Patent Publication Number: US-2013247480-A1

Title: Serviceable soffit vent

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of and claims the benefit of U.S. Non-Provisional Application Ser. No. 13/199,288 filed on Aug. 24, 2011. 
    
    
     FIELD OF THE INVENTION 
     The present invention is a system and device for ventilating the attic of a dwelling. More specifically, a serviceable soffit ventilator is provided having a removable and re-usable filter. 
     BACKGROUND 
     Excessive heat and moisture trapped in an attic or other space underneath the pitched roof of a structure can damage the roof, can damage the remainder of the structure and can promote mold and decay within the attic. To avoid these effects, the ambient air space between the roof and dwelling ceiling, referred to as the attic, must be constantly ventilated, and replaced with fresh contiguous outside ambient air. 
     During daylight hours, the sun shining on the roof warms the deck surface, causing the deck to become warmer than the ambient air. The warm roof deck heats the ambient air in the attic space. During the cold weather, heat and moisture from the living space migrate into the attic space which warms the air in the attic. The warm and moist air within the attic space expands, becomes buoyant and tends to rise. Because the roof is pitched, the warm and moist air stratifies, with the peak of the attic becoming warmer than the floor of the attic. This stratification of unequal temperatures during cold weather can cause a condition referred to as “ice damning”, whereby, the top of the roof absorbs the stratified heat and becomes warmer than the central and lower sections of the roof, thereby melting any accumulated ice or snow from the top of the roof ridge causing the melted ice or snow to gravitationally. 
     In addition, the enclosed attic space is vulnerable to wind gusting through roof and gable vents and entering the attic when the wind pressure is greater than the exhaust pressure of the ridge or roof exhaust vents. This condition causes loose debris, dust, insulation materials and other disturbed materials resident in the attic to become airborne and randomly relocate within the attic space. In most cases, this debris lands and stays on the attic side of the eave or soffit vent, blinding the filter component of the soffit vent and rendering said vent incapable of freely providing unrestricted necessary intake air. 
     Traditional soffit and eave intake vents have a fixed and permanent filter media or “screen” affixed to the vent housing and permanently captured between the vent housing and soffit or eave substrate. The filter component of the fixed vent is necessary to prevent unwanted insects, rodents and other detrimental debris from being drawn into the attic space either through convection, vacuum or migration. Over time, and starting immediately after the installation of traditional soffit vents, the fixed filter screen begins to become blinded by airborne organic material, including but not limited to, dust, dirt, pollen, leaves, organic material and mud. The debris is small enough in size to pass through the vent frame air openings, but large enough to become trapped in the smaller passages in the screen material, rendering the filter to be compromised, blocked and unable to deliver adequate air flow to the attic space. 
     Further, traditional methods contemplate the permanent installation of the captured soffit vent filtered housings, affixing them to the eave/soffit structure with nails, screws or adhesives with no provision for post installation removal for maintenance or service. When the fixed filter material becomes blinded from either the intake or exhaust side of the filter, physical removal of the entire vent housing is required to purge the filter and remove the debris captured in the intake or exhaust side of filter. This removal procedure normally destroys the vent housing, rendering it unusable, and damages the eave or soffit structure that the vent was affixed thereto. 
     The present invention overcomes the shortfalls of the prior art by providing a soffit vent that includes a replaceable and/or reusable filter media. In addition, the soffit vent provides a simple method for the filter media to be removed, cleaned, and re-inserted. In addition, the soffit vent of the present invention provides for additional types of inserts that can block the flow of air into the attic space in case of a fire or store scenarios, wherein restricting airflow to the attic is desired. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention, as disclosed and described herein, in one aspect thereof, is a system and device for the ventilating of an attic or other area under the roof in a new or existing dwelling. The apparatus is a soffit/eave air intake vent that is comprised of a fixed louvered frame which incorporates a separate companion filter which is removable, serviceable, and cleanable and reusable and which further mates with the fixed louvered intake vent. 
     The present invention, in one aspect, provides a user serviceable attic air intake vent that allows the user to restore the net free air flow of the soffit filter media, without the requirement of removing and replacing the affixed vent housing from the eave or soffit substrate, or the requirement to replace the soffit air vent entirely. 
     In addition, the present invention provides an attic soffit system configured to enable ventilation of a building having and attic and soffit, the system having a one piece frame component having an outer flange surrounding a corresponding opening in the dwelling&#39;s horizontal eave or soffit structure. Further, the soffit vent includes a louvered cavity frame that is formed with air intake louvers on the opposing surface to the attic enclosure opening. The soffit vent includes four sides, wherein at least one side includes a slot for inserting and removing a filter insert. A separate perforated metal filter insert is also provided which has a flat metal perforated rectangle with an extended pull-tab at one end. In addition, the vent includes a plurality of attachment holes on its perimeter for attachment and removal of the vent from a surface, such as a wall panel. 
     Further, the frame of the soffit vent is formed from one piece of galvanized steel and the filter is stamped from one piece of metal and includes more than 50% net free open surface area for the incoming air to pass into the attic space. In addition, the frame can be powder coated to insulate the metals from corrosion. Further, the device allows the user to remove, clean and reinsert the filter media. More specifically, the soffit vent of the present invention allows the user to remove the filter media without the removal of the vent frame from the structure. For example, this allows the user to clean the soffit vent insert safely away from the building with high-pressure water or air without removing the vent frame from the building, thereby protecting the structural and aesthetic integrity of the eave/soffit structure or wall panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of the serviceable soffit vent with one embodiment of a removable filter insert. 
         FIG. 2  illustrates a side view of the serviceable soffit vent with removable filter insert of  FIG. 1  illustrating an opening guide slot. 
         FIG. 3  illustrates a perspective view of the serviceable soffit vent with another embodiment of a removable solid insert. 
         FIG. 4  illustrates a perspective view of the serviceable soffit vent with another embodiment of a removable solid insert having a magnetic component. 
         FIG. 5  illustrates a side view of the serviceable soffit vent with the removable solid insert of  FIG. 4  illustrating an opening guide slot. 
         FIG. 6  illustrates a perspective view of the serviceable soffit vent of the present invention affixed to a soffit structure. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1-2  illustrate one embodiment of the serviceable soffit vent assembly  100 . Here, vent  100  includes a frame  150  having a first end  150   a  and a second end  150   b,  top end  150   c  and bottom end  150   d.  In the current embodiment, frame  150  has a rectangular configuration, however, it contemplated within the scope of the invention that frame  150  can be any size, dimension, or shape, including but not limited to a square, circle, cylindrical, oval, ellipsoid, triangular, asymmetrical, or any polygon having three or more sides. Further, frame  150  includes a plurality of fixed louvered openings  154 . In the current embodiment, there are five columns of louvers, wherein each column has  13 , thereby the vent having a total of  65  louvered air openings. However, it is contemplated within the scope of the invention that there can be any number of louvers, louvers columns, air intake openings, or any arrangement or configuration of louvers or air intake openings. In addition, ends  150   a - 150   d  of the frame form a flanged perimeter  156  with a plurality of openings  152  that allow the vent assembly  100  to be secured to an underneath surface of a roof or soffit structure  900 , as shown in  FIG. 6 . In the current embodiment, openings  152  can receive one or more threaded screws or nails to secure the vent. However, it is contemplated within the scope of the invention that any number of methods or devices can be used to secure vent  100  to the underneath surface of a roof, including but not limited to, adhesives, magnetic, straps, solder, welding, rivets, latches, snap-fit, or press-fit. 
     Still referring to  FIGS. 1-2 , on the first end  150   a  of frame  150 , an opening  158  is provided that allows the vent to receive a removable filter insert  110 . Specifically, opening  158  is a substantially rectilinear or rectangular configured slot that allows filter insert  110  to be slideably inserted and/or removed from frame  150 . However, it is contemplated within the scope of the invention that opening  158  can be of any configuration, dimension, or shape, including but not limited to ellipsoid, oval, rounded corners, mitered corners, or any polygon having three or more sides. Further, it is contemplated within the scope of the invention that opening  158  can be on either one or more of ends  150   a,    150   b,    150   c,  and  150   d.  Here, removable insert  110  can be reusable or disposable. If reusable, it can be removed, cleaned, and quickly re-inserted within the vent frame. There are many known cleaning methods within the art, such as using high-pressure water or high-pressure air to clean the filter while it is isolated from the vent frame. Hence, by incorporating a removable filter insert, a user does not need to remove and re-install a new soffit vent. Other cleaning methods can include, but are not limited, various solvents, bleach, hydrogen peroxide, soap, brushing, detergent, ultrasound, air, water, and heat. 
     Still referring to  FIGS. 1-2 , removable filter insert  110  has a substantially rectilinear or rectangular configuration. However, it is contemplated within the scope of the invention that insert  110  can be of any configuration, dimension, or shape, including but not limited to ellipsoid, oval, circular, rounded corners, mitered corners, or any polygon having three or more sides. In the current embodiment, filter insert  110  is made of galvanized steel or metal material and is stamped from one piece of metal. However, it is contemplated within the scope of the invention that any type of material can be used in lieu of steel or metal. 
     Filter insert  110  further includes a plurality of apertures, perforations, or pores  114  across its surface area that help filter incoming air flowing through the vent and into an attic space. In the current embodiment, approximately 50% of the surface area of the filter includes pores  114 . However, it is contemplated within the scope of the invention that any number of pores can be provided within insert  110 , including from 5% up to 95% of the surface area of insert  110 . In other embodiments, any number of additional layers of filtering material or filter media can be provided on the top or bottom surface of insert  110 , or in lieu of insert  110 . 
     In addition, insert  110  includes a projecting pull-tab  112  at one end of the filter with an aperture there through. Tab  112  assists the user in removing the insert from the frame. It is contemplated within the scope of the invention that in lieu of a tab, any type of mechanism can be used to assist a user from removing the filter, including but not limited to a handle, latch, nip, grip, treaded surface, hook, and ring. 
       FIG. 3  illustrates another embodiment for an insert  210 . Here, insert  210  does not include pores or apertures and is intended to block or prevent airflow from flowing through the vent and into the attic space of a dwelling. Similar in operation to insert  110 , insert  210  is removable and also slides within frame  150  via an opening on one side of the frame. Further, insert  210  can also include a projecting pull-tab  212  to assist the user in removing insert  210  from the frame. In certain emergency scenarios, such as a fire scenario within a dwelling or the attic of the dwelling, it is desired to reduce the amount of air flowing into the attic to prevent further exacerbation of the fire and further help improve the choking and/or distinguishing of the fire within the dwelling or within the attic of a dwelling. Hence, in a fire scenario, the configuration of vent  100  allows a user to quickly remove filter insert  110  from the frame  150  and replace it with insert  210 , thereby preventing fire from additionally spreading to the attic and assist distinguishing the fire by preventing additional airflow from reaching the attic space. In addition, insert  210  can also be used in storm or extreme weather or environmental situations, such as hurricanes, tornados, typhoons, floods, and environmental disasters, thereby preventing unwanted air (such as turbulent air), water, dust, snow, ice, chemicals, smoke, or other airborne debris or substances from entering the attic space. 
       FIGS. 4-5  illustrate another embodiment for an insert  310 . Here, insert  310  does not include apertures or pores and is also intended to block airflow from flowing through the vent and into an attic space of a dwelling. Similar in operation to insert  110  and insert  210 , insert  310  is removable and also slides within frame  150  via an opening on one side of the frame. Further, insert  310  can also include a projecting pull-tab  312  to assist the user in removing insert  310  from the frame. In addition, insert  310  includes two adjacent flaps  320  on each side of the insert that allow the insert to be securely fit within frame  150 . Specifically, flaps  320  are comprised of one end  322  and an opposing adjacent end  324  that protrude outwardly with respect to each other. Further, ends  322  and  324  are flexible resilient components that can pivot about one common axis. Hence, ends  322  and  324  can be bent and pressed towards each other so that when the insert is inserted within frame  150  they can provide a secure engagement and fit within the frame. Further, in another embodiment, ends  322  and  324  can also be incorporated into the insert  110  embodiment, thereby further securing insert  110  within the vent. In other embodiments, either of inserts  110 ,  210 , or  310  can include a sealing substance or material, such as a rubber or any other suitable material, affixed around the outer perimeter of the inserts, thereby providing a secure and sealed fit of the inserts within frame  150 . Further, in other embodiments, vent  100  of the present invention can be affixed to any surface of a dwelling, including but not limited to the soffit structure, soffit at rake, soffit at eave, underneath surface of a roof, wall panel, fascia, pipes, or any other suitable area of a dwelling. In addition, a dwelling can include any number of soffit vents  100  affixed to its structure. 
     It will be apparent to those skilled in the art that various modifications and variations can be made in the serviceable soffit vent apparatus. For example, it is contemplated within the scope of the invention that one or more of frame  150 , filter  110 , insert  210 , and insert  310 , or all, can be made from one of more of: plastics, thermoplastics, thermosetting polymers, polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, polypropylene, polystyrene, polycarbonate, polylactide, fiberglass, glass-reinforced plastic, epoxy derived, polyester derived, steel, aluminum, antimony, arsenic, barium, beryllium, bismuth, boron, bronze, cadmium, cesium, chromium, cobalt, copper, gallium, germanium, iridium, iron, lead, lithium, magnesium, manganese, molybdenum, nickel, rhodium, osmium, ruthenium, rhenium, rubidium, scandium, selenium, strontium, tantalum, tellurium, thallium, thorium, tin, titanium, tungsten, vanadium, zinc, and zirconium, fabrics, cotton, polyester, aramid, nylon, olefin fiber, carbon fiber, acrylic, non-woven fibers, activated carbon, antimicrobial, yarn, and ceramic. In addition, it is contemplated within the scope of the invention that any type of manufacturing method can be used to manufacture one or more of frame  150 , filter  110 , insert  210 , and insert  310 , or all, including but not limited, to centrifugal casting, continuous casting, die casting, evaporative-pattern casting, investment casting, lost wax casting, low pressure casting, permanent mold casting, plastic mold casting, resin casting, sand casting, shell molding, slush or slurry casting, spray forming, powder metallurgy, metal injection molding, injection, compression molding, transfer molding, extrusion molding, blow molding, dip molding, rotational molding, thermoforming, laminating, foam, shrink fitting, shrink wrapping, end tube forming, forging, rolling, cold rolling, hot rolling, sheet metal rolling, impact extrusion, hemming, shearing, piercing, stamping, coining, ironing, flattening, swaging, spinning, peening, magnetic pulse, explosive forming, staking, flanging, hot metal gas forming, curling, machining, milling, turning, lathe, facing, boring, spinning, knurling, hard turning, drilling, reaming, countersinking, tapping, sawing, broaching, shaping, planing, honing, finishing, abrasive blasting, buffing, burnishing, electroplating, etching, plating, polishing, wire brushing, ultrasonic machining, electrical discharge, electron beam machining, electrochemical machining, chemical, laser cutting, grinding, gashing, welding, arc welding, plasma arc, carbon arc, gas tunsgsten, plasma-MIG, plasma arc, butt welding, spot welding, shot welding, seam welding, solid state welding, friction weld, cold weld, forge weld, electron beam weld, brazing, soldering, adhesive bonding, epoxy bonding, thermoplastic bonding, polyurethane bonding, adhesive alloy bonding, riveting, nuts, bolts, screwing, nailing, pinning, stitching, stapling, press fitting, and three dimensional printing. 
     It will also be apparent to those skilled in the art that while a method of inserting the filter within the vent is specified, the specific order is not required. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims.