.
18a to extend the
length of a vent channel;
[0053] FIG. 23a is a cut away, perspective view of one embodiment of a roof
ventilation
system showing insulation dams secured adjacent to each other on roof framing
members and a
hinged baffle flap oriented to stop insulation from getting into the eave
space;
[0054] FIG. 23b is a front, perspective view showing the insulation dam of
FIG. 23a installed
in a framing bay; and
[0055] FIG. 24 is a perspective view showing key features of the insulation
dam of FIGS. 23a
and 23b, and how multiple eave components may be compactly stacked for
shipping.
DETAILED DESCRIPTION OF THE INVENTION
[0056] FIGS. 1-22 illustrate the elements of roof ventilation system 20. Roof
ventilation
system 20 is designed to be installed in new or renovated buildings on top of
exposed roof
framing members 22 prior to the installation of roof sheathing 24. Roof
ventilation system 20
comprises one or more eave components 21 and optional continuation components
23
depending on the application. Eave component 21 comprises a panel 26 including
flanged
lateral edges 28a (a.k.a. first flanged lateral edge) and 28b (a.k.a. second
flanged lateral edge).
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Panel 26 also includes a first end 30 and a second end 32, and a panel length
between the first
and second ends. Panels 26 are preferably rectangular. Panels 26 are nominally
16-inches or
24-inches wide to fit over roof framing members 22. Roof framing members 22
are usually
spaced at 16-inches and 24-inches on center. Depending on the application,
panels 26 have a
panel length that may range from 30-inches to 60-inches. The panels may range
in thickness
from 0.010-inches to 0.080-inches. Flanged lateral edges 28a and 28b protrude
upward and
outward from a substantially flat middle section 34 of panel 26. Together
first flanged lateral
edge 28a, middle section 34 and second flanged lateral edge 28b form vent
trough 35, with the
length of the vent trough extending between first end 30 and second end 32 of
panel 26.
Flanged lateral edges 28a and 28b provide a way to secure panel 26 to roof
framing members
22. When in place, the space between the top side of the middle section 34 and
bottom side of
roof sheathing 24 will create a continuous vent channel 36 preferably 1.5-
inches to 2-inches in
depth, FIGS. 3 and 21 a-21 c. Although preferably flat, middle section 34 of
panel 26 may take
on any shape that creates an appropriate vent channel 36. This may include,
but is not limited
to cross-sections that are arcuate, channeled and ridged. Middle section 34
may also have a
formed grid pattern to increase the stiffness of panel 26. The canted section
38 of each flange
allows for easy positioning and provides for compression/tension adjustment of
panel 26
between pairs of roof framing members 22. Canted sections 38 also define the
side walls of
vent channel 36. Canted sections 38 are sized to generally provide 1.5-inches
to 2-inches of
generally unobstructed space between the underside of roof sheathing 24 and
the top side of
middle section 34. This sizing allows for clear air flow and avoids the ends
of roofing nails 40
used during roofing to damage panel 26. Vent channel 36 runs the full width of
framing bay
41 bounded by roof framing members 22. This provides ventilation to nearly
100% of the
underside of roof sheathing 24 versus only a portion of the sheathing as most
other prior art
does. The generally flat portion of flanged lateral edges 28a and 28b that
extends outward from
canted sections 38 and runs along the length of panel 26 is defined as edge
section 42. Canted
section 38 may be at one angle or continuously change angle from middle
section 34 to edge
section 42. The bottom side of edge section 42 is designed for resting on top
of roof framing
members 22 when installed.
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[0057] In several embodiments, FIGS. la, 2-12,14-17, l8b and 19b, edge section
42 may
incorporate or be divided into one or more registration tabs 44 or
registration gaps 46.
However for other embodiments, FIGS. l 8b and 19b-22, registration tabs 44 and
registration
gaps 46 are not present and edge section 42 is a continuous flat edge section
along the length of
panel 26. Edge section 42 may also extend to rest completely over the top of a
roof framing
member 22 and extend to go down the other side of the roof framing member in
sort of a
hooked fashion, FIG. 4d. Edge section 42 is the preferred section of panel 26
through which to
secure the panels to roof framing members 22. Panels 26 may be secured by
nails, screws,
staples or other fasteners 43. A portion of edge section 42 in embodiments
with registration
tabs 44 and registration gaps 46 is defined as stiffening rim 45 and is 1/4`h
to 1/2-inch wide.
Stiffening rim 45 is continuous (uninterrupted by registration gaps 46) along
the length of the
panel and adjacent to canted sections 38. Stiffening rim 45 provides added
rigidity to the edges
of panel 26. A continuous stiffening rim 45 is shown in FIGS 4a, 4b and 4e.
Other portions of
panel 26, such as canted sections 38, may be used to secure the panel to roof
framing members
22 without deviating from the scope of the invention.
[0058] FIGS. 4a-e show several different registration structures for
registration tab 44 for those
embodiments where flanged lateral edge 28a and 28b of eave component 21 have
at least one
registration tab for alignment to an adjacent panel. When installed each
registration tab 44
preferably aligns within a registration gap 46 of an adjacent panel. It is
preferable to have a
plurality of registration tabs 44 and registration gaps 46 on each flanged
lateral edge 28a and
28b of panel 26. It is also preferable to have a series of alternating
registration tabs 44 and
registration gaps 46 on each flanged lateral edge 28a and 28b that have widths
that are
approximately equal, but preferably less than the full width of edge section
42. For a given
location along the length of panel 26 running from first end 30 to second end
32, the first
flanged lateral edge 28a will have a registration tab 44 and the second
flanged lateral edge 28b
will have a corresponding registration gap 46. Further along the length of
panel 26 the first
flanged lateral edge 28a will then have a registration gap 46 and the second
flanged lateral edge
28b will then have a registration tab 44. This structure allows a plurality of
panels 26 to be laid
side-by-side upon roof framing members 22 adjacent to each other and have the
panels self-
register with registration tab 44 in corresponding registration gap 46. It is
also preferable to
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have registration tabs 44 and registration gaps 46 of relatively equal length
with the gaps equal
to or larger than the tabs so that the tabs fit within the gaps to help aid
with registration of
adjacent panels and provide tight alignment tolerances. Overall, registration
tab 44 and
registration gap 46 alignment tolerances should be 0.25-inches or less. For
example,
registration tabs 44 are preferably 5-7/8 inches long, 1-1/8 inches wide
within an edge section
42 having a width of 1-1/2 inches. Registration gaps 46 are preferably 6-1/8
inches long, 1-1/8
inches wide within an edge section 42 having a width of 1-1 /2 inches.
[00591 Eave component 21 further includes a baffle flap 48 on first end 30 of
panel 26. Baffle
flap 48 is preferably 13-1/2 inches long, but the baffle flap may take any
length appropriate for
the exact application. Baffle flap 48 is integrated with panel 26 by way of a
living hinge 50.
Panel 26 and baffle flap 48 are preferably fabricated as one integral unit
during manufacture.
Baffle flap 48 is adjusted down during installation to create a barrier
between attic space 52 and
eave space 54. The purpose of baffle flap 48 is to keep insulation 56, which
may be laid or
blown between ceiling framing members 58, from getting into eave space 54.
Baffle flap 48
has two baffle flap tabs 60a and 60b that are formed from the canted sections
38. Baffle flap
tabs 60a and 60b are secured by fasteners 43 such as nails, screws and staples
to the sides of
roof framing members 22 as shown in FIGS. 2, 10 and 22.
[00601 Baffle flap 48 can adjust for any slope roof by way of living hinge 50,
FIG. 6a. Living
hinge 50 is formed as a thinned region at the first end of panel 26. This
thinned region is
created during the manufacture of panels 26 by a press with a blunt heated
blade, contact with a
hot wire, partial milling or other means similar thinning means. A close-up
view of the
structure of living hinge 50 is shown in FIG. 6b and 6c. Living hinge 50
extends continuously
across the width of middle section 34 of panel 26 at first end 30. Where
middle section 34
meets canted section 38, living hinge 50 terminates as a gap in the canted
sections of both
flanged lateral edges 28a and 28b. Living hinge 50 is not a perforated fold
line or line that
needs to be scored as is the case in the prior art. Fold lines are subject to
creasing and generate
poorly formed folds. Score lines are subject to the user improperly scoring
the baffle and
having the baffle not fold uniformly where needed.
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[0061] In one embodiment, FIGS. la, 5, 9a, 9b, 10, 11, 15 and 17a, eave
component 21 may
further include one or more extension openings 60 near second edge 32 of panel
26. Extension
openings 60 may be a gap, a slot or other appropriately shaped opening.
Extension opening 60
may be positioned adjacent to or just interior second end 32. The primary
function of
extension opening 60 is to accept an interlocking tab 62 from continuation
component 23, FIG.
10. Extension opening 60 also functions to help with self-registering
continuation component
23 to eave component 21 using interlocking tabs 62. Furthermore, extension
opening 60 may
function as a convenient way to carry or hold eave component 21 during
installation, FIG. 11.
[0062] Continuation component 23 is for extending the length of vent trough 35
and resulting
vent channel 36 in certain applications. Continuation component 23, shown in
FIGS. 7-10, 16,
19a, 19b and 22, comprises a panel 26 including flanged lateral edges 28a
(a.k.a. first flanged
lateral edge) and 28b (a.k.a. second flanged lateral edge). Panel 26 also
includes a first end 30
and a second end 32 that respectively define the first end and second ends of
continuation
component 23. Panels 26 are preferably rectangular. Panels 26 are nominally 16-
inches or 24-
inches wide to fit over roof framing members 22. Roof framing members 22 are
usually spaced
at 16-inches and 24-inches on center. Depending on the application, panels 26
have a panel
length that may range from 30-inches to 60-inches. The panels may range in
thickness from
0.010-inches to 0.080-inches. Flanged lateral edges 28a and 28b protrude
upward and outward
from a substantially flat middle section 34 of panel 26. Together first
flanged lateral edge 28a,
middle section 34 and second flanged lateral edge 28b form vent trough 35,
with the length of
the vent trough extending between first end 30 and second end 32 of panel 26.
Flanged lateral
edges 28a and 28b provide a way to secure panel 26 to roof framing members 22.
When in
place, the space between the top side of the middle section 34 and bottom side
of roof sheathing
24 will create a continuous vent channel 36 preferably 1.5-inches to 2-inches
in depth.
Although preferably flat, middle section 34 of panel 26 may take on any shape
that creates an
appropriate vent channel 36. This may include, but is not limited to cross-
sections that are
arcuate, channeled and ridged. Middle section 34 may also have a formed grid
pattern to
increase the stiffness of panel 26. The canted section 38 of each flange
allows for easy
positioning and provides for compression/tension adjustment of panel 26
between pairs of roof
framing members 22. Canted sections 38 also define the side walls of vent
channel 36. Canted
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sections 38 are sized to generally provide 1.5-inches to 2-inches of
unobstructed space between
the underside of roof sheathing 24 and the top side of middle section 34. This
sizing allows for
clear air flow and avoids the ends of roofing nails 40 used during roofing to
damage panel 26.
Vent channel 36 runs the full width of framing bay 41 bounded by roof framing
members 22.
This provides ventilation to nearly 100% of the underside of roof sheathing 24
versus only a
portion of the sheathing as most other prior art does. The generally flat
portion of flanged
lateral edges 28a and 28b that extends outward from canted sections 38 and
runs along the
length of panel 26 is defined as edge section 42. Canted section 38 may be at
one angle or
continuously change angle from middle section 34 to edge section 42. The
bottom side of edge
section 42 is designed for resting on top of roof framing members 22 when
installed.
[0063] In several embodiments, FIGS. 7-10, 16 and 19b, edge section 42 of eave
component 23
may incorporate or be divided into one or more registration tabs 44 or
registration gaps 46.
However for other embodiments, FIGS. 19a, 20a-22, registration tabs 44 and
registration gaps
46 are not present and edge section 42 is a continuous flat edge section along
the length of
panel 26. Edge section 42 may also extend to rest completely over the top of a
roof framing
member 22 and extend to go down the other side of the roof framing member in
sort of a
hooked fashion, FIG. 4d. Edge section 42 is the preferred section of panel 26
through which to
secure the panels to roof framing members 22. Panels 26 may be secured by
nails, screws,
staples or other fasteners 43. A portion of edge section 42 in embodiments
with registration
tabs 44 and registration gaps 46 is defined as stiffening rim 45 and is 1/4`h
to 1/2-inch wide.
Stiffening rim 45 is continuous (uninterrupted by registration gaps 46) along
the length of the
panel and adjacent to canted sections 38. Stiffening rim 45 provides added
rigidity to the edges
of panel 26. A continuous stiffening rim 45 is shown in FIGS 4a, 4b and 4e.
Other portions of
panel 26, such as canted sections 38, may be used to secure the panel to roof
framing members
22 without deviating from the scope of the invention.
[0064] FIGS. 4a-e show several different registration structures for
registration tab 44 for those
embodiments where flanged lateral edge 28a and 28b of continuation component
23 have at
least one tab for alignment to an adjacent panel. When installed each
registration tab 44
preferably aligns within a registration gap 46 of an adjacent panel. It is
preferable to have a
14
CA 02717405 2010-10-14
plurality of registration tabs 44 and registration gaps 46 on each flanged
lateral edge 28a and
28b of panel 26. It is also preferable to have a series of alternating
registration tabs 44 and
registration gaps 46 on each flanged lateral edge 28a and 28b that have widths
that are
approximately equal, but preferably less than the full width of edge section
42. For a given
location along the length of panel 26 running from first end 30 to second end
32, the first
flanged lateral edge 28a will have a registration tab 44 and the second
flanged lateral edge 28b
will have a corresponding registration gap 46. Further along the length of
panel 26 the first
flanged lateral edge 28a will then have a registration gap 46 and the second
flanged lateral edge
28b will then have a registration tab 44. This structure allows a plurality of
panels 26 to be laid
side-by-side upon roof framing members 22 adjacent to each other and have the
panels self-
register with registration tab 44 in corresponding registration gap 46. It is
also preferable to
have registration tabs 44 and registration gaps 46 of relatively equal length
with the gaps equal
to or larger than the tabs so that the tabs fit within the gaps to help aid
with registration of
adjacent panels and provide tight alignment tolerances. Overall, registration
tab 44 and
registration gap 46 alignment tolerances should be 0.25-inches or less. For
example,
registration tabs 44 are preferably 5-7/8 inches long, 1-1/8 inches wide
within an edge section
42 having a width of 1-1/2 inches. Registration gaps 46 are preferably 6-1/8
inches long, 1-1/8
inches wide within an edge section 42 having a width of 1-1/2 inches.
100651 In one embodiment, FIGS. 7-10, continuation component 23 may further
include at
least one interlocking tab 62 at first end 30 for interlocking with a second
continuation
component 23 or an eave component 21. Continuation component 23 may further
include one
or more extension openings 60. Extension openings 60 may be a gap, a slot or
other
appropriately shaped opening. Extension opening 60 may be placed adjacent to
or just interior
second end 32 of panel 26. The primary function of extension opening 60 is to
accept an
interlocking tab 62 from a second continuation component 23. Extension opening
60 also
functions to help with self-registering a first continuation component 23 to a
second
continuation component 23. Furthermore, extension opening 60 may function as a
way to
conveniently carry or hold continuation components 23 during installation.
CA 02717405 2010-10-14
[0066] Eave components 21 and continuation components 23 can both be
fabricated using
several methods. These methods include, but are not limited to stamping,
extrusion, vacuum
forming, pressure forming, thermal molding and injection molding. The
preferred fabrication
material is a plastic such as PVC, ABS, HDPE, LDPE, polystyrene or other
plastic compound.
However, non-plastics such as corrugated cardboard, thin metal sheets and
other composite
materials may be used. Cost, weight, strength, structural rigidity over the
expected
environmental temperature range and fabrication costs all determine which
material is
appropriate for a given application. Since each type of component (eave
component 21 or
continuation component 23) is substantially flat and each type has the same
shape, components
of the same type can be easily stacked and packaged in groups of ten to twenty-
four units at a
time as shown in FIGS. 5 and 17a. These packages can then be easily shipped to
the work site.
[0067] In one embodiment eave component 21 and continuation component 23 may
include
perforations 64 as shown in FIG 8. Perforations 64 provide a way for moisture
to escape from
insulation 56, enter vent channel 36 and be carried away by the flowing air.
Spray foam
insulation having a closed cell structure requires no perforations 64; while
fiberglass, cellulose
and open cell spray foam may require the perforations. Perforations 64 may
range in diameter
from 1/1 6-inch to 1/2-inch and the perforations are spaced from 1-inch to 3-
inches apart
depending on the application.
[0068] In one embodiment panels 26 of eave component 21 or continuation
component 23 may
include reinforcing ventilation elements 100, FIGS. 12a-17b. Reinforcing
ventilation element
100 comprises a stiffening element 102 (a.k.a. reinforcing element 160) and a
ventilation
element 104. Reinforcing ventilation element 100 spans between first lateral
edge 28a and
second lateral edge 28b and is oriented substantially perpendicular to the
first lateral edge and
second lateral edge. A plurality of reinforcing ventilation elements may be
spaced along the
length of panel 26 to achieve the desired ventilation and stiffening.
Stiffening element 102
includes at least one raised wall 106 that extend upward from middle section
34, but preferably
two parallel raised walls creating an elongated structure. Walls 106
preferably are oriented
substantially perpendicular to attic side 122 and roof side 124 of panel 26,
but may be at an
angle to middle section 34. Walls 106 provide stiffness to the panel. The
amount of stiffness is
16
CA 02717405 2010-10-14
proportional to the height of the walls. Ventilation element 104 includes
ventilation openings
108. There are two embodiments for reinforcing ventilation elements 100,
integral reinforcing
ventilation elements 100a and mountable reinforcing ventilation elements I00b.
[0069] FIGS. 12a-c show three structures for integral reinforcing ventilation
element 100a.
Integral reinforcing ventilation elementl00a is formed from middle section 34
of panel 26.
Integral reinforcing ventilation element 100a may be formed by injection
molding or
thermoforming. In a first structure, FIG. 12a, stiffening walls 106 of
stiffening element 102
rise from middle section 34 of panel 26. Stiffening walls 106 span between
flanged lateral
edges 28 and are substantially perpendicular to the flanged lateral edges.
Together top region
110 and stiffening walls 106 form a raised stiffening element 102. Ventilation
openings 108
are shown in walls 106. In a second structure, FIG. 12b, ventilation openings
108 may be in
top region 110. Other variations of integral reinforcing ventilation element
100a may include
an arched versus rectangular cross-section. In such a structure, arched
stiffening walls 106
combined together with ventilation openings 108 generate reinforcement
ventilation element
100a. In a third structure, FIG. 12c, ventilation ledge 114 may be a separate
element that
surrounds stiffening element 102. Vent ledge 114 has a substantially vertical
ledge wall 119
and top shelf 120 creating the ledge. Ventilation openings 108 may exist in
vertical ledge wall
119, top shelf 120 or both.
[0070] FIGS. 13a and 13b show a structure for a mountable reinforcing
ventilation element
I00b. Mountable reinforcing ventilation element 100b is preferably thermally
formed from a
piece of plastic such as PVC, ABS, HDPE, LDPE, polystyrene or other plastic
compound. In
this preferred embodiment, mounted reinforcing ventilation element I00b
comprises a
peripheral sealing edge 118, a vent ledge 114 and a stiffening element 102.
Peripheral sealing
edge 118 is for mounting to middle section 34 of panel 26. Mountable
reinforcing ventilation
element 100b is an elongated element that is mounted substantially
perpendicular to flanged
lateral edges. Mounted reinforcing ventilation element 100b may be adhesively
mounted with
an adhesive 120 that is applied to a portion or the whole sealing edge.
Mounted reinforcing
ventilation element 100b may also be glued, fastened with fasteners or
thermally bonded to
panel 26. Vent ledge 114 has a substantially vertical ledge wall 119 and top
shelf 120 creating
17
CA 02717405 2010-10-14
the ledge. Ventilation openings 108 are cut from peripheral sealing edge 118
into vent ledge
114. Stiffening element 102 includes at least one raised wall 106 that extends
upward from
middle section 34, but preferably two parallel raised walls creating an
elongated structure.
Together top region 110 and stiffening walls 106 form raised stiffening
element 102.
Stiffening element 102 is preferably interior the vent ledge 114 and has
stiffening walls 106
that extend substantially perpendicular to the roof side of panel 26 to
provide stiffness. The
amount of stiffness provided to panel 26 is proportional to the height of the
stiffening walls 106
and the ledge walls 122.
[00711 FIGS. 14a and 14b show how mountable reinforcing ventilation element
100b is
mounted to panel 26 and how when in place it works to allow moisture to pass
from attic side
122 to roof side 124 of the panel. Mountable reinforcing ventilation element
100b is mounted
over a ventilation slot 126 in panel 26 by adhesive 120. Ventilation slot 126
in combination
with mountable reinforcing ventilation element 100b limit the amount of
insulation 56 that can
pass from attic side 122 to roof side 124, however, the structure allows
moisture 128 to pass
from the attic side to the roof side and escape up vent channel 36 and out
ridge vent 82.
[0072] FIGS. 15 and 16 show eave component 21 and continuation components 23
having
reinforcing ventilation elements 100 spaced along the length of each panel 26.
Reinforcing
ventilation elements may be integral reinforcing ventilation elements I00a or
mountable
reinforcing elements I00b.
[0073] In the case of mountable reinforcing ventilation elements 100b,
ventilation slot 126 also
provides an important function for stacking eave components 21 or continuation
components
23, FIG. 17a and 17b. Ventilation slot 126 allows stiffening element 102 to
pass through a
panel 26 placed on top of it and therefore allow for more compact stacking and
shipping of
components. If integral reinforcing elements are used, a similar recess will
exist on attic side
122 of panel 26, again allowing for more compact stacking and shipping of
components.
[00741 In one embodiment panels 26 of eave component 21 or continuation
component 23 may
include reinforcing elements 160 (a.k.a. stiffening element 102), FIGS. 18a-
20a, 20c, 21 a, 21 c
18
CA 02717405 2010-10-14
and 22. Reinforcing element 160 spans between first lateral edge 28a and
second lateral edge
28b and is oriented substantially perpendicular to the first lateral edge and
second lateral edge.
Reinforcing elements 160 may have saddles 162 for added strength. A plurality
of reinforcing
elements 160 may be spaced along the length of panel 26 to achieve the desired
stiffening.
Reinforcing element 160 includes at least one raised wall 106 that extend
upward from middle
section 34, but preferably two parallel raised walls creating an elongated
structure. Walls 106
preferably are oriented substantially perpendicular to attic side 122 and roof
side 124 of panel
26, but may be at an angle to middle section 34. Walls 106 provide stiffness
to the panel. The
amount of stiffness is proportional to the height of the walls.
[0075] In one embodiment panels 26 of eave component 21 or continuation
component 23 may
include vent channel supports 170, FIGS. 18a-22. Vent channel supports 170 are
dimensioned
to extend from middle section 34 to a plane 172 defined by flat edge section
42 of first lateral
edge 28a and second lateral edge 28b, FIG. 21 a-21 c. Each vent channel
support 170 intersects
plane 172 at a single apex 174. Vent channel supports 170 are surrounded on
all sides by a
portion of middle section 34 making them discrete locations of support. Vent
channel supports
170 include but are not limited to structures such as domes, cones and
pyramids. Vent channel
supports 170 may be of different sizes depending on their location within
middle section 34,
but always have a height that allows their single apex 174 to intersect at
plane 172. Gussets
176 may be integrated on the edges of vent channel supports 170 to provide
further stiffness. It
is preferable to have an array of vent channel supports positioned over the
area of middle
section 34. Vent channel supports 170 provide a unique way of supporting a
relatively thin
panel from collapsing into vent channel 36 when insulation is sprayed, blown
or pressed in
from attic side 122 of panel 26. When installed each vent channel support 170
provides a
single point of minimal contact with roof sheathing 24 at apex 174. The array
of single points
of contact provides for close to 100% ventilation of the exposed underside of
roof sheathing 24.
[0076] In one embodiment panels 26 of eave component 21 or continuation
component 23 may
further include a formed grid pattern 180, FIGS. 18a-22. Formed grid pattern
180 is a series of
ridges and troughs imprinted within an area of a generally uniform thickness
sheet. This
formed grid pattern is used to strengthen a relatively thin flat section of
panel such as middle
19
CA 02717405 2010-10-14
section 34 and canted sections 38 of panel 26. This pattern is critical for
integrity of the panel
for certain materials such as PVC in the thickness range of 0.010-inches to
0.030-inches.
Manufacturing the panels from thinner material helps reduce materials costs.
Therefore the
addition of a formed grid pattern 180 allows for the use of thinner materials
and decreases the
cost to fabricate the panels.
[0077] In one embodiment panels 26 of eave component 21 or continuation
component 23 may
further include interlocking elements 190 (190a and 190b), first interlocking
element 190a at
first end 30 and second interlocking element 190b at second end 32, FIGS.18a-
19b, 20c, 21c
and 22. These types of interlocking elements can be used instead of the
interlocking tabs 26
and extension openings 60. They provide the ability to add continuation
components 23 along
the length of roof framing members 22 to extend the length of vent trough 35.
First
interlocking element 190a fits over and interlocks with second interlocking
element 190b.
Interlocking elements 190 may include one or more vent channel supports 170
and a
reinforcing element 160. By having the first end 30 of each continuation
component 23
shingle-lapped over other components already in place, a secondary rain
barrier is created
below roof sheathing.
[0078] Eave components 21 and continuation components 23 of roof ventilation
system 20 are
designed to be installed on top of exposed roof framing members 22 just prior
to applying roof
sheathing 24. This installation can occur in new building construction or when
a roof structure
is being renovated. The overall roof structure at installation is similar to
that shown in FIGS.
1 a, 9a and 9b. Although the embodiment of eave components 21 and expansion
components 23
without reinforcing elements and with registration tabs and gaps is shown, any
of the
embodiments disclosed could be installed in a similar manner. Installation
occurs without roof
sheathing 24 and without roofing 66 in place. The roof structure comprises
roof framing
members 22 typically spaced at 16-inches or 24-inches on center. Ceiling
framing members
58 are secured to roof framing members 22 and wall top plate 68. Ceiling 70 is
secured to the
bottom of ceiling framing members 58. The slope of roof framing members 22 may
be any
slope as defined by the building design. Where roof framing members 22
overhang the edge of
the building they create eave 72. Eave 72, facia 74, soffit 76 and exterior
wall 78 of the
CA 02717405 2010-10-14
building create eave space 54. Soffit vents 80 are provided continuously or at
intervals along
soffit 76 as fresh air 77 intakes. As shown in FIG. 2, a first panel 26a (in
this case an eave
component) is laid on roof framing members 22 and living hinge 50 is aligned
with the face of
exterior wall 78. Baffle flap 48 overlaps top plate 68 of the exterior wall 78
of the building.
Top plate 68 and exterior wall 78 may or may not be covered with plywood 79.
If the panel
has registration tabs 44, then the registration tabs are fastened to the top
of roof framing
members 22 as required to hold in place, using fasteners 43, for example
staples. Baffle flap
tabs 60a and 60b are then secured to roof framing members 22 by appropriate
fasteners 43,
again for example staples. A second panel 26b is then laid adjacent to first
panel 26a between
the next two adjacent roof framing members 22. Registration tabs 44 of second
panel 26b are
then placed within and registered to corresponding registration gaps 46 of
first panel 26a. First
panel 26a and second panel 26b are now self-registered. The result of
registering first panel
26a to second panel 26b causes the two panels to be aligned to each other. If
the panels do not
have the feature of registration tabs and registration gaps, but instead a
continuous edge section
42 as shown in FIGS. 18a, 19a and 20a-22, then the panels are just laid with
the continuous
edge sections next to or on top of each other. Baffle flap 48 of second panel
26b is then
adjusted and secured to roof framing members 22. This process continues with
successive
panels until the entire eave side of the roof structure is fitted with eave
components. Once the
eave components are in place, roof sheathing 24 and roofing 66 are installed
over roof framing
members 22 and panels 26, FIGS. 1 a, 3, 9a, 9b and 21 a-21 c. This process
completes the
formation of vent channels 36. Insulation 56 can then be blown, sprayed or
laid around the
edges of attic space 52 without worry of the insulation getting into eave
space 54 and clogging
soffit vents 80. Once roof ventilation system 20 is complete, fresh air 77
enters through soffit
vents 80, flows through channel vent 36 and exits through ridge vent 82, FIG.
lb.
100791 In certain applications such as cathedral ceilings 84 (FIG. 9a) or
finished attics 86 (FIG.
9b) eave components 21 may require the use of continuation components 23 to
extend the
length of vent channel 36. FIGS. 10 and 22 show for a single framing bay 41
how continuation
component 23 may be added to eave component 21. Because each component
comprises a
panel 26, this structure includes a first panel added adjacent to a second
panel along the length
of roof framing members 22. In FIG. 10 interlocking tabs 62 of continuation
component 23 fit
21
CA 02717405 2010-10-14
within extension openings 60 of eave component 21. Interlocking tabs 62 help
register the two
components in place. In FIG. 22 first interlocking element 190a of
continuation component 23
fits over the interlocking element 190b of eave component 21. Additional
continuation
components 23 can be added in a similar manner to the structure to continue
the extension of
vent channel 36 as required. In some cases where eave component 21 and
continuation
component 23 do not have ventilation mechanisms built in to the panels, the
panels could be
extended by having a small 1/2-inch to 2-inch space between the ends of each
panel to aid in
ventilation. This would be the case for some types of batt insulations such as
fiberglass and
rock wool are used.
[0080] As shown in FIG. 11, if panel 26 has extension openings 60 at the
second end 32 of the
panels 26 a complete installation system 88 for installing roof ventilation
system 20 is created.
Extension openings 60 can be used as a method of holding panels 26 by a panel
hanger 90
while they are being installed by the worker 92.
[0081] The embodiments disclosed in this application provide a simple and
inexpensive way to
create a roof ventilation system with air pathways along the bottom side of a
roof. The
ventilation system is efficient and easy to install. Furthermore, the
ventilation system can be
used in numerous roof ventilation applications by incorporating multiple
components
comprising panels that register and interlock together.
[0082] If ventilation channels are not required as part of the roof formation
and insulation
process (i.e., a non-vented roof), an alternative to the above disclosed eave
and continuation
components may be used. This is usually the situation for when open or closed
cell spray foam
or dense pack fiber insulation is used. This alternative component, an
insulation dam 130, is
used to create a barrier between attic space 52 and eave space 54, FIGS. 23a
and 23b.
Insulation dam 130 comprises a generally flat and rectangular top panel 132.
Top panel 132
includes a top edge 134, a bottom edge 136, a first top panel edge 138 and a
second top panel
edge 140. Top panel 132 has a width that is greater than the width between
roof framing
members 22. However, it is preferable to have the width of top panel 132 equal
to or less than
the combination of the width between roof framing members 22 and the width of
the two
22
CA 02717405 2010-10-14
framing members. First top panel edge 138 and second top panel edge 140 of top
panel 132 are
for mounting between roof framing members 22 and roof sheathing 24. First top
panel edge
138 and second top panel edge 140 are preferably mounted on top of roof
framing members 58.
Roof sheathing 24 may include one or more layers such as wood sheathing 142
(plywood,
OSB) and an underlayment weather protecting membrane 144 such as TYVEK or
other
similar product. Attached to bottom edge 136 of top panel 132 is a baffle flap
48a having a top
blocking edge 150, a bottom blocking edge 152 and opposite framing edges 154a
and 154b.
Baffle flap 48a spans the width between roof framing members 22. Top panel 132
and baffle
flap 48a are integrated by way of a living hinge 50a between bottom edge 146
and top blocking
edge 150. Baffle flap 48a is adjusted down during installation to create a
barrier between attic
space 52 and eave space 54. The purpose of baffle flap 48a is to keep
insulation 56, from
getting into eave space 54. Baffle flap 48a has two baffle flap tabs 60c and
60d that extend
from opposite framing edges 154a and 154b of the baffle flap. Baffle flap tabs
60c and 60d are
preferably rectangular baffle flap tabs. Baffle flap tabs 60c and 60d are
created from the same
material as baffle flap 48a, but have fold line 160 created by a score or
crease at opposite
framing edges 154a and 154b of the baffle flap, this allows the tabs to bent
to extend towards
eave space 54 when installed. When installed, baffle flaps tabs 60c and 60d
are oriented to
attach substantially parallel to the inside of roof framing members 22.
Insulation dam 130
further comprises a baffle flap gap 156 between top panel 132 and each baffle
flap tab 60c and
60d. Baffle flap gap 156 is dimensioned so that baffle flap tabs 60c and 60d
do not stick into
the plane of roof sheathing 24 when secured to the inside of roof framing
members 22. Top
panel 132, baffle flap 48a and baffle flap tabs 60c and 60d are preferably
fabricated as one
integral unit during manufacture. Insulation dams 130 may be stacked flat in
groups of forty to
one hundred for shipping as shown in FIG. 24.
[0083] The self-registering roof ventilation system described above is not
limited to the
embodiments represented but includes all variants notably those concerning the
materials used
to form the eave components, the continuation components and the insulation
dams, the exact
shape and spacing of registration tabs and gaps, the exact type and shape of
elements to
interlock eave and continuation components, the size and shape of any vent
channel supports
and the cross-sectional shape used to form vent channels. Nothing in the above
specification is
23
CA 02717405 2010-10-14
intended to limit the invention more narrowly than the appended claims. The
examples given
are intended only to be illustrative rather than exclusive.
24
