Abstract:
Various embodiments of the invention are directed to a method for installing an elevated batten system that includes a horizontal batten strip to which cylindrical-shaped pads are coupled. The pads elevate the horizontal batten strip above the roof deck surface, preventing water and debris from gathering on the roof deck surface and eliminating the need to install the vertical and horizontal battens in separate steps. Other various embodiments of the invention are directed to an elevated batten system that includes a horizontal batten strip to which pads are coupled that define a depressed portion. The depressed portion receives a fastener for coupling each pad to the horizontal batten strip, and in some embodiments, prevents irregularities in the height of the horizontal batten strip relative to the roof deck surface when installed on the roof deck surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. application Ser. No. 11/832,406, filed Aug. 1, 2007, which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     Counterbatten systems are used with tile roof installations to elevate the roof tiles above the roof deck surface. By elevating the roof tiles, water is prevented from gathering under and/or around the roof tiles, which protects the roof deck from damage, and the air space created between the roof deck and the roof tiles facilitates ventilation of the roof. 
     Counterbatten systems are typically created by fastening wood strips, which are called vertical battens, in a vertical direction up the roof at 16″ or 24″ on center onto the roof decking. Horizontal, or anchor, battens are then fastened directly onto these vertical battens. The size of the batten strips will vary according to spacing and load factors, but the minimum dimensions are typically ⅜″ thick for the vertical strips and nominal 1″×3″ for the horizontal strips. By installing the horizontal battens onto the vertical battens, nail penetrations into the roof decking are minimized, and the nails that penetrate the roof deck are less likely to be exposed to water because they only penetrate the vertical strips that run parallel to water flow. 
     Although such counterbatten systems provide some advantages to tile roof installations, they may be time consuming to install. U.S. Pat. No. 6,536,171 discloses an elevated batten system solution in which pads or blocks are attached to the underside of the horizontal batten strips prior to installation, and these pads serve the function of the vertical strips of the counterbatten system. By not having to install the vertical strips, the installation may progress more quickly and with less materials. This elevated batten system uses diamond-shaped pads, which diverts the flow of any water to either side of the pad. Such systems require relatively accurate orientation and attachment of the pads relative to the strips, which can increase the amount of time and cost it takes to manufacture the batten strips. In addition, inconsistencies in the height of the batten strips at each pad may be introduced when the pads are attached to the horizontal strips if a fastener, such as a nail or staple, is not inserted into the pad properly or if varying amounts of adhesive are used to couple the pads to the horizontal strips. 
     Thus, there remains a need in the art for an improved elevated batten system. 
     SUMMARY OF THE INVENTION 
     Various embodiments of the invention provide a method for installing an improved elevated batten assembly for use atop an inclined roof supporting surface and for supporting tiles above the inclined roof supporting surface. The elevated batten assembly comprises (1) an elongate horizontal batten strip that has an underside for generally facing the inclined roof supporting surface and (2) a plurality of support pads that are spaced apart and coupled to the underside of the batten strip. The support pads each include opposing first and second sides, wherein each of the first and second sides comprises a substantially flat surface. The first side is coupled adjacent to and substantially in planar contact with the underside of the batten strip. In addition, the second side of each support pad is configured for being substantially in planar contact with the inclined roof supporting surface, the support pads support the batten strip above the inclined roof supporting surface, and each of the support pads have a cylindrical wall that extends between the first and second sides. According to one embodiment of the invention, the cylindrical-shaped pads do not require orientation relative to the horizontal batten, which may be required when using square or rectangular shaped pads. In addition, the cylindrical wall of the pads deflects water around the pads to prevent pooling, and the first and second sides of the pads allow the pads to fit substantially flush against the underside of the horizontal battens and the roof deck surface, which prevents debris and other materials from getting caught between the pads and the batten and/or the roof deck and prevents damming that can result in roof leaks or premature deterioration of the underlayment, battens, and/or fasteners. 
     According to other various embodiments of the invention, a method for installing an elevated batten assembly for use atop an inclined roof supporting surface and for supporting tiles above the inclined roof supporting surface is provided. The elevated batten assembly comprises (1) an elongate horizontal batten strip that has an underside for generally facing the inclined roof supporting surface and (2) a plurality of support pads that are spaced apart and coupled to the underside of the batten strip. The support pads each include opposing first and second substantially flat side portions, and the first substantially flat side portion of each support pad is coupled adjacent to and substantially in planar contact with the underside of said batten strip. The second substantially flat side portion of each support pad is configured for being substantially in planar contact with the inclined roof supporting surface. In addition, the support pads support the batten strip above the inclined roof supporting surface, and each of the second substantially flat side portions defines a depressed portion that is configured for receiving a fastener for coupling the support pad to the horizontal batten strip. According to one embodiment, installing the fastener in the depressed portion can prevent inconsistencies in the height of the horizontal batten along the length of the batten due to an improperly attached fastener. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of an elevated batten assembly  10  according to various embodiments of the invention. 
         FIG. 2A  is a lower plan view of the elevated batten assembly  10  assembled according to a first configuration, according to various embodiments of the invention. 
         FIG. 2B  is a lower plan view of the elevated batten assembly  10  assembled according to a second configuration, according to various embodiments of the invention. 
         FIG. 3  is schematic diagram of the flow of water  13  around an exemplary pad, according to various embodiments of the invention. 
         FIG. 4A  is a lower plan view of a support pad having a depressed portion according to various embodiments of the invention. 
         FIG. 4B  is a side elevational view of the support pad shown in  FIG. 4A . 
         FIG. 5  is a pictorial view showing the outline of an exemplary group of tiles  100  installed atop the elevated batten assembly  10  according to various embodiments of the invention. 
         FIG. 6  shows two configurations of batten assemblies  10   a ,  10   b  stacked relative to each other such that the pads of the two batten assemblies have nest between each other in an alternating fashion, according to various embodiments of the invention. 
         FIG. 7A  is a lower plan view of an assembled elevated batten assembly according to an alternative embodiment of the invention. 
         FIG. 7B  is a perspective view of two of the assembled elevated batten assemblies shown in  FIG. 7A  stacked together according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The elevated batten system according to various embodiments of the present invention is designed to eliminate the need to install the vertical and horizontal battens in separate steps. In particular, pads  14  are attached to the underside of the horizontal battens  12  at the lumber mill or other assembly facility. These pads serve the function of spacing the horizontal batten strips above the roof deck surface, which was served by the the vertical strips used in the prior art counterbatten system described above, but the pads provide a more efficient method of installation and reduce the amount of materials used during installation. 
     According to various embodiments of the invention, the pads may be cylindrical-shaped or rectangular or square-shaped and made from wood (e.g., plywood) or another suitable material such as rubber, plastic (e.g., HDPE) or other polymer, and/or recycled materials. The pads are attached at pre-defined increments along horizontal batten strips with a suitable fastener (e.g., staples, adhesive, or nails) prior to bundling and shipping from the assembly facility. The pre-defined increments and the dimensions of the pads and the horizontal strips may depend on the load conditions and/or weather conditions to which the roof will be subject. The elevated batten system according to various aspects of the invention may then be installed horizontally along a roof such that the pads are disposed immediately adjacent the roof deck surface or underlayment. In addition, the pre-assembled elevated batten system can be used with any profile of roof tiles and in a variety of load conditions, according to various embodiments. Furthermore, in a particular embodiment, the battens may be treated with pressure treating or other weather resistant properties as needed. 
     In a particular embodiment, the pads  14  are cylindrical and have a diameter of about 1½″ and a thickness of about ⅜″. The pads are installed on one side of the horizontal batten  12  at 12″ intervals using a staple or other suitable fastener. The pads elevate the horizontal batten above the roof deck by a height substantially equal to the thickness of the pads  14  and provide adequate support for the horizontal batten  12  to prevent deflection. 
     Elevating the battens  12  allows for water and debris to pass freely beneath the battens and allows improved airflow above the roof support surface, which reduces heat gain in the roof system and reduces cooling costs. In addition, unlike rectangular or square-shaped pads, which may require orientation into a diamond-shape relative to the horizontal axis of the horizontal batten prior to attachment to the horizontal batten, cylindrical-shaped pads do not require orientation relative to the horizontal batten. Furthermore, the cylindrical walls of the pads deflect water around the pads to prevent pooling, and the flat sides of the pads allow the pads to fit substantially flush against the underside of the horizontal battens and the roof deck surface, which prevents debris and other materials from getting caught between the pads and the batten and/or the roof deck and prevents damming that can result in roof leaks or premature deterioration of the underlayment, battens, and/or fasteners. For example, as shown in  FIG. 3 , water and/or debris  13  flow around the pad  14 . 
     In other various embodiments, the pads  14  have rectangular, square, or other polygonal shapes, have thicknesses greater than or less than ⅜″ depending on the height requirements of the installation, and may be installed at alternative selected intervals (e.g., 16 inches on center, 24 inches on center, or other selected distances). 
     According to a particular embodiment of the invention which is shown in  FIGS. 2A and 2B , the pads  14  are spaced from the ends of the horizontal battens in at least two configurations. A first configuration  10   a  is shown in  FIG. 10A  and a second configuration  10   b  is shown in  FIG. 10B . The pads  14   a  in the first configuration  10   a  are positioned closer to the end of the horizontal batten  12   a  than the pads  14   b  in the corresponding second configuration  10   b . The pads  14   b  in the second configuration  10   b  are spaced from the end of the horizontal batten  12   b  such that a pair of battens  10   a ,  10   b  may be stacked with their respective pad sides cofacing, with the pads nesting between each other in an alternating fashion, such as shown in the embodiment in  FIG. 6 . In addition, this alternating configuration provides for more efficient stacking and shipping and provides solid support at each end of adjoining battens. The batten assemblies  10   a,    10   b  can be aligned and bundled with plastic strapping. 
     In an alternative embodiment, which is shown in  FIGS. 7A and 7B , the pads are spaced from the ends of the battens to minimize the risk of splitting during the attachment to the roof. In a particular embodiment, the pads are positioned about three inches from each end of the batten, and when stacked, as shown in  FIG. 7B , the ends of the battens are slightly staggered with respect to the each other. 
     The horizontal batten strips  12  are manufactured from wood, according to various embodiments of the invention. In a particular embodiment, the wood used for the strips  12  is Douglas Fir lumber, which is a strong, construction-grade material. Furthermore, the horizontal strips may be nominal about 1″×about 3″ or about 1″×about 2″ lumber and cut into about 4 foot or about 8 foot strips, according to various embodiments. The thickness of the lumber may be between about ⅜″ and about 1″ (e.g., about ¾″) and the height of the lumber may be between about 1″ and about 3″ (e.g., about 1½″ or about 2½″), according to various embodiments of the invention. 
     In addition, in a particular embodiment, twenty four 4 foot strips that are assembled with the support pads are bundled together and strapped, and each bundle provides a sufficient number of battens for installing approximately one square (100 square feet) of roofing tile. In another embodiment, twelve 8 foot strips assembled with support pads are bundled together and strapped, and each bundle provides a sufficient number of battens for installing approximately one square (100 square feet) of roofing tile. Furthermore, according to various embodiments, the strips  12  may be marked on the side of each strip  12  opposite the side to which the pads  14  are attached with to indicate nailing points, making installation easier for the roof system installers. 
     In other various embodiments such as those embodiments shown in  FIGS. 1 ,  4 A, and  4 B, the pads  14  comprise two substantially flat sides that are opposite each other. The first substantially flat side  16   a  is installed adjacent the horizontal batten  12 , and the second substantially flat side  16   b  is installed adjacent the roof deck surface. 
     In a particular embodiment which is shown in  FIGS. 4A and 4B , a depressed portion  15  is further defined in at least one of the first and/or second substantially flat sides  16   a ,  16   b . According to one embodiment, the depressed portion  15  is defined in the second substantially flat side  16   b  and a fastener, such as a staple, nail, or screw, is engaged into the depressed portion  15  to attach the pad  14  to the horizontal batten  12 . The depth of the depressed portion  15  is dimensioned such that the head of the fastener when attached to the pad  14  and the horizontal batten  12  does not extend past the plane in which the substantially flat side  16   a ,  16   b  lies (e.g., the depth of the depressed portion  15  is at least as deep as the thickness of the head of the fastener and may further include some additional tolerance to provide for variations in manufacture of the fasteners, according to one embodiment), and the width of the depressed portion  15  is at least as wide as the width of the head of the fastener. 
     Installing the fastener in the depressed portion  15  prevents inconsistencies in the height of the horizontal batten  12  along the length of the batten  12  due to an improperly attached (e.g., protruding) fastener, for example. In addition, according to various embodiments such as the embodiment shown in  FIG. 5 , the horizontal battens  12  are secured to the roof deck surface  200  using fasteners that are installed into the surface of the battens  12  opposite the underside to which the pads  14  are attached. 
     By installing the fasteners  20  through the batten  12  and the pad  14 , according to one embodiment, a hole in the roof deck surface  200  made by the fastener is protected from water and debris by the edges of the pads&#39;  14  substantially flat sides  16   b . In addition, the depressed portion  15  allows for flush and non-flush type fasteners to be used to secure the pads  14  to the battens  12 . Upon installing the batten assemblies  10  to the roof deck surface  200 , tiles  100  may be installed over the batten in a conventional manner on the upwardly facing side of the battens. 
     CONCLUSION 
     Although this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims.