Abstract:
Devices, methods, and systems are provided herein for spacing an outer skin of a roof from the supporting structure of the roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface, a top surface inclined at an angle relative to the bottom surface, and an integral support structure connecting the top surface and the bottom surface, the support structure including a plurality of ribs and a plurality of nail boxes.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/398,461, filed on Jun. 25, 2010, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     The field of the invention relates to roofing materials, and more particularly to methods and systems for spacing panels on roofs. 
     2. Description of the Related Art 
     Roofs cover the uppermost part of a space or building, protecting the space or building interior from rain, snow, wind, cold, heat, sunlight, and other weather effects. Many roofs are pitched or sloped to provide additional protection against the weather, allowing rain or snow to run off the angled sides of the roof. Roofs generally include a supporting structure and an outer skin, which can be an uppermost weatherproof layer. The supporting structure of a roof typically includes beams of a strong, rigid material such as timber, cast iron, or steel. The outer layer of a roof can comprise panels or boards constructed of timber, metal, plastic, vegetation such as bamboo stems, or other suitable materials. 
     In some cases, a pitched roof is desired to shield a space against elements such as rain or snow, while still admitting light into the space and allowing air to freely circulate through the roof and into the space. Thus, methods and systems to efficiently and reliably attach an outer skin to the supporting structure of a roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation are desired and remain a significant challenge in the design of roofing systems. 
     SUMMARY OF CERTAIN EMBODIMENTS 
     The systems, methods, and devices of the invention each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description” one will understand how the features of this invention provide advantages over other roofing systems. 
     Methods and devices for spacing panels on a roof are provided. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface; a top surface inclined at an angle α relative to the bottom surface; and an integral support structure connecting the top surface and the bottom surface. The support structure includes a plurality of support ribs and a plurality of nail boxes. 
     Another embodiment provides a method of installing roof panels on roof support beams. The method includes fastening a plurality of wedge-shaped spacers to a top surface of one or more roof support beams; and fastening a bottom surface of one or more roof panels to the spacers. 
     In yet another embodiment, a roof panel spacer system for constructing a roof is provided. The system includes a plurality of support beams; a plurality of spacers fastened to at least some of said support beams; and a plurality of roof panels fastened to the plurality of spacers. Each spacer orients each roof panel substantially horizontal to the ground. Each spacer is positioned to create a space between adjacent roof panels allowing air and light to pass through the roof. Each spacer is also positioned to create an overlap between adjacent roof panels, inhibiting rain and other weather elements from passing through the roof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a top perspective view of an embodiment of a roof panel spacer device. 
         FIG. 1B  is a bottom perspective view of the device of  FIG. 1A . 
         FIG. 1C  is a bottom elevational view of the device of  FIG. 1A . 
         FIGS. 2-7  illustrate the device of  FIG. 1A  in use on a roof. 
         FIG. 8  is a top elevational view of the device of  FIG. 1A . 
         FIG. 9A  is a side elevational view of the device of  FIG. 1A . 
         FIG. 9B  is a side elevational view of the device of  FIG. 1A  showing additional internal features. 
         FIG. 10A  is a back elevational view of the device of  FIG. 1A . 
         FIG. 10B  is a back elevational view of the device of  FIG. 1A  showing additional internal features. 
         FIG. 11A  is a bottom perspective view of another embodiment of a roof panel spacer device. 
         FIG. 11B  is a bottom elevational view of the device of  FIG. 11A . 
         FIG. 11C  is a cross-sectional view of the device of  FIG. 11A  taken along line  11 C- 11 C of  FIG. 11B . 
         FIG. 11D  is a cross sectional view of the device of  FIG. 11A  taken along line  11 D- 11 D of  FIG. 11B . 
         FIGS. 12-15  illustrate the device of  FIG. 11A  in use on a roof. 
     
    
    
     DETAILED DESCRIPTION 
     Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this description, and the knowledge of one skilled in the art. In addition, any feature or combination of features may be specifically excluded from any embodiment of the present invention. For purposes of summarizing the present invention, certain aspects, advantages, and novel features of the present invention are described herein. Of course, it is to be understood that not necessarily all such aspects, advantages, or features will be present in any particular embodiment of the present invention. 
     It is to be understood that embodiments presented herein are by way of example and not by way of limitation. The intent of the following detailed description, although discussing exemplary embodiments, is to be construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the spirit and scope of the invention. 
     Roof Panel Spacer for Two-Sided Roof 
       FIG. 1A  is a top perspective view of an embodiment of a roof panel spacer  100  according to the present invention.  FIG. 1B  is a bottom perspective view of the spacer  100 .  FIG. 1C  is a bottom elevational view of the spacer  100 . The spacer  100  generally has a width W measured along an x-axis of the spacer  100 , a length L measured along a y-axis of the spacer  100 , and a height H measured along a z-axis of the spacer  100 . The spacer  100  includes a top surface  102 ; a bottom surface  104 ; sides  106 ,  108 ; a back  110 ; and a front  112 . 
     The height H of the spacer  100  can be measured at different locations along the spacer  100 . For example, the height of the spacer  100  at the back  110  can be H BACK , while the height of the spacer  100  at the front  112  can be H FRONT . Embodiments of the spacer  100  can be wedge-shaped. For example, the top surface  102  can be inclined at an angle α relative to the bottom surface  104 . Additionally, the bottom surface  104  can be inclined at an angle β relative to the back  110 . In some aspects, the top surface  102  is oriented at an angle of 90° or about 90° relative to the back  110 . 
     The spacer  100  can include an integral support structure connecting the top surface  102  and the bottom surface  104 . The support structure can include a plurality of support ribs. For example, the spacer  100  includes width ribs  130 ,  132  extending along the width W of the spacer  100  between the sides  106 ,  108 . The spacer  100  can also comprise a length rib  134  extending along the length L of the spacer  100  between the back  110  and the front  112 . Bottom surfaces of the ribs  130 ,  132 ,  134  can form all or a portion of the bottom surface  104  of the spacer  100 . 
     In some aspects, the support structure also includes a plurality of nail boxes. For example, the spacer  100  includes nail boxes  150 ,  152 ,  154 ,  156 , which will be described in greater detail below with reference to  FIGS. 8-10B . The nail boxes can be configured to accept nails or other fasteners. Some embodiments of the nail boxes  150 ,  152 ,  154 ,  156  comprise a hollow tube extending from the top surface  102  and the bottom surface  104 . The nail boxes can be connected to the width ribs  130 ,  132  via flanges  160 ,  162 ,  164 ,  166 , respectively. The spacer  100  may also comprise a nail box  168  disposed in the length rib  134 . Other configurations are possible. For example, in some aspects, the spacer  100  may not comprise one or more of width ribs, length ribs, nail boxes, and/or flanges. 
       FIGS. 2-7  illustrate one embodiment of a spacer according to the present invention in use on a roof  268 . Referring now to  FIG. 2 , a first spacer  200  according to one embodiment is positioned between a first support beam  270  and a roofing panel or board  275 . The support beam  270  includes a top surface  272 . The panel  275  comprises a top surface  276  and a bottom surface  278 . A second spacer  200  is also positioned between a second support beam  280  and the panel  275 . The support beams  270 ,  280  can comprise portions of the support structure of a roofing system, and the panel  275  can comprise a portion of the outer skin of the roofing system. 
     A top surface  202  of the spacers  200  are adjacent to and contact the bottom surface  278  of the panel  275 , while a bottom surface  204  of the spacers  200  are adjacent to and contact the top surfaces  272  of the support beams  270 ,  280 . Other configurations are possible. For example, in another embodiment, the top surface  202  of the spacers  200  may be adjacent to the support beams  270 ,  280  and the bottom surface  204  of the spacers  200  may be adjacent to the panel  275 . 
       FIGS. 3 and 4  illustrate embodiments of the spacers  200  in use. The support beams  270 ,  280  are inclined relative to a horizontal axis x of the roof  268  by an angle θ BEAM . The panel  275  is inclined relative to the horizontal axis x of the roof  268  by an angle θ PANEL . As described above, the spacers  200  are positioned between the panel  275  and the support beams  270 ,  280 . Additional spacers  200  (not illustrated in  FIGS. 3 and 4 , but illustrated in  FIG. 5 ) are positioned between a panel  282  and the support beams  270 ,  280 . An “n” number of panels can be positioned on the support beams  270 ,  280  using the spacers  200 . Additionally, the panels  275 ,  282  can be positioned on “n” number of support beams using the spacers  200  in order to construct the roof  268 . 
     In some embodiments, the spacers  200  are positioned on the support beams  270 ,  280  such that the panels  275 ,  282  are horizontal or substantially horizontal to the ground and θ PANEL  is 0° or about 0°. The spacers  200  may be positioned on the support beams  270 ,  280  such that a vertical space  284  separates the panels  275 ,  282 . In the embodiment illustrated in  FIG. 3 , for example, each of the adjacent panels on the roof  268  are separated by the vertical space  284 . The spacers  200  can be positioned along the support beam  270  at the same or substantially the same distance intervals, such that the vertical spaces  284  separating adjacent panels are the same or substantially the same. It will be understood, however, that the vertical space  284  separating adjacent panels of the roof  268  need not be the same or substantially the same across the entire roof  268 . The vertical spaces  284  can advantageously allow for air to enter the space underneath the roof  268  and circulate within the space. Advantageously, the vertical spaces  284  can also allow light to enter the space underneath the roof  268 . 
     In some aspects, the top surface  276  of the panel  275  and the bottom surface  278  of the panel  282  overlap in a region  286 . This overlap between adjacent panels  275 ,  282  can advantageously restrict rain and other weather elements from passing through the vertical space  284  and entering the space underneath the roof  268 . For example, embodiments of spacers described herein can shield the interior of a building or other space below a roof from light rain and/or rain without horizontal wind. 
     Persons of skill in the art will understand that the spacers  200  can be used with roofs  268  of varying slope or pitch. For example, the support beams  270 ,  280  may be less sloped relative to the horizontal axis x of the roof  268  (corresponding to a smaller beam angle θ BEAM  than that illustrated in  FIGS. 2-7 ), in which case the angle α of the spacer  200  may be decreased. Similarly, the support beams  270 ,  280  may be more sloped relative to the horizontal axis x of the roof  268  (corresponding to a greater beam angle θ BEAM  than that illustrated in  FIGS. 2-7 ). In such cases, the angle α of the spacer  200  can be increased accordingly. Of course, it will be understood that beam angle θ BEAM  may not be equal to the angle α of the spacer  200 . 
       FIG. 5  illustrates a plurality of spacers  200  use on adjacent panels  275 ,  282 . For example, the panel  275  is spaced from the support beam  270  by a first spacer  200 , from the support beam  280  by a second spacer  200 , and from a support beam n BEAM  by a third spacer  200 . The panel  282  is spaced from the support beam  270  by a fourth spacer  200 , from the support beam  280  by a fifth spacer  200 , and from the support beam n BEAM  by a sixth spacer  200 . Each of the panels of the roof  268  can be spaced from the support beams in a similar manner. 
       FIG. 6  illustrates the vertical spaces  284  that can be provided between adjacent panels  275 ,  282  according to some embodiments of the present invention. As described above with reference to  FIGS. 3 and 4 , the vertical spaces  284  between adjacent panels of the roof  268  can allow air and light to enter through the roof  268 , while also preventing weather elements such as rain from entering the space below the roof  268 . 
       FIG. 7  illustrates a plurality of spacers  200  in use on the roof  268 . A spacer is provided at the interface between each panel and each supporting beam. As described above with reference to  FIG. 3 , the top surface of a first panel and the bottom surface of a second, higher panel are horizontally overlapped such that rain and other weather elements falling in a vertical direction do not enter the vertical spaces  284  and penetrate the space below the roof  268 . 
     Embodiments of the spacers  200  can advantageously be used to construct two-sided roofing structures. For example, the roof  268  illustrated in  FIGS. 2-9  comprises a first side  288  and a second side  290 . The spacers  200  are positioned between support beams and panels on the first side  288 , as well as between support beams and panels on the second side  290 . 
       FIG. 8  is a top elevational view of the spacer  100 .  FIG. 9A  is an elevational view of the side  106  of the spacer  100 , illustrating internal features in dashed lines.  FIG. 9B  is an elevational view of the side  106  showing additional internal features such as the width ribs  130 ,  132 .  FIG. 10A  is an elevational view of the back  110  of the spacer  100 , illustrating internal features in dashed lines.  FIG. 10B  is an elevational view of the back  110  illustrating additional internal features, including ribs and nail box features. 
     As described above with reference to  FIGS. 1A-1C , the spacer  100  can include nail boxes  150 ,  152 ,  154 ,  156 , and  168 . In one embodiment, the nail box  150  comprises a recessed area  151  and the nail box  152  comprises a recessed area  153 . The recessed areas  151 ,  153  can accommodate the head of a nail or other fastener disposed in nail boxes  150 ,  152 , respectively. It will be understood that other nail boxes of the spacer  100  can comprise recessed areas, and that the spacer  100  need not comprise any recessed areas around the nail boxes. 
     Referring now to  FIG. 9A , the bottom surface  104  of the spacer  100  may be inclined at an angle α relative to the top surface  102 . The angle α can be between about 10° and about 25°. In one embodiment, the angle α corresponds to the angle θ BEAM  of the support beams of the roof relative to a horizontal axis x of the roof. Where α equals θ BEAM , the top surface  276  of the panels of the roof may lie substantially horizontally on the spacers, such that the angle θ PANEL  of the panels relative to the horizontal axis x of the roof is 0° or about 0°. 
     Additionally, the bottom surface  104  can be inclined at an angle β relative to the back  110 . The angle β can be between about 80° and about 65°. In the embodiment illustrated in  FIG. 9A , angle α is about 18° and the angle β is about 72°. Other configurations are possible. For example, for a roof comprising support beams disposed at an angle θ BEAM  of 20°, the spacer  100  can be modified such that the angle α is 20° and the angle β is 70°. 
       FIGS. 10A and 10B  show additional views of the spacer  100 .  FIG. 10A  illustrates nail boxes  150 ,  152 ,  154 ,  156 ,  168 , as well as recessed areas  151 ,  153  in dashed lines.  FIG. 10B  illustrates rib  134  in dashed lines. 
       FIG. 1A  illustrates advantageous dimensions of certain specific embodiments of the spacer  100 . For example, the top surface of the spacer  100  is about 6 inches by about 4 inches; and the back  110  is about 4 inches by about 2 inches. Persons of skill in the art will understand that other dimensions are possible, and embodiments of the spacer  100  are not limited to the number or configuration of nail boxes shown, or the dimensions of spacer  100 . 
     Roof Panel Spacer for Roof with Three or More Sides 
       FIG. 11A  is a bottom perspective view of an embodiment of a roof panel spacer  1300  according to the present invention.  FIG. 11B  is a bottom elevational view of the spacer  1300 .  FIG. 11C  is a cross-sectional view taken along line  11 C- 11 C of  FIG. 11B .  FIG. 11D  is a cross-sectional view taken along line  11 D- 11 D of  FIG. 11B . Embodiments of the spacer  1300  can be used to construct roofing structures with three or more sides. 
     The spacer  1300  generally has a width W measured along an x-axis of the spacer  1300 , a length L measured along a y-axis of the spacer  1300 , and a height H measured along a z-axis of the spacer  1300 . The spacer  1300  includes a first top surface  1302 A; a second top surface  1302 B; a bottom surface  1304 ; and sides  1306 ,  1308 ,  1310 ,  1311 ,  1312 , and  1313 . In some aspects, the spacer  1300  includes a peaked top surface. 
     The height H of the spacer  1300  can be measured at different locations along the spacer  1300 . For example, the height of the spacer  1300  where the sides  1310 ,  1311  meet can be H MAX , while the height of the spacer  1300  where the sides  1308 ,  1311  meet can be H MID . Embodiments of the spacer  1300  can be wedge-shaped. For example, the top surface  1302  of the spacer  1300  may be inclined at an angle α relative to the bottom surface  1304 . The bottom surface  1304  can also be inclined by an angle β 1  relative to the intersection of the sides  1308 ,  1311 . Additionally, the bottom surface  1304  can be inclined at an angle β 2  relative to the intersection of the sides  1310 ,  1311 . 
     The spacer  1300  can include an integral support structure connecting the top surface  1302  and the bottom surface  1304 . The support structure can include a plurality of support ribs. For example, the spacer  1300  includes width ribs  1330 ,  1332  extending along the width W of the spacer  1300  between the sides  1306 ,  1308 . The spacer  100  can also comprise a length rib  1334  extending along the length L of the spacer  1300  between the sides  1310 ,  1311  and the sides  1312 ,  1313 . Bottom surfaces of the ribs  1330 ,  1332 ,  1334  can form a portion of the bottom surface  1304  of the spacer  1300 . 
     In some aspects, the support structure includes a plurality of nail boxes. For example, the spacer  1300  comprises nail boxes  1350 ,  1352 ,  1354 ,  1355 ,  1356 , and  1357 . Some embodiments of the nail boxes  1350 ,  1352 ,  1354 ,  1355 ,  1356 , and  1356  comprise a hollow tube extending from the top surface  1302  and the bottom surface  1304 . The nail boxes  1354 ,  1355  can be connected to the width rib  1331  via flanges  1360  and  1362 . Other configurations are possible. For example, in some aspects, the spacer  1300  may not comprise width ribs, length ribs, nail boxes, and/or flanges. 
     In some aspects, the nail box  1354  comprises a recessed area  1351  and the nail box  1355  comprises a recessed area  1353  (not illustrated). The recessed areas  1351 ,  1353  can accommodate the head of a nail or other fastener disposed in nail boxes  1354 ,  1355 , respectively. It will be understood that other nail boxes of the spacer  1300  can comprise recessed areas, and that the spacer  1300  need not comprise any recessed areas around the nail boxes. 
       FIGS. 12-15  illustrate this embodiment of a spacer according to the present invention in use on a roof  1468  that has three or more sides. Referring now to FIG.  12 , a spacer  1400  according to one embodiment is positioned between a support beam  1470  and a first roofing panel or board  1475 . The roof  1468  also comprises a second spacer  1400  positioned between the support beam  1470  and a second panel  1482 . The support beam  1470  includes a top surface  1472 . The panels  1475 ,  1482  each include a top surface  1476  and a bottom surface  1478 . The support beam  1470  can comprise a portion of the support structure of a roofing system, and the panels  1475 ,  1482  can comprise a portion of the outer skin of the roofing system. 
     A top surface  1402  of the spacers  1400  are adjacent to and contact the bottom surfaces  1478  of the panels  1475 ,  1482 , while a bottom surface  1404  of the spacers  1400  are adjacent to and contact the top surface  1472  of the support beam  1470 . Other configurations are possible. 
     In one embodiment of the present invention, the spacers  1400  are positioned on the support beam  1470  such that a vertical space  1484  separates the panels  1475 ,  1482 . In some aspects, each of the adjacent panels on the roof  1468  are separated by a vertical space  1484 . As described above with reference to  FIG. 3 , the vertical spaces  1484  can advantageously allow for air to enter the space underneath the roof  1468  and circulate within the space. Advantageously, the vertical spaces  1484  can also allow light to enter the space underneath the roof  1468 . 
     In some aspects, the top surface  1476  of the panel  1475  and the bottom surface  1478  of the panel  1482  overlap in a region  1486 . This overlap between adjacent panels  1475 ,  1482  can advantageously restrict rain and other weather elements from passing through the spaces  1484  and entering the space underneath the roof  1468 . 
       FIGS. 13-15  illustrate a plurality of panels spaced from the support beam  1470  by the spacers  1400 . The panel  1475  and a panel  1492  are positioned on a first spacer  1400  (not illustrated), and the panel  1482  and a panel  1494  are positioned on a second spacer  1400  (not illustrated). A third spacer  1400  is also positioned on the support beam  1470 , ready to receive panels. As described above, the spacers  1400  allow the panels  1492 ,  1494  to be advantageously separated by a vertical space  1484 . 
     Installation of Roofing Spacers 
     Embodiments of the roofing spacers described herein can be installed using fasteners such as nails. In one embodiment, a spacer according to the present invention is first positioned on a support beam. Nails are driven into one or more nail boxes of the spacer. The nails may be driven into nail boxes comprising recessed areas, for example. These nails may initially restrict movement of the spacer relative to the support beam until additional nails are driven into the spacer. Next, a panel is positioned over the spacer, and additional nails are driven through the panel into the spacer. In some aspects, the installer is aware of the general location of the nail boxes which remain empty, but is not able to see the precise location of the empty nail boxes through the panel. The installer can estimate the location of the empty nail boxes and aim the nails so that they enter the spacer at or near the empty nail boxes. 
     It will be understood by those of skill in the art that positioning nails precisely in the nail boxes is not required to install embodiments of spacers described herein. Nails and other fasteners can effectively secure the spacers to support beams, and panels to the spacers, if they are driven into the nail boxes, the ribs, and/or the flanges described herein. It will also be understood that a nail need not be driven into each nail box provided on the spacers in order to secure the spacer to a support beam, or to secure a panel to the spacer. 
     Materials for a Roofing Spacer 
     Embodiments of the spacers described herein can be made of any suitable material, including plastic or metal. In one embodiment, spacers according to the present invention are made of polypropylene copolymer. In some aspects, the comonomer of the polypropylene copolymer is ethylene. Polypropylene copolymer is characterized as having high impact resistance strength. Polypropylene copolymer also has slightly increased elongation at break, and is thus more pliable, compared to unmodified polypropylene homopolymer. Typical material properties of polypropylene copolymer are provided in Table 1 below. 
     
       
         
               
               
             
               
               
               
               
             
               
               
               
             
               
               
               
               
             
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 Property 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Yield Point 
                 24 
                 MPa 
               
             
          
           
               
                   
                 Elongation at Yield 
                 10-12% 
               
             
          
           
               
                   
                 Tensile Break 
                 33 
                 MPa 
               
             
          
           
               
                   
                 Elongation at Break 
                   650% 
               
             
          
           
               
                   
                 Tensile Modulus 
                 1050 
                 MPa 
               
               
                   
                 Flexural Modulus 
                 1270 
                 MPa 
               
               
                   
                 Flexural Strength 
                 25-26 
                 MPa 
               
               
                   
                 Tensile Impact 
                 800 
                 kJ/m2 
               
               
                   
                   
               
             
          
         
       
     
     Spacers described herein need not be made of polypropylene copolymer, and can be made of any suitable material, including but not limited to materials exhibiting material properties similar to that of polypropylene copolymer. Spacers made of polypropylene copolymer can advantageously accept fasteners without shattering or suffering other adverse structural effects which may result when a nail or other fastener is driven into the spacer. 
     Embodiments of the spacers described herein can be molded from one piece of injection-molded plastic, such that the spacer is monolithic. The spacers described herein can also be manufactured by connecting together separate components, such as the top surface, the bottom surface, the back, and the integral support structure, to form one spacer. 
     The above-described embodiments have been provided by way of example, and the present invention is not limited to these examples. Multiple variations and modifications to the disclosed embodiments will occur, to the extent not mutually exclusive, to those skilled in the art upon consideration of the foregoing description. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the disclosed embodiments.