Note: Descriptions are shown in the official language in which they were submitted.
GAS PERMEABLE ARRESTER SEAL WITH INTEGRATED WEEP CONDUIT
FOR RIDGE VENTS
[0001]
Technical Field
[0002] This disclosure relates generally to roofing systems, and more
particularly, to
systems and methods for preventing ingress of foreign matter to the interior
of a structure
through a ridge vent.
Background
[0003] Many residential and commercial structures include a pitched roof.
Such roofs
often preserve an air path at the apex of the pitch (the "ridge") to encourage
the ventilation of
air from the interior of the structure to the external environment. In many
cases, the air path
at the ridge (the "ridge vent") can be ducted to other vents or ventilation
systems (such as
gable vents, soffit vents, louvers, and so on) to provide additional
ventilation to the structure.
[0004] Traditionally, ridge vents are accompanied by a screen assembly at the
output of
the air path such as a wire mesh, a reticulated matting, a baffle, or a
tightly-corrugated or
pleated plastic in order to prevent the intrusion of insects, animals, wind-
blown precipitation,
organic or inorganic debris, or any other foreign matter into the structure or
beneath the roof.
Ridge vent screen assemblies are typically disposed between the roofing
material (e.g.,
shingles, tiles, metal sheeting, and so on) and a ridge cap positioned over
the ridge.
However, conventional ridge vent screen assemblies have proven difficult to
secure to both
the ridge cap and to the roofing material in a manner that both prevents
ingress of foreign
matter and permits largely unrestricted air flow through the ridge vent,
reliably, for an
extended period of time and in a cost-effective manner.
[0005] For example, some ridge vent screens are made from high-cost and high
weight
materials such as injection-molded plastics (e.g., polypropylene). Such ridge
vent screens
may be expensive to purchase and ship to a building site, may be cumbersome
and/or time
consuming to hoist to a ridge termination, and/or may be expensive or
difficult to repair,
clean, or replace.
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[0006] Other conventional ridge vent screens may require fixed-height portions
of rigid
and air-impermeable material in order to fasten to a pitched roof. For
example, certain
conventional ridge vent screens may require spacers, bridges, or columns of
rigid material to
support the ridge cap disposed thereon and to maintain the gap introduced
between the
ridge cap and roofing material that defines the airway associated with the
ridge vent. Such
spacers can increase the vent screens' air flow resistance and/or decrease the
vent screens'
maximum airflow volume, thereby decreasing the effectiveness of the
ventilation provided to
the structure. Further, adjacent spacers may be formed with, or may settle
over time to have,
slightly different heights (e.g., manufacturing variations), which in turn can
introduce
structural stresses and/or deformations (especially during thermal expansion
or contraction)
in the roofing material, ridge cap, or the ridge vent screen itself,
necessitating repair or
replacement. Additionally, if adjacent spacers are unequal in height,
buckling, bending or
other deformation of the roofing material, ridge cap, or vent screen can
occur, which may
introduce a channel or other pathway for foreign matter or liquid to intrude
within the
structure. Additionally, the relative rigidity of such spacers can increase
the likelihood of
dimpling or buckling of the roofing material upon fastening the vent screen
spacer to the roof
(e.g., driving a screw too tightly). Similarly, the relative rigidity of such
spaces can also cause
dimpling or breaking of the ridge cap upon fastening the ridge cap to the vent
screen spacer
which, in turn, can increase the time, attention to detail, and cost required
to install said vent
screen to a pitched roof.
[0007] Furthermore, other conventional ridge vent screens are often caulked to
(or
otherwise hermetically or semi-hermetically sealed to) a ridge termination. In
high humidity
climates or climates experiencing both high wind and high levels of
precipitation, liquid water
can forcibly penetrate the ridge vent ,screen and/or condense behind the ridge
vent screen
thereby accumulating (e.g., pooling) behind the conventional ridge vent
screen, potentially
resulting in damage or premature degradation of the roof, the conventional
ridge vent
screen, the ridge cap, or the structure itself.
[0008] As a result, there may be a present need for a cost effective,
lightweight, and easy-
to-install system or apparatus for preventing ingress and accumulation of
foreign matter to
the interior of a peaked-roof structure through a ridge vent.
Summary
[0009] Many embodiments described herein reference an arrester seal for a
ridge vent
(e.g., a ventilation pathway introduced by a ridge termination ducting the
interior of a
structure to the exterior environment). The arrester seal can provide an
effective liquid
barrier at the surface of the roof to inhibit intrusion of water adhered to
the surface of the roof
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via surface tension and, additionally, the arrester seal can provide a low
airflow resistance to
facilitate ventilation of air from the interior of the structure to the
external environment.
[0010] The arrester seal can include at least a foundation layer with a gas
permeable
layer disposed thereon. The foundation layer can be formed from a rigid, semi-
rigid, or self-
supporting material. In many embodiments, the foundation layer can provide
structural
definition to the arrester seal. As noted above, the arrester seal can also
include a gas
permeable layer coupled to the top surface of the foundation layer. The gas
permeable layer
can be formed from a material having a determinable airflow resistance and the
foundation
layer may be-formed from a fluid impermeable material.
[0011] In many embodiments, the bottom surface of the foundation layer of an
arrester
seal may be formed to substantially contour to a transverse profile (e.g.,
lateral cross-
section) of a roofing material (e.g., tiles, shingles, ribbed metal, and so
on). The gas
permeable layer may be formed to contour to an underside of a ridge cap that
can be
positioned over an associated ridge termination. In one example including a
substantially
planar ridge cap underside, the gas permeable layer can define a substantially
planar
surface.
[0012] In many examples, the arrester seal can also include a weep conduit in
the bottom
surface of the foundation layer to facilitate the removal of liquid
accumulation via a standard
drainage system associated with the structure.
[0013] Some embodiments may provide an adhesive strip on the bottom surface of
the
foundation layer in order to couple the arrester seal to the roofing material.
Other
embodiments may provide an adhesive strip on the gas permeable layer in order
to couple
the arrester seal to the ridge cap.
[0014] Some embodiments reference a gas permeable layer formed from an open
cell
foam or a bonded-fiber matting, selected at least in part to minimize the
airflow resistance.
Some embodiments reference a foundation layer formed from a closed-cell foam.
[0015] Further embodiments described herein reference an arrester seal for
venting a
ribbed metal roof, the arrester seal including at least a foundation layer
with a sealing
surface formed to substantially contour to a transverse profile of the ribbed
metal roof and a
gas permeable layer formed from a bonded-fiber matting and including at least
a bottom
surface coupled to a top surface of the foundation layer. The bottom surface
of the gas
permeable layer may be formed to contour to the top surface of the foundation
layer, and a
top surface of the gas permeable layer may be formed to contour to the
underside of a ridge
cap.
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[0016] Some embodiments reference a foundation layer formed from one of a
polymeric
material, a closed cell foam, an in-filled bonded-fiber matting, or a
collapsed bonded-fiber
matting. In many cases, a foundation layer also includes a seal-finished edge.
[0017] Some embodiments reference a sealing surface of an arrester seal that
includes a
major rib pocket to receive and contour to a major rib of the ribbed metal
roof, and a minor
rib pocket to receive and contour to the minor rib of the ribbed metal roof.
[0018] Further
embodiments described herein may relate to, include, or take the form of a
method of sealing a ridge vent, the method including at least the operations
of removing a
backing to expose an adhesive strip coupled to a sealing surface of an
arrester seal,
positioning the arrester seal adjacent to a ridge termination of a roofing
section, orienting the
arrester seal parallel to the ridge termination, press-fitting the adhesive
strip against an
external surface of the roofing section, fastening the arrester seal to the
roofing section by
driving a fastener (e.g., screw, nail, bolt, clip, and so on) through a gas
permeable layer of
the arrester seal, through the sealing surface of the arrester seal, and into
the roofing
section. The method can continue with the operation of positioning a ridge cap
over the ridge
termination such that the ridge cap at least partially rests on the gas
permeable layer.
[0018a]
Accordingly, in one aspect, the present invention resides in an arrester seal
for
venting a ribbed metal roof comprising a stiffening rib, the arrester seal
comprising: a
foundation layer comprising a sealing surface formed to substantially contour
to a transverse
profile of the ribbed metal roof across the stiffening rib, the foundation
layer defining a weep
conduit adjacent to the stiffening rib; an adhesive strip coupled to the
sealing surface and
formed from an adhesive material configured to interface with and adhere to an
external
surface of the ribbed metal roof; and a gas permeable layer formed from a
compressible
bonded-fiber matting and comprising: a bottom surface coupled to and extending
across an
entirety of an upper surface of the foundation layer and across at least a
portion of the
stiffening rib, the bottom surface of the gas permeable layer formed to
contour to the upper
surface of the foundation layer; and a top surface configured to contour to
and support an
underside of a ridge cap when the gas permeable layer is placed in compression
between the
ridge cap and the stiffening rib.
[0018b] In another aspect, the present invention resides in an arrester seal
for coupling a
ridge cap to a ridge vent, the arrester seal comprising: a foundation layer
configured to contour
to an entirety of a transverse profile of a roofing section that includes at
least a first major rib
and a second major rib, the foundation layer comprising: a top surface; a
bottom surface
opposite the top surface; and a weep conduit defined in the bottom surface and
positioned
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between the first major rib and the second major rib; and a gas permeable
layer extending
above, and continuously across an entirety of, the top surface of the
foundation layer, the gas
permeable layer configured to continuously contour to and support the ridge
cap over the ridge
vent; wherein: the foundation layer is formed from a self-supporting rigid
material that is liquid
and gas impermeable; and the gas permeable layer is coupled to the foundation
layer and:
separates the foundation layer from an underside of the ridge cap; compresses
between the
first major rib and an underside of the ridge cap to prevent installation
damage to the ridge
cap; and compresses between the second major rib and the underside of the
ridge cap to
prevent installation damage to the ridge cap.
Brief Description of the Drawings
[0019] Reference will now be made to representative embodiments illustrated in
the
accompanying figures. It should be understood that the following figures are
not intended to
limit the disclosure to one preferred embodiment. To the contrary, each is
intended to cover
alternatives, modifications, and equivalents as may be included within the
spirit and scope of
the described embodiments and as defined by the appended claims.
[0020] FIG. 1 depicts an isometric projection view of an example structure
incorporating a
pitched roof.
[0021] FIG. 2A depicts a cross-section view of the example structure of FIG. 1
taken
through section A-A, showing an air path through an arrester seal.
[0022] FIG. 2B depicts a cross-section view of the example structure of FIG. 1
taken
through section A-A, showing a weep conduit through an arrester seal.
[0023] FIG. 3A depicts a foundation layer of an arrester seal.
[0024] FIG. 36 depicts a gas permeable layer affixed to the foundation layer
of the
arrester seal of FIG. 3A.
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[0025] FIG. 30 depicts an example interlocking arrester seal.
[0026] FIG. 4A depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B.
[0027] FIG. 4B depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B, depicting one example embodiment of a gas permeable layer
as a
bonded-fiber matting.
[0028] FIG. 4C depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B, depicting one example embodiment of a gas permeable layer
as an in-
filled bonded-fiber matting.
[0029] FIG. 4D depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B, depicting one example embodiment of a gas permeable layer
as a
partially collapsed bonded-fiber matting.
[0030] FIG. 5A depicts an isometric projection view of the removal of a
backing strip from
the foundation layer of an arrester seal, exposing an adhesive strip disposed
partially
thereon.
[0031] FIG. 5B depicts an isometric projection view of the removal of a
backing strip from
the foundation layer of an arrester seal, exposing an uninterrupted adhesive
strip disposed
thereon.
[0032] FIG. 5C depicts an isometric projection view of the removal of a
backing strip from
the gas permeable layer of an arrester seal, exposing an uninterrupted
adhesive strip
disposed thereon.
[0033] FIG. 6 depicts an isometric projection view of the fastening of an
arrester seal to a
metal roofing panel.
[0034] FIG. 7 depicts an isometric projection view of the fastening of an
arrester seal to a
metal roofing panel and to a ridge cap.
[0035] FIG. 8 depicts example operations of a method of manufacturing an
arrester seal
formed from a foundation layer and a gas permeable layer.
[0036] FIG. 9 depicts example operations of a method of affixing an arrester
seal between
roofing surface and a ridge cap.
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[0037] The use of the same or similar reference numerals in different drawings
indicates
similar, related, or identical items.
[0038] The use of cross-hatching or shading in the accompanying figures is
generally
provided to clarify the boundaries between adjacent elements and also to
facilitate legibility
of the figures. Accordingly, neither the presence nor the absence of cross-
hatching or
shading conveys or indicates any preference for particular materials, material
properties,
element proportions, element dimensions, commonalities of similarly
illustrated elements, or
any other characteristic, attribute, or property for any element illustrated
in the
accompanying figures.
Detailed Description
[0039] Many embodiments described herein reference a multi-layer arrester seal
for ridge
vents of pitched roofs. It should be appreciated that the various embodiments
described
herein, as well as the functionality, operation, components, and capabilities
thereof may be
combined with other elements as necessary, and so any physical, functional, or
operational
discussion of any element or feature is not intended to limit the disclosure
solely to a
particular embodiment to the exclusion of others, or to favor a particular
implementation for
all embodiments or related embodiments. Particularly, although many
embodiments are
described herein with reference to arrester seals having two layers, other
embodiments can
take other forms.
[0040] A structure (e.g., residential, industrial, or commercial) can
include a ventilation
system (e.g., passive, forced-air, or mixed) to facilitate the circulation of
air within the
structure. Additionally, a ventilation system can be ducted to the ambient
environment via
one or more vent outlets (more generally, "vents") in order to normalize,
regulate, or control
the quality, temperature, pressure, and/or humidity of air within the
structure. A structure can
incorporate gable vents, soffit vents, louvers, and so on. In the case that a
structure
incorporates a pitched roof, the structure may also include a ridge vent.
[0041] Traditionally, a ridge vent is provided to a structure by introducing a
gap between a
ridge cap and the roofing material adjacent the ridge termination below the
ridge cap. The
gap can be ducted to another ventilation system and/or to the interior of the
structure in
order to allow fresh ambient air to replace stale, hot, or humid air within
the structure. In one
example, air within the structure (e.g., within an attic) can be withdrawn to
the external
environment via convection. In another example, air within the structure can
be withdrawn to
the external environment from a leeward ridge vent as a result of a pressure
differential
caused by wind passing over the pitched roof. (e.g., wind suction). In yet
another example,
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air can be forced out of the structure by an electrical fan or other powered
ventilation system
(e.g., duct fan).
[0042] Ventilation of air from the interior of a structure to the ambient
environment can,
among other things, improve air quality, regulate air temperature, balance air
pressure,
regulate air humidity, and inhibit condensation of vapor within the structure.
In this manner, a
ventilation system can reduce the likelihood (or delay the onset) of
structural damage (e.g.,
wood rot, mold, expansion, contraction, damage resulting from ice dams and ice
expansion,
and so on) associated with moisture accumulation or heat retention that might
otherwise
occur in an unventilated or poorly-ventilated structure. A ventilation system
ducted to a ridge
vent can additionally afford these benefits to the interior of the pitched
roof itself (e.g., air
space between rafters, etc.). As a result, an intentionally designed
ventilation system
incorporating or ducted to a ridge vent may reduce the deterioration rate of
the pitched roof
in addition to the associated structure itself.
[0043] As noted above, ridge vents are conventionally accompanied by a screen
assembly disposed at the output of the air path (e.g., the gap between the
ridge cap and roof
surface) such as a wire mesh, a reticulated matting, a baffle, or a tightly-
corrugated, bladed,
or pleated plastic in order to prevent the intrusion of foreign matter into
the structure or
beneath the roof. Conventional ridge vent screen assemblies are typically
disposed to cover
the gap introduced between the ridge cap and the roofing material at the ridge
termination.
[0044] However, also as noted above, conventional ridge vent screens have
often proven
difficult and/or time consuming to secure to both the ridge cap and to the
roofing material in
a manner that effectively prevents ingress of foreign matter at the same time
permitting
largely unrestricted air flow through the ridge vent, reliably, for an
extended period of time
and in a manner that is cost-effective for both construction and maintenance
of the structure.
[0045] Accordingly, embodiments described herein reference multi-layer ridge
vent screen
assemblies (herein referred to as "arrester seals") configured to seal to a
pitched-roof
structure in a manner that prevents the ingress of foreign matter (e.g.,
insects, plant matter,
organic or inorganic debris, and the like) and foreign liquid (e.g.,
precipitation, drainage,
other water or liquids, and so on) into the interior of the structure, while
also providing a low-
resistance and high-volume airflow path for ventilation between the interior
of the structure
and the ambient environment, while additionally providing an egress path
(herein referred to
as "weep holes" or "weep conduit") for internally-accumulated moisture to exit
the structure
and flow onto the roof to be expelled from the structure via a standard
drainage system.
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[0046] FIG. 1 depicts an isometric projection view of an example structure
incorporating a
pitched roof. The structure 100 can be any building or structure providing an
enclosed or
semi-enclosed volume. For example, the structure 100 can be a residential
building, a
storage building, a commercial building, an industrial building, a scale model
of a building, an
animal enclosure, or any other suitable building or structure incorporating a
roofing section
terminating at a ridge. In this manner, it may be appreciated the structure
100 is provided, for
simplicity of illustration, only as a simplified single example of a structure
that may
incorporate embodiments described herein. It may be further appreciated that
other
structures (or structure types) taking different shapes, sizes, or having
different
configurations or constructions may incorporate embodiments described herein
and,
additionally or alternatively, embodiments related thereto.
[0047] The enclosed volume of the structure 100 can be defined, at least in
part, by the
intersection of several sidewalls and a roof. As illustrated, four sidewalls
of approximately
equal width cooperate to define the volume enclosed by the structure 100. Two
of the four
sidewalls of the structure 100 can be topped by a substantially-triangular
gable that contours
to the pitch of the roof of the structure 100 so as to provide support
thereto.
[0048] As noted above, the structure 100 is finished with a pitched roof that
takes a
substantially triangular shape. For example, as illustrated, two roof sections
rise to meet one
another at a single apex. This configuration is typically referred to as a
simple gable roof.
Positioned over the apex of the simple gable roof of the structure 100 can be
a ridge cap
102. The ridge cap 102 can serve as flashing to the end portions of the two
roof sections
(the "ridge termination") of the pitched roof of the structure 100. In other
words, the ridge cap
102 can be disposed to cover at least a portion of the roofing material 104 at
the ridge
termination (not shown) that forms the outermost layer of the two roof
sections of the
structure 100.
[0049] The roofing material 104 can be any suitable roofing material
including, but not
limited to, metal sheeting, ribbed metal sheeting, shingles,, tiles, tar
paper, roll roofing, slate,
wood shakes, or any other type of synthetic or organic roofing material.
[0050] The roof of the structure 100 can be constructed using any number of
suitable
techniques. In one example, the roof of the structure 100 can be constructed
with one or
more beams, trusses, rafters, joists, decking layers, sheathing, insulation,
strapping, battens,
vapor/moisture control layers, breathable membranes, fascia boards, rake
boards, flashing,
underlayrnent, and so on. For simplicity of illustration, the structure 100 is
depicted in FIG. 1
without many of these elements, each of which may be included or enclosed,
partially,
optionally, or entirely, within the roof of the structure 100. In other
embodiments, the
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structure 100 can be finished with a pitched roof taking another form, such as
a gambrel
roof, a hipped roof, a shed or lean-to roof, or any other suitable roofing
type incorporating at
least one roofing section terminating at a ridge. In other embodiments, the
structure 100 can
include more than one type of pitched roof section.
[0051] For embodiments described herein, a ventilation path may be preserved
at the
ridge of the pitched roof of the structure 100 to encourage the ventilation of
air from the
interior of the structure 100 to the external environment. More specifically,
an air path can be
introduced between the ridge cap 102 and the ridge termination defined at the
meeting point
of the two illustrated roof sections. As noted above, a ventilation path
between a ridge cap
and a ridge termination is conventionally referred to as a ridge vent.
[0052] FIG. 2A depicts a cross-section view of the ridge of the example
structure of FIG. 1
taken through section A-A, showing a sealed ridge vent incorporating two
arrester seals
(each identified as an arrester seal 200) disposed on opposite sides of a
ridge termination
between the ridge cap 102 and the roofing material 104.
[0053] The arrester seal 200 can incorporate a foundation layer 200a and a gas
permeable layer 200b. The gas permeable layer 200b can be disposed onto a top
surface of
the foundation layer 200a. In some examples, the gas permeable layer 200b can
be adhered
to the top surface of the foundation layer 200a via a weatherproof adhesive
(e.g., caulking,
silicone, etc.). In other embodiments the gas permeable layer 200b can be
formed onto or
into the top surface of the foundation layer 200a.
[0054] In many embodiments, the foundation layer 200a can be formed from a
fluid
impermeable material. For example, the foundation layer 200a can be formed
from a closed-
cell foam such as polyethylene foam, neoprene foam, polystyrene foam, foamed
rubber,
foamed polymer, foamed elastomer, foamed metal, or any other suitable closed-
cell foam. In
other embodiments, the foundation layer 200a can be formed from a plastic
material that
may be injection molded, blow molded, cast, or molded in another manner. In
other
embodiments, the foundation layer 200a can be milled, machined, or cut from a
sheet of
source material.
[0055] In other embodiments, the foundation layer 200a can be formed form a
non-foam
material. For example, the foundation layer 200a can be formed from plastic,
rubber, metal,
composite, or any other suitable fluid-impermeable material or combination of
materials.
[0056] In other embodiments, the foundation layer 200a can be formed to be
hollow or
substantially hollow, defining an enclosed internal volume. In these cases,
the internal
volume of the foundation layer 200a can be hermetically sealed from the
external
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environment (e.g., entirely closed) to prevent the ingress of foreign matter
or foreign liquid
therein.
[0057] In still further embodiments, the foundation layer 200a can be formed
from a non-
foam material and may be hollow or substantially hollow, defining an enclosed
internal
volume which may be filled with a filler material. In these cases, the
internal volume of the
foundation layer 200a can be filled with a closed-cell or an open-cell foam or
maybe filled
with another non-foamed material. In some cases, the filler material may be a
liquid or an
inert (or non-volatile) gas.
[0058] In many cases, the foundation layer 200a can provide a structural
definition to the
arrester seal 200. For example, the foundation layer 200a can be formed into a
shape (or
from a material) such that the foundation layer 200a is substantially self-
supporting. For
example, in many embodiments, the foundation layer 200a can be configured to
take a
shape that contours to the transverse profile of a roofing section. In these
embodiments, the
foundation layer 200a can be formed to have a sufficient rigidity so as to
maintain the shape
of the transverse profile of the roofing section.
[0059] In many embodiments, the foundation layer 200a can define a top
surface, a
bottom surface, a front surface, and a back surface, although rectilinear
forms of the
foundation 200a may not be required in all embodiments. As noted above and
with respect
to other embodiments described herein, the bottom surface of the foundation
layer 200a can
be formed and configured to contour to a transverse profile of a roofing
section. Also as
noted above, the top surface of the foundation layer 200a can be formed and
configured to
interface with the bottom portion of the gas permeable layer 200b. In some
embodiments,
the top surface of the foundation layer 200a and the bottom surface of the
foundation layer
200a can take a substantially similar shape. In other words, the top surface
of the foundation
.. layer 200a can be formed to take the same shape as the bottom surface of
the foundation
layer 200a which itself is formed to contour to a transverse profile of a
roofing section.
However, parity between the top surface of the foundation layer 200a and the
bottom
surface of the foundation layer 200a may not be required or favored for all
embodiments. For
example, in some cases, the top surface of the foundation layer 200a can be
formed to take
a substantially planar shape. In other embodiments, the top surface of the
foundation layer
200a can be formed to take a shape that facilitates a permanent or semi-
permanent bond
with the bottom portion of the gas permeable layer 200b. For example, in some
cases, the
top surface of the foundation layer 200a can include one or more serrated,
grooved, or
scalloped indentations or protrusions that cooperate with the gas permeable
layer 200b to
form a bond therebetween.
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[0060] The front surface of the foundation layer 200a can be configured to
orient toward
the external environment. As illustrated in FIG. 2A, the front surface of the
foundation layer
200a is oriented to face toward the left, downwardly, in the direction of the
roof. Oppositely,
the back surface of the foundation layer 200a can be configured to orient
toward the internal
environment. As illustrated in FIG. 2A, the back surface of the foundation
layer 200a is
oriented to face to the right, upwardly in the direction of the inside of the
structure 100.
[0061] In some embodiments, the arrester seal 200 can be longitudinally
symmetric; the
front surface and the back surface can each be configured to orient in the
direction of the
roof or, alternatively, the direction of the internal environment of the
structure.
[0062] In many cases, the front surface and the back surface of the foundation
layer 200a
can be seal-finished. For example, in the case that the foundation layer is
formed from a
polymeric foam material, a seal-finished edge may be formed by hot-melting the
front
surface and back surface to ensure that any of the closed-cell portions of the
foam that may
have been exposed or opened during manufacture of the arrester seal 200 are
fully closed.
In this manner, a seal-finished edge can provide a substantially uniform
surface and,
separately, a more durable and more fluid impermeable surface.
[0063] In other embodiments, the front surface and the back surface of the
foundation
layer 200a can be seal-finished using another method. For example, in some
cases, the
front surface and the back surface can be sealed with a cladding such as a
sealing paint or
other a fluid-impermeable layer. For example, in some cases, the front and
back surface of
the foundation layer 200a can be painted with a silicone-based paint.
[0064] In many cases, the font surface and the back surface of the foundation
layer 200a
can be seal finished at least partially in order to prevent water from
intruding into the interior
of the structure 100. For example, given certain weather conditions, wind may
cause
precipitation to enter below the ridge cap 102. In these cases, the
precipitation may take one
of three paths. First, precipitation may be caused to be wetted to the surface
of the roofing
material 104, blown up the slope of the pitched roof toward the arrester seal
200.
Additionally, precipitation may be caused to be wetted to the underside of the
ridge cap 102,
also blown upward the slope of the ridge cap 102 toward the arrester seal 200.
Lastly,
precipitation may be blown directly toward the arrester seal 200, without
wetting to either the
underside of the ridge cap 102 or to the top surface of the roofing material
104.
[0065] Sustained gusts of wind sufficiently angled to maintain
precipitation to directly
impact the arrester seal 200 without becoming wetted to either the underside
of the ridge
cap 102 or to the top surface of the roofing material 104 may be mitigated, in
many
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embodiments, by intentional relatively placement of the arrester seal 200 and
the ridge cap
102. For example, as illustrated in FIG. 2A, the arrester seal 200 is
positioned closer toward
the ridge termination than the toward the end portions of the ridge cap 102.
In other words,
the ridge cap 102 is disposed over the arrester seal 200 in such a manner so
as to
discourage wind-blown precipitation that does not wet to either the underside
of the ridge
cap 102 or to the top surface of the roofing material 104 from impacting the
arrester seal
200. As a result of the intentional (and relative) placement of the arrester
seal 200 and the
ridge cap 102, the volume of precipitation blown toward the arrester seal 200
may be
sufficiently minimal such that the gas permeable layer 200b can provide a
sufficient intrusion
barrier thereto.
[0066] The relatively placement of the arrester seal 200 and the ridge cap 102
depicted in
FIG. 2A may not be required or favored for all embodiments. For example, in
many
embodiments, (such as the embodiment depicted in FIG. 2B) the arrester seal
200 can be
positioned closer toward the end portion of the ridge cap 102. In other
embodiments, other
placements and relative proportions may be favored. For example, in some
embodiments
implemented for structures constructed in environments unlikely to receive
wind-blown
precipitation, an arrester seal 200 can be positioned flush with the end
portion of the ridge
cap 102. Alternatively in some embodiments implemented for structures
constructed in
environments likely to receive wind-blown precipitation, an arrester seal 200
can be
positioned a greater distance from the end portion of the ridge cap 102. In
this manner, the
ridge cap 102 can serve as flashing to the arrester seal 200 itself, improving
the
performance thereof.
[0067] Sustained gusts of wind sufficiently angled to maintain precipitation
wetting to the
underside of the ridge cap 102 may be unlikely for many environments. In
certain cases,
vortices may be formed below the ridge cap 102 that encourage precipitation
wetting to the
underside thereof to flow downwardly, away from the arrester seal 200.
Accordingly, the
volume of precipitation likely to be wetted to the underside of the ridge cap
and additionally
forced toward the arrester seal 200 may be sufficiently minimal such that the
gas permeable
layer 200b can provide a sufficient intrusion barrier thereto.
[0068] Additionally, sustained gusts of wind sufficiently angled to
maintain precipitation
wetting to the top surface of the roofing material 104 may be, in some cases,
more likely or
more common for some environments. In these cases, and as noted above, the
fluid
impermeability of the material selected for the foundation layer 200a or the
seal-finished
front (or back) surface of the foundation layer 200a can provide an effective
liquid barrier
preventing the further intrusion of said wetted liquid into the interior of
the structure. In this
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manner, the arrester seal 200 can provide an effective foreign liquid barrier
to the structure
100.
[0069] As noted with respect to other embodiments described herein, the
arrester seal
200 can also include a gas permeable layer 200b that may be adhered, coupled,
or formed
onto or into the top surface of the foundation layer 200a. In many
embodiments, the gas
permeable layer 200b can be formed from a material that is substantially air
permeable. For
example, in some embodiments, the gas permeable layer 200b can be formed from
a
substantially open-cell foam. The average size of the cells within the open-
cell foam selected
for the gas permeable layer 200b can be selected, at least in part, an airflow
resistance
provided thereby. For example, the larger the average size of cells within an
open-cell foam,
the lower the effective airflow resistance. Similarly, the smaller the average
size of cells
within an open-cell foam, the higher the effective airflow resistance.
[0070] In many cases, other manufacturing or structural parameters of the gas
permeable
layer 200b may affect (either positively or negatively) the airflow resistance
provided by the
gas permeable layer 200b. For example, for certain open-cell foam materials,
the
connections between adjacent cells may be small, resulting in a small number
of air paths
through the foam, which, in turn, can increase the airflow resistance provided
by the foam.
Similarly, certain open-cell foam materials having small average cell size can
include a high
number of air paths between adjacent cells which, in turn, can decrease the
airflow
resistance provided by the foam.
[0071] Furthermore, as may be appreciated, certain embodiments can favor
different air
flow rates for different structures. For example, certain structures may favor
rapid pressure
normalization over gradual pressure normalization. For these embodiments, the
gas
permeable layer 200b may be selected to provide a high rate of air flow or, in
another non-
limiting phrasing, may be selected to provide a low airflow resistance.
Alternatively, certain
structures may favor gradual pressure normalization over rapid pressure
normalization. For
these embodiments, the gas permeable layer 200b may be selected to provide a
low rate of
air flow or, in another non-limiting phrasing, may be selected to provide a
high airflow
resistance.
[0072] Accordingly, in many embodiments, the gas permeable layer 200b may be
selected or manufactured, at least in part, based on an expected, desired, or
determinable
airflow resistance that may be favored for a selected embodiment.
[0073] In other embodiments, the gas permeable layer 200b can be formed from
another
gas permeable material such as a bonded-fiber matting, matrix, or mass. The
bonded-fiber
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matting can be formed from any number of suitable fiber or stranded materials
such as
plastics, nylons, elastomers, glass or metal fibers, and so on. In many
embodiments, the
bonded-fiber matting can be formed from a weatherproof and/or waterproof
material.
[0074] Upon selection of a favorable fiber or stranded material for a
particular
embodiment, the selected fiber material can be bonded and/or cross-linked
together at
random, semi-random, or patterned locations in order to form a three
dimensional structure
defining the matting. In some cases, the bonds between individual fibers can
be formed by
entangling a number of fibers together and, thereafter, exposing the
entanglement to
pressure or heat so as to fuse individual fibers together. In many cases, the
open space
providing gas permeability can be defined by, or controlled by, the
manufacturing
parameters selected for a particular bonded-fiber matting. For example, in
some
embodiments, the average open space within a particular bonded-fiber matting
can be less
than 1 mm3.
[0075] In other embodiments, the average open space defined by a particular
bonded-
fiber matting can be larger. One may appreciate that the average open space
defined by a
particular bonded-fiber matting can affect the airflow resistance. For
example, the smaller
the average open space defined by a particular bonded-fiber matting is, the
larger the airflow
resistance provided by said bonded-fiber matting may be. Conversely, the
larger the average
open space defined by a particular bonded-fiber matting is, the smaller the
airflow resistance
provided by said bonded-fiber matting may be.
[0076] Similarly, the average open space defined by a particular bonded-fiber
matting can
impact that matting's ability to impede or mitigate the intrusion of foreign
matter to the interior
of the structure 100. For example, the smaller the average open space defined
by a
particular bonded-fiber matting is, the more ingress protection against
foreign matter (e.g.,
insects, animals, wind-blown precipitation, organic or inorganic debris, or
any other foreign
matter) said bonded-fiber matting may provide. Conversely, the larger the
average open
space defined by a particular bonded-fiber matting is, the less ingress
protection against
foreign matter said bonded-fiber matting may provide.
[0077] In some embodiments, the properties (including average open space) of a
particular gas permeable layer may be selected based, at least in part, on
expected
conditions of the environment in which the structure 100 is constructed. For
example, certain
environments may host a wide variety of small-size insects. For such
environments, the gas
permeable layer 200b may be selected or manufactured to have an average open
space
sufficient to prevent such small-sized insects from invading the structure
100. Other
environments may not necessarily host a wide variety of insects, but may,
instead be subject
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to high-speed winds. For such environments, the gas permeable layer 200b may
be selected
or manufactured to have an average open space sufficiently large so as to
provide gradual
pressure normalization between the external environment and the structure 100
(e.g., to
mitigate wind noise and drafts).
[0078] Returning to FIG. 2A, the arrester seal 200 can be positioned between
the ridge
cap 102 and the roofing material 104. As illustrated, the roofing material 104
may include a
protruding geometry, such as the protrusion 202. In some embodiments the
protrusion 202
can be a stiffening rib of a metal roof. In other embodiments, the protrusion
202 can be a
protruding tile of a tiled roof. In still further embodiments, the protrusion
202 can be a
shingle. Accordingly, one may appreciate that the protrusion 202 can take any
number of
forms appropriate, required, or favored for a selected roofing material.
[0079] As noted above, the bottom surface of the foundation layer 200a of the
arrester
seal 200 may be formed to substantially contour to a transverse profile (e.g.,
lateral cross-
section, not shown in FIG. 2A) of a roofing material 104 (e.g., tiles,
shingles, ribbed metal,
and so on). More specifically, the bottom surface of the foundation layer 200a
can be formed
to substantially contour to the protrusion 202 and to the non-protruding
portions of the
roofing material 104. For example, in certain embodiments, the roofing
material 104 can be a
ribbed metal and the protrusion 202 can be a major rib thereof. In this
example, the bottom
surface of the foundation layer 200a can have a portion or pocket (not shown)
that rises to
accept and engage the protrusion 202 (e.g., major rib). The bottom surface of
the foundation
layer 200a can also have a substantially flat portion that engages with the
non-protruding
portions of the roofing material 104. In this manner, the bottom surface of
the foundation
layer 200a can contour (and seal) to the entire transverse profile of the
roofing material 104.
[0080] Additionally as noted above, the gas permeable layer 200b may be formed
to
contour to the underside of the ridge cap 102. As illustrated, the underside
of the ridge cap
102 may be substantially flat. In these embodiments, the top surface of the
gas permeable
layer 200b may also be substantially flat or otherwise planar. In other
embodiments, the
underside of the ridge cap 102 can take other forms to which the gas permeable
layer 200b
can contour. For example, in cases where a ridge cap 102 is formed to
aesthetically match a
roofing material 104, the ridge cap 102 may include protrusions (or cavities).
In these
examples, the gas permeable layer 200b may also include protrusions or
cavities which
complement the protrusions or cavities of the ridge cap 102. In this manner,
the gas
permeable layer 200b of the arrester seal 200 can contour (and seal) to the
entire transverse
profile of the ridge cap 102.
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[0081] As noted above, the roof of the structure 100 can be constructed using
any number
of suitable techniques. In one example, the roof of the structure 100 can be
constructed with
one or more beams, trusses, joists, decking layers, sheathing, insulation,
strapping, battens,
vapor/moisture control layers, breathable membranes, underlayment, and so on
that are
collectively shown in FIG. 2A, for simplicity of illustration, as the roof
substructure 204.
[0082] The roof substructure 204 can be supported by the rafters 206 or other
internal
beams or trusses extending from the eaves of the structure 100 to the ridge of
the structure
100. The rafters 206 can be supported at the peak of the ridge by a
longitudinal support
beam that runs the length of the ridge. In other embodiments, the rafters 206
associated with
.. one roof section can directly engage the rafters associated with an
opposite roof section.
[0083] As noted above, a ridge vent such as the ridge vent illustrated in FIG.
2A can be
ducted to one or more ventilation systems or enclosed volumes within the
structure 100. For
example, in many embodiments, an air path (illustrated as a dotted line) can
be introduced
between the rafters 206 and a gable-shaped space 208, such as an attic, so
that air can flow
between the gable-shaped space 208 and the external environment through the
arrester
seal 200.More particularly, as illustrated, an air path can be introduced such
that air can flow
from the gable-shaped space 208 into a volume adjacent to the ridge
termination and below
the ridge cap 102, generally referred to herein as a ridge termination opening
210. From the
ridge termination opening 210, air can flow to the external environment
through the arrester
seal 200.
[0084] Additionally, an air path can be introduced between the roofing
material 104 and
the roof substructure 204. For example, in some cases, the protrusion 202 can
define an air
path from a soffit vent (not shown) adjacent the eaves of the structure 100 to
the ridge
termination open 210.
[0085] Also as noted above, the ventilation of air from the interior of the
structure 100 to
the ambient environment can, among other things, improve air quality, regulate
air
temperature, balance air pressure, regulate air humidity, and inhibit
condensation of vapor
within the structure.
[0086] Accordingly, certain embodiments can select various properties of the
ridge
termination opening 210 (e.g., height, width, total volume, etc.), the
arrester seal 200, the
rafters 206, the roof substructure 204, or any other aspect of the roof
structure or
substructure in order to effect a particular or favorable rate at which
ventilation may occur.
For example, if rapid ventilation is favored for a particular embodiment or
structure, the ridge
termination opening 210 may introduce a smaller air path that ducts the
arrester seal 200 to
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other ventilation systems or enclosed volumes of the structure 100. In other
examples, if
gradual ventilation is favored for a particular embodiment or structure, the
arrester seal 200
may implement a gas permeable layer 200b with higher airflow resistance.
[0087] In certain limited cases, however, moisture may still accumulate behind
the
arrester seal 200. For example, internal humidity of the structure 100 may
condense behind
the arrester seal 200 if there is insufficient ventilation between the
structure and the ambient
environment (e.g., no pressure differential). As noted above, conventional
ridge vent screens
are often caulked to (or otherwise hermetically or semi-hermetically sealed
to) to the ridge
termination. In these conventional examples, accumulated moisture will pool,
potentially
causing damage to the structure 100, the roof substructure 204, or the roofing
material 104.
In extreme examples, the accumulated water may spill into (e.g., drip) into
the structure 100
itself.
[0088] In high humidity climates or climates experiencing both high wind and
high levels
of precipitation, liquid water can forcibly penetrate the ridge vent screen
and/or condense
behind the ridge vent screen thereby accumulating (e.g., pooling) behind the
conventional
ridge vent screen, potentially resulting in damage or premature degradation of
the roof, the
conventional ridge vent screen, the ridge cap, or the structure itself.
[0089] Accordingly, many embodiments described herein introduce a weep conduit
within
the bottom surface of the foundation layer 200a, such as depicted in FIG. 2B.
The weep
conduit (not shown) can be a straight, curved or other thin path within the
bottom surface of
the foundation layer 200a. As a result of the weep conduit, the water 212 that
may pool
behind the arrester seal 200 can exit the structure and flow onto the roofing
material 104 to
be expelled from the structure via a standard drainage system (e.g., gutters).
In many
embodiments the depth and geometry of the weep conduit can be selected, at
least in part,
to minimize backf low of liquid resulting from wind-blown precipitation wetted
to the top
surface of the roofing material 104. Similarly, in many embodiments the depth
and geometry
of the outlet of the the weep conduit can be selected, at least in part, to
minimize the
likelihood of an insect or other foreign matter from invading the structure
100 through the
weep hole. For example, in some embodiments, the weep conduit may be a
triangularly-
shaped channel approximately 0.5 cm in width at its base. In other
embodiments, differently-
shaped weep conduits may be used.
[0090] FIGS. 3A ¨ 3B depicts an arrester seal 300 that may be used to seal
ridge vents of
structures incorporating a pitched roof finished with ribbed metal sheeting
(not shown). As
may be known, metal sheeting for roofing purposes may typically include one or
more ribs to
increase the stiffness of the metal sheet. In some cases, a single section of
ribbed metal roof
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can include a major rib and a minor rib. The major rib may protrude a greater
distance from
the main surface of the metal sheeting than the minor rip.
[0091] As noted with respect to other embodiments described herein, the
foundation layer
302 can define a top surface 302a, a bottom surface 302b, a front surface
302c, and a back
surface 302d. The bottom surface 302b of the foundation layer 302 can be
formed and
configured to contour to a transverse profile of a ribbed metal roofing
section. As used
herein, the term "transverse" may refer to the horizontal dimension extending
from a first
gable to a second gable of a pitched roof structure, or, in other words, the
horizontal
dimension that is perpendicular to the direction and orientation of the ribs
of a conventional
metal roof.
[0092] As depicted in FIGS. 3A ¨ 3B, the foundation layer 302 may be
configured to
contour to a ribbed metal roofing section that includes two prominently
protruding major rips,
two minor ribs protruding between each pair of major ribs, and two minor ribs
protruding at
locations adjacent to each of the two major ribs. To contour to such geometry,
the foundation
layer 302 can be formed to include two major rib pockets 304 and six minor rib
pockets 306.
Each of the two major rib pockets 304 can be configured and sized to contour
to the major
ribs of the ribbed metal roofing section. Similarly, each of the six minor rib
pockets 306 can
be configured and sized to contour to the minor ribs of the ribbed metal
roofing section.
[0093] In addition to contouring to the transverse profile of an example metal
roofing
section (not shown), the foundation layer 302 can also contour to a bottom
surface of a gas
permeable layer. More particularly, the top surface 302a of the foundation
layer 302 can be
formed and configured to interface with the bottom portion of a gas permeable
layer, such as
the gas permeable layer 310 depicted in FIG. 3B. In some embodiments, the top
surface
302a and the bottom surface 302b can take a substantially similar shape, such
as depicted.
In other words, the top surface 302a can be formed to take the same shape as
the bottom
surface 302b which itself is formed to contour to the transverse profile of
the ribbed metal
roofing section.
[0094] However, parity between the geometry of the top surface 302a and the
bottom
surface 302b may not be required or favored for all embodiments. For example,
in some
.. cases, the top surface 302a can be formed to take a substantially planar
shape. In other
embodiments, the top surface 302a can be formed to take a shape that
facilitates a
permanent or semi-permanent bond with the bottom portion of the gas permeable
layer 310.
For example, in some cases, the top surface 302a of the foundation layer 302
can include
one or more serrated, grooved, or scalloped indentations or protrusions that
cooperate with
the gas permeable layer 310 to form a bond therebetween.
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[0095] As noted with respect to other embodiments described herein, the front
surface
302c and the back surface 302d of the foundation layer 302 can be seal-
finished. For
example, in the case that the foundation layer 302 is formed from a polymeric
closed-cell
foam material, a seal-finished edge may be formed by hot-melting the front
surface 302c and
back surface 302d to ensure that any of the closed-cell portions of the foam
that may have
been exposed or opened during manufacture of the arrester seal 300 are fully
closed. In this
manner, a seal-finished edge can provide a substantially uniform surface and,
separately, a
more durable and more fluid impermeable surface.
[0096] Additionally, disposed between each of the rib pockets can be weep
conduits 308.
As illustrated, nine independent weep conduits are shown, although such a
configuration is
not required. Similarly, although each weep conduit 308 is shown as a linear
channel defined
from the front surface 302c to the back surface 302d of the foundation layer
302 taking a
substantially triangular cross section, such a configuration may not be
required for all
embodiments. For example, in some embodiments, the weep conduits 308 can be
formed to
take a substantially semicircular shape in cross section. In other examples,
the weep conduit
308 can take a serrated shape along the channel so as to prevent insects or
other matter
from intruding into the structure while maintaining an egress path for liquid
accumulated
behind the arrester seal 300. In other embodiments, a fewer number or a
greater number of
weep conduits may be include (see, e.g., FIG. 3C).
[0097] As noted with respect to the embodiment depicted in FIG. 2A, the gas
permeable
layer 310 can be formed from a material that is substantially air permeable.
For example, in
some embodiments, the gas permeable layer 310 can be formed from a
substantially open-
ed! foam. In other embodiments, the gas permeable layer 310 can be formed from
another
gas permeable material such as a bonded-fiber matting, matrix, or mass. The
bonded-fiber
matting can be formed from any number of suitable fiber or stranded materials
such as
plastics, nylons, elastomers, glass or metal fibers, and so on. In many
embodiments, the
bonded-fiber matting can be formed from a weatherproof and/or waterproof
material.
[0098] In some embodiments the arrester seal 300 can be manufactured in
sections, such
as shown in FIGS. 3A ¨ 3B. For example, in some cases the arrester seal 300
can be
manufactured in approximately meter-long sections. In other embodiments, other
the
arrester seal 300 can be manufactured in different lengths (e.g., longer or
shorter lengths).
In further embodiments, the arrester seal 300 can be manufactured in a roll.
In such
embodiments, the material selected for the foundation layer 302 and the gas
permeable
layer 310 may be at least partially flexible.
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[0099] In other embodiments, the arrester seal 300 can be manufactured to form
a
repeating pattern when coupled to or positioned adjacent to a second arrester
seal of the
same variety. For example, as depicted in FIG. 3C, adjacent arrester seal can
be dovetailed
to one another by inserting a tail 312 into a socket of an adjacently-
positioned arrester seal.
.. In other embodiments, other means can be used to secure adjacent arrester
seals. For
example, in some cases, adjacent arrester seals can be adhered to one another
with simple
weatherproof and/or waterproof adhesive. In other embodiments, adjacent
arrester seals can
be snap-fit to one another.
[0100] FIG. 4A depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B. The arrester seal 400 is depicted with a foundation layer
402 including
a major rib pocket 404, a minor rib pocket 406, and a weep conduit 408. A gas
permeable
layer 410 is disposed above to top surface of the foundation layer 402.
[0101] As noted with respect to other embodiments described herein, the
foundation layer
402 can be formed from a fluid impermeable material and the gas permeable
layer 410 can
be formed from a gas permeable layer. The permeability of the gas permeable
layer 410 can
be selected, at least in part, based on the environment and intended use of
the structure
onto which the arrester seal 400 may be disposed. In many examples, the
permeability of
the gas permeable layer 410 can be selected to reduce the airflow resistance
thereof while
providing an effectively tight barrier to prevent the ingress of insects and
other foreign
matter.
[0102] As illustrated, the gas permeable layer 410 may extend above the
foundation layer
402, forming a contiguous secondary layer of the arrester seal 400. As a
result of this
configuration, a much larger airflow volume may pass through the arrester seal
than may
pass through a more conventional ridge vent screen assembly. More
particularly, because a
.. greater portion of the arrester seal 400 is gas permeable, a greater volume
of air can move
therethrough. In turn, this configuration allows for a greater airflow
resistance (e.g., tighter
gas permeable layer) while permitting the same net airflow resistance as an
arrester seal
permitting a smaller volume of air to flow therethrough. In this manner, the
gas permeable
layer 410 can be manufactured with smaller average openings, thereby
increasing the
resistance of the gas permeable layer 410 to ingress of foreign matter and
foreign liquid.
[0103] Further resulting from the depicted configuration, when the arrester
seal 400 is
fastened to either or both of a ridge cap or roofing material adjacent a ridge
termination, the
gas permeable layer 410 may at least partially compress, placing the gas
permeable layer
410 into a compressed state. As a result of the compressed state, the gas
permeable layer
410 provide an effective seal against the underside of a ridge cap,
independent of the force
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with which the ridge cap is secured to the arrester seal and independent of
any movement or
settling of the ridge cap, the roofing material, or the arrester seal itself
overtime. In some
embodiments, the gas permeable layer 410 may be sufficiently locally
compressed during
installation as to be locally liquid and/or gas impermeable. For example, the
gas permeable
layer 410 can be so compressed between a ridge cap and a major rib of a ribbed
metal
roof. Any such compressed region may be localized; as one example, only the
portion (or a
portion) of the gas permeable layer overlying a major rib may be gas and/or
liquid
impermeable. Section of the gas permeable layer to either side may remain gas
and/or
liquid permeable, thereby creating separate pockets or regions that may permit
liquid and/or
gas flow therethrough. It should also be appreciated that, in some
embodiments, the gas
permeable layer 410 is not compressed to this extent or may not be capable of
compressing
to such an extent.
[0104] In many cases, the permeability of the gas permeable layer 410 once
installed
(e.g., under compression) may be used as selection criteria for the material
properties of the
gas permeable layer 410.
[0105] Accordingly, many embodiments described herein reference a gas
permeable
layer 410 that is both compressible and permeable to air (and other gasses),
such as a
bonded-fiber matting formed from a material such as polyester or nylon.
[0106] FIG. 4B depicts a cross-section view of the example arrester seal of
FIG. 3A taken
through section B-B, depicting one example embodiment of a gas permeable layer
as a
bonded-fiber matting. As noted with respect to the embodiment depicted in FIG.
2A and
embodiments related thereto, the gas permeable layer 410 can be formed from a
bonded-
fiber matting, matrix, or mass, such as depicted in FIG. 4B. The bonded-fiber
matting 410a
can be formed from any number of suitable fiber or stranded materials such as
plastics,
nylons, elastomers, glass or metal fibers, and so on. In many embodiments, the
bonded-fiber
matting 410a can be formed from a waterproof material.
[0107] As noted above, upon selection of a favorable fiber for a particular
embodiment of
the bonded-fiber matting 410a, the selected fiber material can be bonded
and/or cross-linked
together at random, semi-random, patterned or specific locations in order to
form a three-
.. dimensional structure defining the bonded-fiber matting 410a. In some
cases, the bonds
between individual fibers can be formed by entangling a number of fibers
together and,
thereafter, exposing the entanglement to pressure or heat so as to fuse
individual fibers
together.
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[0108] In some embodiments, such as the embodiment depicted in FIG. 4B, the
bonded-
fiber matting 410a can be adhered to the top surface of the foundation layer
402 via a
weatherproof adhesive (e.g., caulking, silicone, etc.). In other embodiments
the bonded-fiber
matting 410a can be formed onto or into the top surface of the foundation
layer 402. For
example, if the foundation layer is formed from a foam material, the bonded-
fiber matting
410a can be pressed onto the foundation layer 402 prior to final
solidification, curing, or
drying of the foundation layer 402.
[0109] In other cases, the foundation layer 402 can be formed as a portion or
layer of the
bonded-fiber matting 410a. For example, as depicted in FIG. 4C, the foundation
layer can be
formed as an in-filled portion 402a of the bonded-fiber matting 410a. In this
embodiment, the
in-filled portion can be formed from a rubber material, a foam material, a
silicone material, or
any other suitable material that can provide a substantially fluid-impermeable
characteristic
to the volume of the bonded-fiber matting 410a in which the in-filled portion
402a is filled. In
another embodiment such as depicted in FIG. 4D, the foundation layer can be
formed as a
collapsed portion 402b of the bonded-fiber matting 410a. In this embodiment,
the collapsed
portion 402b can be formed by melting a portion of the bonded-fiber matting
410a into the
shape configured to contour to the transverse profile of a roofing section. In
this
embodiment, the depth of the collapsed portion 402b can be selected to be
different for
different embodiments.
[0110] FIG. 5A depicts an isometric projection view of the removal of a
backing strip from
the foundation layer of an arrester seal, exposing an adhesive strip disposed
partially
thereon. The arrester seal 500 can be manufactured with an adhesive disposed
on a bottom
surface of the foundation layer 502 in order to adhere to the top portion of a
roofing material.
In the illustrated embodiment, a backing strip 504 made from waxed or
otherwise non-
adherent paper can be withdrawn in order to expose an adhesive strip 506.
Although the
adhesive strip 506 is illustrated as covering only a portion of the bottom
surface of the
foundation layer 502, one may appreciate that such a deposition of adhesive is
not required
and may not be favored for all embodiments. For example, in some embodiments
more than
one adhesive strip can be exposed by the withdrawal of the backing strip 504.
[0111] In other examples, a backing strip 504 may not be required. For
example, the
adhesive strip 506 may be formed from a pressure sensitive adhesive that bonds
to a roofing
material upon the application of pressure thereto. In other embodiments, the
adhesive strip
506 may be formed from an adhesive that cures and adheres given specific
conditions. For
example, the adhesive strip 506 may be formed from an ultraviolet-cured
adhesive. In other
cases, the adhesive strip 506 can be formed from a heat-cured adhesive.
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[0112] In the illustrated embodiment, the adhesive strip 506 is disposed only
over the
flattened portions of the arrester seal 500. More specifically, in the
illustrated embodiment,
the adhesive strip 506 does not cover the inner surface of the weep conduits,
minor rib
pockets, or major rib pockets of the arrester seal 500. In some cases, this
deposition pattern
of the adhesive strip 506 may be employed to reduce the full amount of
adhesive used to
secure the arrester seal 500 to the top surface of a roofing material.
However, this
configuration is not required of all embodiments. For example, as shown in
FIG. 5B, certain
embodiments can include an adhesive strip 508 that covers the inner surface of
the weep
conduits, the minor ribs pockets, and the major rib pockets of the arrester
seal 500.
[0113] FIG. 5C depicts an isometric projection view of the removal of a
backing strip from
the gas permeable layer of an arrester seal, exposing an uninterrupted
adhesive strip
disposed thereon. The arrester seal 500 can be manufactured with an adhesive
disposed on
a top surface of the gas permeable layer 510 in order to adhere to the
underside of a ridge
cap (see, e.g., FIG. 2A). In the illustrated embodiment, a backing strip 512
made from waxed
or otherwise non-adherent paper can be withdrawn in order to expose an
adhesive strip 514.
Although the adhesive strip 514 is illustrated as covering only a portion of
the top surface of
the gas permeable layer 510, one may appreciate that such a deposition of
adhesive is not
required and may not be favored for all embodiments. For example, in some
embodiments
more than one adhesive strip can be exposed by the withdrawal of the backing
strip 512.
[0114] In other examples, a backing strip 512 may not be required. For
example, as with
the adhesive strip 514 depicted in FIGS. 5A ¨ 5B, the adhesive strip 514 may
be formed
from a pressure sensitive adhesive that bonds to a roofing material upon the
application of
pressure thereto. In other embodiments, the adhesive strip 514 may be formed
from an
adhesive that cures and adheres given specific conditions.
[0115] FIG. 6 depicts an isometric projection view of the fastening of an
arrester seal to a
metal roofing panel. As noted with respect to other embodiments described
herein, an
arrester seal can be formed to contour to the transverse profile of a
particular roofing
material, such as the ribbed metal roof 602 depicted in FIG. 6. As with other
arrester seal
embodiments, the arrester seal depicted can include a foundation layer 604 and
a gas
permeable layer 606. The foundation layer 604 can include a major rib pocket
608 that is
sized and configured to contour to a major rib of the ribbed metal roof 602.
Additionally, the
foundation layer 604 can include a minor rib pocket 610 that is sized and
configured to
contour to a minor rib of the ribbed metal roof 602. Additionally, the
foundation layer 604 can
include one or more weep conduits 612.
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[0116] The arrester seal can be affixed to the ribbed metal roof 602, in one
embodiment,
via the adhesive strips shown in FIG. 5A ¨ 5B. Additionally or alternatively,
the arrester seal
can be affixed to the ribbed metal roof 602 by driving the fasteners 614
through the gas
permeable layer 606, through the foundation layer 604 and into the ribbed
metal roof 602. In
many cases, and as illustrated, the fasteners 614 may be driven into the major
ribs of the
ribbed metal roof 602 (or alternatively the portion of the ribbed metal roof
602 that protrudes
the farthest), although this is not required. For example, in some
embodiments, the fasteners
614 can be driven into other portions of the ribbed metal roof 602.
[0117] In some embodiments, the fasteners can be nails, screws, bolts, clips,
or any other
suitable mechanical fastener.
[0118] FIG. 7 depicts an isometric projection view of the fastening of an
arrester seal to a
metal roofing panel and to a ridge cap. As noted with respect to the
embodiment depicted in
FIG. 6 and described in relation thereto, an arrester seal can be formed to
contour to the
underside of a ridge cap in addition to the top surface of a roofing material,
such as the ridge
cap 700 (partially shown) and the ribbed metal roof 702 as depicted in FIG. 7.
As with other
arrester seal embodiments described herein, the arrester seal depicted in FIG.
7 can include
a foundation layer 704 and a gas permeable layer 706. The foundation layer 704
can include
a major rib pocket 708 that is sized and configured to contour to a major rib
of the ribbed
metal roof 702. Additionally, the foundation layer 704 can include a minor rib
pocket 710 that
is sized and configured to contour to a minor rib of the ribbed metal roof
702. Additionally,
the foundation layer 704 can include one or more weep conduits 712.
[0119] The arrester seal can be affixed to the ridge cap 700, in one
embodiment, via the
adhesive strips shown in FIG. 5C. Additionally or alternatively, the arrester
seal can be
affixed to the ridge cap 700 by driving the fasteners 714 through the ridge
cap 700, through
.. the gas permeable layer 706, through the foundation layer 704, and into the
ribbed metal
roof 702. In many cases, and as illustrated, the fasteners 714 may be driven
into the major
ribs of the ridge cap 700 (or alternatively the portion of the ridge cap 700
that protrudes the
farthest), although this is not required. For example, in some embodiments,
the fasteners
714 can be driven into other portions of the ribbed metal roof 702.
[0120] FIG. 8 depicts example operations of a method of manufacturing an
arrester seal
formed from a foundation layer and a gas permeable layer. The method can begin
at
operation 802 in which a foundation layer for an arrester seal can be formed.
As noted
above, in many examples, the foundation layer may be formed to have a bottom
surface
configured to contour to a top surface of a particular roofing material. At
operation 804, a gas
permeable layer can be attached, adhered, or otherwise coupled to the
foundation layer.
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Although described as separate steps, one may appreciated that the operations
802 and 804
can be performed in an alternate order or, in some cases, at the same time.
For example, as
noted above, certain foundation layer embodiments may be integrated portions
of certain
gas permeable layer embodiments (e.g., in-filled bonded-fiber matting,
collapsed bonded-
.. fiber matting, etc.). At operation 806, an adhesive material can be
attached to the arrester
seal. The adhesive material can be disposed onto a bottom surface of the
foundation layer
or, in additional or alternative embodiments, the adhesive material can be
disposed onto a
top surface of the gas permeable layer.
[0121] FIG. 9 depicts example operations of a method of affixing an arrester
seal between
roofing surface and a ridge cap. The method can begin at operation 902 in
which a bottom
surface of an arrester seal may be positioned adjacent a ridge termination of
a roof and
oriented transverse thereto. At operation 904, a ridge cap can be disposed
over the gas
permeable layer of the arrester seal.
[0122] One may appreciate that although many embodiments are describe herein
with
reference to multi-layered (e.g., two) arrester seals for ridge vents, other
layer configurations
are possible. For example, in some embodiments, additional layers can be
disposed upon
the gas permeable layer.
[0123] Furthermore, although many embodiments are described herein with
reference to
ridges having the same or similar arrester seals disposed on opposite sides of
the ridge
termination, such parity is not required of all embodiments. For example, in
certain
embodiments, one arrester seal with certain properties can be positioned on
one side of a
ridge termination and a second arrester seal with different properties can be
positioned on a
second side of a ridge termination. For example, for certain structures, the
most common
direction of prevailing wind may be determinable. Accordingly, the windward
arrester seal
may be configured to have a different airflow resistance than the leeward
arrester seal.
[0124] Many embodiments of the foregoing disclosure may include or may be
described in
relation to various methods of operation, use, manufacture, and so on.
Notably, the
operations of methods presented herein are meant only to be exemplary and,
accordingly,
are not necessarily exhaustive. For example an alternate operation order, or
fewer or
additional steps may be required or desired for particular embodiments.
[0125] The foregoing description, for purposes of explanation, used specific
nomenclature
to provide a thorough understanding of the described embodiments. However, it
will be
apparent to one skilled in the art that the specific details are not required
in order to practice
the described embodiments. Thus, the foregoing descriptions of the specific
embodiments
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described herein are presented for purposes of illustration and description.
They are not
meant to be exhaustive or to limit the embodiments to the precise forms
disclosed. It will be
apparent to one of ordinary skill in the art that many modifications and
variations are
possible in view of the above teachings. In particular, any features described
with respect to
one embodiment may also be used in other embodiments, where compatible.
Likewise, the
features of the different embodiments may be exchanged, substituted, or
omitted where
compatible and appropriate.
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