Abstract:
A baffled roll vent for covering the ridge slot of a roof for allowing ventilation from the space of a building below the ridge slot, the baffled roll vent having a first vent section having a male part and a second vent section having a female part, wherein the male part of the first vent section attaches to the female part of the second vent section. The male and female parts are preferably located at opposite edges of each vent section, allowing each vent section in the baffled roll vent to attach to the next vent section in the baffled roll vent. A center hinge allows flexing of the panel to conform to the pitch of a roof.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
     This application is a continuation-in-part of U.S. patent application Ser. No. 11/069,127, filed Mar. 1, 2005 now U.S. Pat. No. 7,537,518. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to vents for covering an opening at a peak of a roof. More particularly, the invention relates to baffled roll vents comprised of a unitary panel capable of rolling into a coil configuration prior to installation, and capable of unfolding to lay flat on the roof ridge at installation. 
     2. Background 
     Vents for attics of residential or commercial buildings are commonly perforated or have baffled openings in the underside of the eaves of an overhanging roof or fascia and on the roof ridge overlaying the open roof along the length of the roof. The vent openings allow air to flow into the attic to equalize the interior attic temperature and pressure with that of the outside environment. The equalization helps to control attic temperature and reduces the accumulation of condensation in the attic thereby increasing the efficiency of heating and cooling of the living space in the building covered by the roof structure. 
     A roof ridge ventilator overlays a roof ridge slot along the length of the roof. The roof ventilator is for exhausting air from the space below the roof and above the floor of the attic. 
     Ventilation systems should provide against insects and other unwanted elements entering the attic space of buildings. While larger perforations in soffit and roof ridge ventilation panels produce a desired flow of air through the attic space, they also allow ingress to insects. In addition to having good ventilation of the attic space and preventing ingress of water, snow and insects into the attic space, ventilation systems should have structural strength and stability to withstand the effects of the elements, including high wind; strong structural support against collapse or warping, such as might occur by the accumulation of snow or ice or by weight of the installers accidentally stepping on the roof ridge ventilator; ease of installation; and low costs. 
     The present invention is directed to roof ridge vents that preferably are used in conjunction with an adequate soffit ventilator of the prior art. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a baffled roll vent is provided that is manufactured from flexible polymer compounds. The vent is spirally rollable for easy handling and installation. The baffled roll vent is for covering the ridge of a roof having an opening therein or ridge slot providing for the flow of air from the space below the roof ridge to the outside environment while preventing entry of water and other unwanted elements. 
     The ridge vent preferably comprises a unitary plastic panel that is disposed over the ridge of the roof covering the ridge slot as well as overlapping portions of the roof shingles adjacent to the ridge slot. The plastic panel may not be integrally unitary but instead may comprise substantially fluid tight hinges connecting partitions into a unitary piece. 
     The panel is flexible and can be contoured to roofs having from 0 degree to 45 degree slope at the peak or more. The panel can be contoured at a center line where a hinge is incorporated. Also a hinge may be incorporated at two parallel lines spaced from the central point line running longitudinally of the panel. These hinges provide flexibility in the panel. The panel has a topside or surface facing the exterior and an opposite, underside or surface facing the attic space. The underside is reinforced by supports spaced throughout the length of the panel. Preferably, the underside also comprises rain baffles, also called weather blocks, located at points where precipitation or particulate may enter the ridge slot. 
     The vent of the present invention comprises a unitary panel defined by a length and width. The vent preferably has projections located at the length sides that can be joined to another succeeding length. The width terminates at external baffles at either end of the width. A center hinge located substantially at the topside and preferably integral with the panel divides the panel longitudinally. The center hinge is preferably embossed onto the unitary panel. 
     Louver portions at the width ends can comprise rows of slots and slats running parallel to each other in transverse direction to the length of the partition. However, the louvers can be in a parallel direction to the length of the partition or in any other configuration that provides for the desired ventilation. The louver portions are discrete and independent to each partition defined by side baffle walls and an external baffle. 
     At the underside, located substantially at the internal end of the louver portion and on or adjacent to the side baffle walls, can be rain baffles. These rain baffles substantially prevent precipitation and particulate from infiltrating the vent. The underside also comprises multiple supports to reinforce the vent. The supports preferably have a nail boss for driving a nail through. Every number of supports, the number of which is predetermined prior to manufacture, preferably has a support peg and no nail boss. The nail boss can be adapted for use with a nail gun and can be countersunk from the topside. 
     Further, a baffled roll vent for covering a roof ridge slot is provided, the baffled roll vent comprising a first vent section having a male part and a second vent section having a female part, wherein the male part of the first vent section attaches to the female part of the second vent section. 
     The installation of the baffled roll vent comprises the steps of placing the spirally rolled baffled roll vent on the ridge of a roof with a ridge slot, uncoiling the baffled roll vent over the ridge slot, adjusting the position of the baffled roll vent so that the center hinge is substantially centered over the ridge slot, flexing from the center hinge the baffled roll vent downward so that side edges of the baffled roll vent substantially conform to the roof slope and tiles or shingles adjacent to the ridge slot, and fixing the baffled roll vent to the roof. Preferably, the vent is fixed by nailing through the nail bosses of the underside supports. 
     To completely cover the ridge slot at the peak of the roof, additional baffled roll vents can be used as needed and placed end-to-end with the previously installed baffled roll vent. The baffled roll vent preferably can be cut with known cutting implements to any desired length. 
     At the beginning and end of each panel, are weather flaps and melt tabs for aligning and joining the panel with a succeeding section. 
     Additionally, the baffled roll vent can be installed by placing a fibrous mat along the roof ridge parallel with the ridge slot so that the lower portion of the baffled roll vent covers the fibrous mat. The use of the fibrous mat prevents small particles from entering into the attic space through the slots of the louver. The fibrous mat can also be integrated with the baffled roll vent by known methods. Another method of installing the baffled roll vent for covering the ridge of a roof is provided, the method comprising providing a baffled roll vent comprising two or more vent sections, each vent section having one or more male part(s) and one or more female part(s), the male part(s) of one vent section being attached to the female part(s) of a next vent section in the baffled roll vent, positioning the baffled roll vent in a spirally-rolled configuration onto an end of a roof ridge, and detaching one vent section from the next vent section by detaching the one or more male part(s) of the one vent section from the one or more female part(s) of the next vent section. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a baffled spirally rolled vent embodying the present invention; 
         FIG. 2  is a perspective view of the baffled roll vent in a straight, unrolled configuration; 
         FIG. 3   a  is a top plan view of the baffled roll vent in a straight, unrolled configuration; 
         FIG. 3   b  is an underside plan view of the baffled roll vent in a straight, unrolled configuration; 
         FIG. 4  is a top plan view of the baffled roll vent in a straight, unrolled configuration; 
         FIG. 5  is a second underside plan view of the baffled roll vent as a single panel in a straight unrolled configuration; 
         FIGS. 6   a - 6   d  are detailed underside plan views of embodiments of the baffled roll vent; 
         FIG. 7  is a cross-sectional view of the baffled roll vent installed on a roof ridge; and  FIG. 8  is a cross-sectional view of the baffled roll vent and an end cap installed on the roof ridge; 
         FIG. 9  is an isolated view of the baffled roll vent adapted for use with a nail gun; 
         FIG. 10  is a plan view of a further embodiment of the baffled roll vent of the present invention; 
         FIG. 11  is a top perspective view of the baffled roll vent; and 
         FIG. 12  is a bottom plan view of the baffled roll vent. 
         FIG. 13  is an underside plan view of a vent section of the baffled roll vent in a straight unrolled configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of the baffled roll vent of the present invention, generally designated by the numeral  100 , in a spirally-rolled configuration made from a water proof, flexible material, preferably of polymers that include, but are not limited to, natural and synthetic rubbers, polyester, polystyrene, polyethylene, high impact styrene and copolymers and/or blends thereof. 
     In  FIGS. 1 and 2  the baffled roll vent  100  comprises a topside  60  and an underside  80 . The vent preferably comprises a unitary panel  82 . The panel comprises a center hinge  70  that is preferably soft and located at or near the topside  60  but can be located substantially at the underside  80 . The hinge  70  offers resistance that provides for bending pressure easily produced by a user to effectively bend the vent to coincide with the slope of the roof. However, the hinge  70  substantially retains its memory so that upon release of the external force they substantially return to their original shape or configuration. The center hinge  70  is preferably embossed onto the topside  60  of the panel. 
     As best seen in  FIG. 2 , each panel is preferably of an elongated rectangular configuration defined by length  72 , width  74 , and height  76  from underside  80  to topside  60 . The size of the length  72  is preferably from about 2 feet to 20 feet, and most preferably from about 4 feet to 5 feet, while the width  74  is from about 5 inches to 15 inches, preferably 7 inches to 13 inches, and most preferably from 8 inches to 12 inches. The length  72  terminates at length end edges  84 . The width  74  terminates at discrete and independent louver portions  370  comprising an external baffle  260  and side baffles  320 . 
     As shown in  FIGS. 3A and 3B , the length edges  84  can be butt welded or molded together in succeeding sections or the panels may be indexed in a continuous operation to form preferably 5 feet to 40 feet continuous lengths and most preferably 20-25 foot lengths. These lengths are spirally rolled for packaging and shipping.  FIG. 2  additionally shows the length end edges  84  with melt tabs  114 . The length end edge  84  comprises the edge of the unitary panel  82  as well as an end barrier  116  that depends downward from the unitary panel  82 . The end barrier  116  is broken or split the length of its height at the center hinge  70 , to provide flexibility and coverage when fixing the vent to the slope of the roof. The end barrier  116  substantially prevents precipitation and particulate from getting under the vent from the length ends. 
     The louver portions  370  are each discrete from the other and comprise side baffles  320 , the external baffle  260 , and slats  380 . The width of the louver portion  370  is preferably about 1 inch to 4 inches, and most preferably about 2-3 inches measured from end baffle  260  to the end of the slats  380 . The length is preferably about 0.25″ to 3″, and most preferably about 1″ to 2″ measured from side baffle to side baffle. The side baffles  320  have a height of preferably about 0.5 inches to 2 inches or equal to the height of the partition  120 . 
     The louver portion  370  preferably can have tapered side baffles  320  and external baffle  260  that gradually decrease in width from the topside  60  towards the underside  80  to help facilitate removal from molds during manufacturing if the vent is molded. 
     The slats  380  of the louver portion  370  preferably extend from side baffle to side baffle and are provided from the underside  80  to the topside  60  at an angle of preferably about 15° to 95°, and most preferably about 30° to 45°. The slats  380  provide for the ventilation of gases and moisture from below the roof ridge. 
       FIG. 5  is a plan view of the underside  80  of  FIG. 4 .  FIG. 5  shows the underside  80  of the baffled roll vent panel that faces the ridge slot and space below the vent. Multiple supports  90  are used to prevent sagging or collapse of the vent and provide for adequate air circulation from the ridge slot to the outside environment. These supports  90  are preferably “I” or “Y” shaped braces but are not limited to such shapes. Every several support  90  can have a nail boss  92  at its end closest to the louver portion  370 , which is a passage through a support from the topside  60  to the underside  80 . The nail boss  92  provides support and housing for a nail that can be used to fix the vent to a roof. The nail may be preinserted into the nail boss  92  from the topside  60  prior to installation. Pegs  94  may also be placed on a support  90  for additional support. Pegs  94  may further act as rain baffles for blocking rain and other elements from entering under the roll vent. 
     The nail boss  92  may also be adapted to receive a nail from a nail gun as shown in  FIG. 9 . This embodiment can provide for a countersunk or recessed nail hole at the topside  60 . Preferably, the recessed area substantially conforms to accept the base (where the nail exits the gun) of most commercially available nail guns. Also preferably, the recessed area has a tapered side that provides for the base of the nail gun to slide into the area. Opposite the tapered side is a substantially vertical wall that stops the sliding of the nail gun and aligns the base at the intended position on the vent. Beneath the recessed area is the nail boss, which in this embodiment is preferably reinforced compared to a non-nail gun embodiment. The reinforcement provides for crush resistance and nail support. 
     The embodiment shown in  FIG. 9  shows the recessed area as thickened section of the unitary panel. This can be accomplished by molding a recessed area onto the unitary panel rather than incorporating the recessed area directly into the unitary panel. This type of thickened nailing zone provides for greater holding power of cap shingle nails that in turn provides for more securely attaching the cap shingles to the roof. The thickened plastic area will offer greater holding strength on the nail shank than the more thin area of the top unitary panel. There will be more surface area (thickness) of the top panel on the nail shank which helps to hold the nail in conjunction with the tip of the nail embedded into the plywood decking. 
       FIG. 5  also shows drain holes  96  that can be placed in the length end edges  84  providing for drainage of precipitation accumulating under the vent  100 . Preferably, the underside can comprise weather flaps that provide additional support and edge closure for when a length is cut to size at installation. To provide for the desired rolled configuration, the weather flaps can be straight flaps  100  from the external baffle  200  to the center hinge  70  opposite left and right cornered flaps  102 ,  104  respectively. Also, the weather flaps can comprise rain baffles. 
       FIG. 6   a  shows overlapping rectangular and “L” shaped rain baffles integral with the side baffle walls. These rain baffles substantially prevent precipitation and particulates from entering the ridge slot. Further embodiments of rain baffles are shown in  FIGS. 6   b - 6   d .  FIG. 6   b  shows a single rain baffle  111  blocking the passage formed between side baffle walls.  FIG. 6   c  shows an “L” shaped baffle along with a peg baffle  112  that works in conjunction to substantially prevent the flow of rain.  FIG. 6   d  shows two overlapping pegs  113 . These and other rain baffle embodiments are made possible in the present invention. 
       FIG. 7  is a cross-sectional view of the baffled roll vent installed on a roof ridge. The baffled roll vent  100  is described in relation to a sloped roof covered with roof tiles  440  and  440 ′ overlapping each other. The tiles  440 ,  440 ′ direct the flow of precipitation from the roof ridge downward. The sloped roof comprises a ridge board  460  to which the rafters are attached (not shown); plywood or some other decking or sheathing  480  and  480 ′; and roof tiles or shingles  440  and  440 ′ laid over the sheathing. The plywood decking  480 ,  480 ′ and covering roof tiles  440 ,  440 ′ do not completely cover the roof. At the ridge of the roof there is a ridge slot  500  that serves as an exit for air from the attic space  520  or any space under the ridge slot. The ridge slot  500  defines a space at the peak of the roof so that the air below can be vented to the outside. While the ridge slot  500  provides for ventilation of this space, it also allows entry of rain, snow, insects and debris to enter into the space. To prevent such entry, the ridge vent covers the ridge slot  500  and overlaps the plywood deck and tiles of the roof. The overlap helps ensure that precipitation and other elements do not enter the attic space. The baffled roll vent  100  is secured to the ridge board and/or roof deck by roofing nails, adhesives or other appropriate securing means known in the art. 
     The baffled roll vent  100  is preferably used with a mat of fibrous material  540  and  540 ′ that can be of randomly oriented synthetic, air-permeable fibers with varying mesh sizes. The synthetic fibers, such as made by nylon and polyester are randomly aligned into a web. The thickness of the mat typically is of from about 0.5 to 3 inches. The air-permeable mat  540 ,  540 ′ can be cut into strips the length and width of which is determined by the length and width of the baffled roll vent for which the strip is used. The mat  540 ,  540 ′ can be placed on roof tiles  440  and  440 ′ and underneath louver portion  370 . Alternatively, the mat  540 ,  540 ′ may be integrated to the baffled roll vent  100  during manufacture or post-manufacture by any known method including, but not limited to, adhesively fixing, using burrs or by hooking the mat with hooks integral with the baffled roll vent  100 . 
     The process of installing the baffled roll vent  100  includes the steps of placing the spirally-rolled vent  100  over the ridge slot  500  of the roof ridge; uncoiling the baffled roll vent  100  on the ridge slot  500  of the ridge; flexing the baffled roll vent at a center hinge to conform to the roof; and fixing the baffled roll vent  100  to the roof. Nails, screws, hooks, rivets or adhesives or any other known method can fix the baffled roll vent  100  to the roof. Further, a fibrous mat  540 ,  540 ′ can be placed along the roof ridge adjacent to the ridge slot  500  prior to placing the spirally rolled vent  100  over the ridge slot  500 . 
     An end cap  560  can cover the baffled roll vent as shown in  FIG. 8 . The end cap  560  is fixed to the roof over the baffled roll vent  100  with traditional means including, but not limited to, nails, screws or adhesives. 
     In  FIG. 10  a side view shows the present-invention with a raised baffle area  600  relative to the center portion  610  of the unitary panel. The top perspective view of this embodiment is depicted in  FIG. 11 . In this embodiment the louver portions  670  begin at a greater height  676  and extend downwards to be substantially level with the bottom of the end barrier  616 . At the inside edge  602  of the louver portions  670 , the unitary panel  604  slopes downward toward the center of the panel. This creates the raised baffle area  600  including the, louver portions  670  and the sloping portion of the unitary panel  604  and a lower center portion of the unitary panel  610 . The panel may have a center hinge allowing it to flex in conformity to the slope of a roof ridge. 
     By creating a lower center portion and raised baffle area the invention is able to increase the net free area of the vent. “Net Free Area” or NFA means the cross-sectional area of a ventilator system which is open for passage of air there through. This embodiment also provides for better application with a nail gun. The lower center portion is preferably ⅝ inches in height providing for a fastener from a nail gun to fully penetrate into the roofing substrates below the vent. 
     The unitary panel  604  extends laterally between the louver portions  670  and is integral with the external baffle  606 . This creates discreet but semi-independent louver portions substantially enclosed by the unitary panel  604 . The end baffle  606  is preferably a unitary baffle extending the length of the panel. Side baffles  612  extend downward from the unitary panel  604  between the louver portions  670  at a length substantially equal to the panel&#39;s height. 
     The underside of the invention may be of the embodiment partially shown in  FIG. 12 . This figure shows multiple supports  620  extending downward from the unitary panel  604  that may be “I” or “Y” shaped but are not limited to such shapes. These supports may have nail holes but in this embodiment they do not. Instead, this embodiment has independent support pegs  622  that may act as a nail boss. The independent support pegs  622  also can act as weather blocks. The multiple supports  620  do not extend to the louver portion  670  and generally end at or within the sloping portion. 
     The side baffles  612  are shown in  FIG. 12  depending from the unitary panel  604  and fixed to the slats  624  of the louver portions  670 . Also shown in  FIG. 12  are connecting means for connecting a series of vent panels to each other. 
       FIG. 13  is another type of plan view of an underside  80  of a baffled roll vent  100  of the present invention.  FIG. 13  shows a vent section  750  of the baffled roll vent panel  100 . Several vent sections  750  can make up the entire baffled roll vent  100 . Similar to  FIG. 5 , multiple supports  90  can be used to prevent sagging or collapse of the vent and provide for adequate air circulation from the ridge slot to the outside environment, and can be “I” or “Y” shaped braces but are not limited to such shapes. Every several support  90  can have a nail boss  92  at its end closest to the louver portion  370 , which is a passage through a support from the topside  60  to the underside  80 . The nail boss  92  provides support and housing for a nail that can be used to fix the vent to a roof. The nail may be preinserted into the nail boss  92  from the topside  60  prior to installation. Pegs  94  may also be placed on a support  90  for additional support. Pegs  94  may further act as rain baffles for blocking rain and other elements from entering under the roll vent. 
     Further,  FIG. 13  shows a male interlock part  700  located on an edge  720  of vent section  750  and a female interlock part  710  located at an edge  730  of vent section  750 . Preferably, as seen in  FIG. 13 , two male interlock parts  700  are used on an upper side of edge  720  and two male interlock parts  700  are used on a lower side of edge  720 . Similarly, two female interlock parts  710  are used on an upper side of edge  730  and two female interlock parts  710  are used on a lower side of edge  730 . These male and female interlock parts  700  and  710 , respectively, are each placed substantially in the same location with respect to the width  74  on opposite edges  720  and  730  of vent section  750 . 
     Preferably, male interlock parts  700  protrude from the edge  720  of vent section  750 , and female interlock parts  710  are cut into or built into the edge  730  of vent section  750 . As shown, the male interlock parts  700  are t-shaped and of a peg structure, and the female parts  710  are shaped as receptacles, but they are not limited to such structures. The shape of the male interlock parts  700  can be t-shaped, peg shaped, oval shaped, square shaped, round shaped, and the female interlock parts  710  will have a structure corresponding to or accommodating the male interlock parts  700 , such as appropriate openings or receptacles. Any other type of geometry known for male-female connectors can be used and is not limited to the above. The shape of the male and female interlock parts are also designed so that it is easy to separate the vent sections  750  from each other, as well as to attach the vent sections  750  to each other. 
     In this manner, when each separate vent section  750  is rolled to form the baffled roll vent  100 , the male interlock parts  700  of one vent section  750  line up with the female interlock parts  710  of another vent section  750 , and lock together in place to keep the baffled roll vent  100  together. 
     As seen in  FIG. 13 , four male interlock parts  700  are used and four female interlock parts  710  are used. However, one male and female structure may be used, and more than four male and female structures may be used on each vent section  750 , depending on the width  74  of the vent panel and the stability required. However many are used, they are preferably placed in a substantially equal interval on the edges  720  and  730  along the width  74  of the vent section  750 . 
     More male interlock parts  700  and corresponding female interlock parts  710  can be used to provide more stability, with consideration given to cost, design, ease of manufacture and installation, etc. Such a structure of a baffled roll vent  100  provides a baffled roll vent that does not have to be cut or separated by the manufacturer or installer, but can be attached and/or broken into separate vent sections  750 . No tools or cutting equipment are required. 
     Accordingly, it should be readily appreciated that the device and method of the present invention has many practical applications. Additionally, although the preferred embodiments have been illustrated and described, it will be obvious to those skilled in the art that various modifications can be made without departing from the spirit and scope of this invention. Such modifications are to be considered as included in the following claims.