Patent Publication Number: US-7901278-B2

Title: Hybrid metal-plastic roof vent

Description:
CLAIM FOR PRIORITY 
     This application claims the priority benefit under 35 U.S.C. §119(e) of Provisional Application Ser. No. 60/709,856, filed Aug. 20, 2005. The full disclosure of this priority application is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to roof vents, and more particularly for vents adapted for use on a tile roof. 
     2. Description of the Related Art 
     Known systems for venting roofs employ vents that are substantially formed of a single material. Some roof-vents are formed substantially of plastic, which is inexpensive and highly impact resistant, but degrades relatively easily when exposed to rain, snow, and the sun. In particular, the cover of a roof-vent is continually exposed to the elements and may degrade more rapidly than the rest of the vent. Other roof-vents are formed substantially of metal, which is more resistant to the elements but is expensive and susceptible to rust, denting, and other damage during transport and installation. 
     Some buildings include “stack vents” (i.e., pipes or ducts) with lower ends terminating in rooms likely to have higher pollutant levels, such as kitchens, bathrooms, and laundry rooms, and upper ends extending vertically through the roof. These stack vents are also sometimes referred to as “soil vents.” The stack vent typically extends upward through the ceiling of the room and eventually through the roof of the building, terminating at an upper open end. The stack vent typically also extends upward through other rooms and/or an attic of the building. 
     The prior art teaches roof-vents that can connect with various sizes of stack vents. Examples of such vents include U.S. Pat. No. 4,399,743 to Izzi, Sr. and U.S. Pat No. 5,081,914 to Mejia. Izzi and Mejia teach structures that are integral with a vent cap and which have fittings of a few discrete sizes for receiving a few different sizes of stack vents. These arrangements preclude connection of the vent to stack vents having sizes other than those conceived in the original design. The prior art also discloses roof vents that reside and blend in with a roof, while connecting directly to the upper end of a stack vent. For example, U.K. Patent Application Publication No. 2 317 947 A to Hensey et al. discloses a covert roof ventilator manufactured by rotation molding from plastics material and provided with an upper wall of shape complementary to roof tiles and an apertured lower wall. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect, a vent for a roof is provided comprising: a first member substantially formed of a metal or alloy; a second member substantially formed of a plastic material and having at least one opening; and an air-conveying connector configured to attach to an underside of the second member and in fluid communication with the opening. The first member is adapted to be positioned within and exposed at an upper surface of a roof. The second member is configured to attach to and be positioned below and spaced apart from the first member to define a ventilation gap therebetween. The at least one opening is covered by the first member when the first and second members are attached to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member when the first and second members are installed within a roof. A lower air-conveying portion of the connector is configured to connect with an air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. 
     In accordance with another aspect, a vent for a tile roof is provided comprising a body formed substantially of a plastic material and a cover formed substantially of a metal or alloy. The body has an opening. The cover substantially covers the body. The cover and the body have a gap therebetween. The gap is in fluid communication with a region above the cover. The gap and the opening are together configured to permit airflow between the region above the cover and a region below the opening. The body and cover are adapted to be positioned in a roof such that the cover is exposed at an upper surface of the roof. 
     In accordance with another aspect, a method of ventilating a building is provided. The method comprises providing an air conduit having a lower end terminating within a building and an upper end terminating below and proximate to a roof having a layer of tiles. A first vent member is provided within the tile layer. The first member is substantially formed of a metal or an alloy. A second vent member substantially formed of a plastic material is provided. The second member is positioned below and spaced apart from the first member to define a ventilation gap therebetween. The second member has at least one opening that is covered by the first member to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member. An air-conveying connector is attached to an underside of the second member and in fluid communication with the opening. A lower air-conveying portion of the connector is connected with the upper end of the air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. 
     In accordance with another aspect, a vent for a roof is provided comprising a first member adapted to be positioned within and exposed at an upper surface of a roof; a second member configured to attach to and be positioned below and spaced apart from the first member to define a ventilation gap therebetween and having at least one opening; and an air-conveying connector configured to attach to an underside of the second member and in fluid communication with the opening. The at least one opening is covered by the first member when the first and second members are attached to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member when the first and second members are installed within a roof. A lower air-conveying portion of the connector is configured to connect with an air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. The first member and second member are releasably connected to each other to facilitate selective attachment and detachment of the first and second members while the second member remains installed on a roof. 
     In accordance with another aspect, a method of ventilating a building is provided. The method comprises providing an air conduit having a lower end terminating within a building and an upper end terminating below and proximate to a roof having a tile layer. A first vent member is then provided within the tile layer. A second vent member is positioned below and spaced apart from the first member to define a ventilation gap therebetween. The second member has at least one opening that is covered by the first member to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member. An air-conveying connector is attached to an underside of the second member and in fluid communication with the opening. A lower air-conveying portion of the connector is connected with the upper end of the air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. The first and second members are releasably connected together to facilitate selective attachment and detachment of the first and second members while the second member remains installed on the roof. 
     In accordance with another aspect, a vent for a roof is provided comprising: a first member adapted to be positioned within and exposed at an upper surface of a roof; a second member configured to attach to and be positioned below and spaced apart from the first member to define a ventilation gap therebetween and having at least one opening; and a plurality of air-conveying connectors each configured to attach to a lower fitting of the second member and be in fluid communication with the opening. The at least one opening is covered by the first member when the first and second members are attached to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member when the first and second members are installed within a roof. Only one of the connectors is able to attach to the lower fitting at a time. A lower air-conveying portion of each connector is configured to connect with an air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. The lower portions of the connectors have different sizes and/or shapes to be compatible with a plurality of different sizes and/or shapes of air conduits. 
     In accordance with another aspect, a method of ventilating a building is provided. The method comprises providing a stack vent having a lower end terminating within the building and an upper end terminating below and proximate to a roof having a layer of tiles. Then, a first vent member is provided within the tile layer. A second vent member is positioned below and spaced apart from the first member to define a ventilation gap therebetween. The second member has at least one opening that is covered by the first member to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member. A plurality of air-conveying connectors is provided. Each of the air-conveying connectors is configured to attach to a lower fitting of the second member and be in fluid communication with the opening. Only one of the connectors is able to attach to the lower fitting at a time. A lower air-conveying portion of each connector is configured to connect with an air conduit to allow airflow from the air conduit upward through the connector, the opening, and the ventilation gap. The lower portions of the connectors have different sizes and/or shapes to be compatible with a plurality of sizes and/or shapes of air conduits. One of the connectors is selected. The selected connector has a lower air-conveying portion configured to connect with and fluidly communicate with the upper end of the stack vent. The selected connector is attached to the lower fitting of the second member in fluid communication with the opening. The lower portion of the selected connector is connected to the upper end of the stack vent. 
     In accordance with another aspect, a vent for a roof is provided comprising: a first member adapted to be positioned within and exposed at an upper surface of a roof; a second member configured to attach to and be positioned below and spaced apart from the first member to define a ventilation gap therebetween, and having at least one opening; an air-conveying connector configured to attach to an underside of the second member and in fluid communication with the opening and having a lower fitting; and a plurality of air-conveying adapters each having an upper end configured to connect with and convey air into the lower fitting of the connector. The opening is covered by the first member when the first and second members are attached to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member when the first and second members are installed within a roof. Each adapter has a lower end configured to connect with and receive air from an upper end of an air conduit to allow airflow from the air conduit upward through the adapter, the connector, the opening, and the ventilation gap. Only one of the adapters is able to connect with the lower fitting at a time. The lower ends of the adapters having different sizes and/or shapes to be compatible with a plurality of different sizes and/or shapes of air conduits. 
     In accordance with yet another aspect, a method of ventilating a building is provided. The method comprises providing a stack vent having a lower end terminating within the building and an upper end terminating below and proximate to a roof having a layer of tiles. A first vent member is provided within the tile layer. A second vent member is provided below and spaced apart from the first member to define a ventilation gap therebetween. The second member has at least one opening that is covered by the first member to substantially prevent rain from entering the opening. The ventilation gap is in fluid communication with an area above the first member. An air-conveying connector is attached to an underside of the second member and in fluid communication with the opening. The connector has a lower fitting. A plurality of air-conveying adapters are provided, each having an upper end configured to connect with and convey air into the lower fitting of the connector. Each adapter has a lower end configured to connect with and receive air from an upper end of an air conduit to allow airflow from the air conduit upward through the adapter, the connector, the opening, and the ventilation gap. Only one of the adapters is able to connect with the lower fitting at a time. The lower ends of the adapters have different sizes and/or shapes to be compatible with a plurality of different sizes and/or shapes of air conduits. One of the adapters is selected such that the selected adapter has a lower end configured to connect with and fluidly communicate with the upper end of the stack vent. The selected adapter is attached to the lower fitting of the connector in fluid communication with the opening. The lower end of the selected adapter is connected to the upper end of the stack vent. 
     For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
     All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a building with a tile roof having roof vents according to one embodiment of the invention; 
         FIG. 2  is a top perspective view of a vent according to one embodiment of the invention; 
         FIG. 3  is a bottom perspective view of the vent of  FIG. 2  viewed from below; 
         FIG. 4  is an exploded top perspective view of the vent of  FIG. 2 ; 
         FIG. 5  is a bottom perspective view of the vent of  FIG. 2  with the stack vent connector removed; 
         FIG. 6A  is a side view of the stack vent connector of the vent of  FIG. 2 ; 
         FIG. 6B  is a front view of the stack vent connector of the vent of  FIG. 2 ; 
         FIG. 6C  is a top view of the stack vent connector of the vent of  FIG. 2 ; 
         FIG. 7A  is a top view of the vent of  FIG. 2 ; 
         FIG. 7B  is a front view of the vent of  FIG. 2 ; 
         FIG. 7C  is a side view of the vent of  FIG. 2 ; 
         FIG. 8  is an exploded top perspective view of a connection of a stack vent connector to a stack vent through an adapter according to one embodiment of the invention; and 
         FIG. 9  is a cross-sectional view of a tile roof with a vent connected to a stack vent according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     One aspect of the invention provides a roof vent including a metallic cover and a plastic body. A metal is typically more resistant to the elements than a plastic material. On the other hand, the latter is less expensive than the former and does not rust. Since the cover is more exposed to the elements than the intermediate member, the combination of a metallic cover and a plastic body enhances the lifetime of the roof vent while reducing the overall manufacturing cost. Another aspect of the invention provides a cover releasably connected to the remainder of the vent body, which allows replacing a damaged cover while re-using an undamaged vent body. Yet another aspect of the invention provides modularity of connectors and adapters, which allows a standardized roof vent to fit various sizes and configurations of stack vents. 
       FIG. 1  shows a building  1  with a roof  2  according to one embodiment. The roof  2  comprises two fields  3   a  and  3   b  that are joined at their upper ends to define a ridge  4 . Lower edges  5  of the fields are referred to as “eaves.” The fields  3   a  and  3   b  that comprise a roof supporting structure (not shown) covered with tiles  9  (e.g., clay or concrete). The roof typically comprises rafters, a deck on top of the rafters, battens, and the tiles  9 . 
     The building  1  also includes a living space  6  which typically requires ventilation. Examples of such living space include, but are not limited to, a restroom, a kitchen, a bedroom, a dining room, a living room, and a basement. In certain embodiments, drains or soil pipes of the building  1  may also require ventilation. 
     Such a living space  6  or drains may be provided with an active or passive ventilation system. The illustrated ventilation system is of an active type. The ventilation system includes a fan  7 , a stack vent  8 , and a roof vent  10 . It will be understood that a passive ventilation system would not employ any fans  7 . The fan  7  generates airflow from the living space  6  through the stack vent  8  to the roof vent  10 . The stack vent  8  provides an air conduit between the living space  6  and the roof vent  8 . The stack vent  8  may comprise a pipe, a flexible tube, hose, or a combination of two or more of the foregoing. In another embodiment, the fan  7  may be omitted and the stack vent  8  may terminate below the ceiling of the living space  6 . Skilled artisans will appreciate that the configuration of the ventilation system may vary depending on ventilation needs and building designs. Also, skilled artisans will appreciate that the roof vent  10  may be provided in a wide variety of different types of roofs, including those not having ridges or sloped fields. Additional vents may be provided on different parts of the field  3   a  and,  3   b  that, depending on the ventilation needs of the building  1 . 
       FIGS. 2-4  show a vent  10  comprising a stack vent connector  12 , an intermediate member  14 , and a cover  16 . The vent  10  is preferably designed to conform to the profile of a tile roof. Accordingly, the intermediate member  14  and the cover  16  are preferably shaped like the tiles of a tile roof. A wide variety of shapes and sizes of the intermediate member  14  and the cover  16  are possible, depending upon the type of tiles employed in the tile roof. 
     Referring to  FIG. 4 , the intermediate member  14  is substantially formed of a plastic material. Examples of the plastic material include, but are not limited to, polyvinyl chloride (PVC), polyethylene, polypropylene, and polyurethane. The intermediate member  14  includes a central section  18  that permits airflow through the intermediate member  14 . The central section  18  can be a single large opening. The opening may be covered by a screen to prevent entry of insects, vermin, and debris larger than the screen openings. Alternatively, the central section  18  may comprise a plurality of small openings in the body of the intermediate member  14  or in a separate piece assembled with the body of the intermediate member  14 . The intermediate member  14  may also include one or more baffles configured to prevent water from entering the central section  18 , such as an upstanding baffle wall  19  surrounding the central section  18 . The baffle wall  19  is configured to prevent ingress of water into the opening(s) of the central section  18 . The intermediate member  14  also includes four spacer tubes  20 , described in detail below. A storm clip  22  is secured to the underside of the intermediate member  14  at an opening  24 . The storm clip  22  is configured to receive the upper end of an immediately lower tile for the purpose of restraining the tiles against winds. 
     The cover  16  is substantially formed of a metallic material. Examples of the metallic material include, but are not limited to, steel, galvanized steel, aluminum, and copper. Other metallic materials suitable to withstand various weather conditions may also be used. The cover  16  preferably has substantially the same profile as the intermediate member  14 . The cover  16  includes openings  26  configured to align with the spacer tubes  20 . The cover  16  also includes snap-lock members  28  configured to extend through the openings  26  into the spacer tubes  20 , to thereby engage the intermediate member  14  and the cover  16  in a spaced relationship. The number and size of the spacer tubes  20 , openings  26 , and snap-lock members  28  can vary. Additionally, other fastening means can be used within the scope of the invention. In a preferred embodiment, the snap-lock members  28  are configured to detach from the spacer tubes  20 , so that the cover  16  can be selectively attached and detached from the intermediate member  14 . 
     In certain embodiments, the spacer tubes  20  may be replaced by spacer elements configured to serve as baffles to further prevent ingress of water into the opening(s) of the central section  18 . Such spacer elements may be of various shapes depending on the configurations of the cover  16  and the intermediate member  14 . The spacer elements may also be shaped to direct airflow between the cover  16  and the intermediate member  14 . For example, the spacer elements may be horizontally elongated such that winds blowing into the ventilation gap  15  of the vent  10  do not directly reach the central section  18 . This configuration further deflects rain from entering the opening(s) of the central section  18 . It will be appreciated that in any of the embodiments described above, each of the spacer tubes  20  or other spacer elements may be attached to either the cover  16  or the intermediate member  14 . It will be also appreciated that the shapes of the spacer tubes  20  or other spacer elements can vary widely depending on the baffling needs and/or configurations of the cover  16  and the intermediate member  14 . 
     The cover  16  includes a central portion  30  positioned over the central section  18  of the intermediate member  14 . The central portion  30  does not include any openings, thereby covering the central section  18  and limiting the ingress of rain and other debris down through the central section  18 . The cover  16  includes wing portions  32  having openings  34 . 
     The stack vent connector  12  is formed of a plastic material. Preferably, the stack vent connector  12  is formed of the same material as that of the intermediate member  14 . It comprises a lower (e.g., tubular) portion  46  and an upper fitting  47  configured to connect to the underside of the intermediate member  14 . As shown in  FIG. 5 , the underside of the central section  18  of the intermediate member  14  includes a lower fitting  36  for connection to the upper fitting  47  of the stack vent connector  12 . This connection can optionally be substantially air-tight and preferably allows selective attachment and detachment of the stack vent connector  12  and intermediate member  14 . 
     In the illustrated embodiment, the lower fitting  36  comprises a rectangular flange  38  having two elongated tracks or grooves  40 . As shown in  FIG. 4 , the upper fitting  47  comprises a rectangular flange  42  having two elongated tongues  44  configured to slide into the tracks  40 . The lower portion  46  is configured to connect with, receive, or be received within the upper end of a stack vent. The lower portion  46  can have surface grooves  48  for more securely receiving a flexible tube-type stack vent. The illustrated lower portion  46  is tubular, but other shapes are possible within the scope of the invention. 
     Stack vent connectors  12  can be provided in different sizes and types to facilitate the connection of the vent  10  to stack vents of different sizes and types. Each connector  12  can have a standard fitting (e.g., upper fitting  47 ) for connection to the fitting (e.g., lower fitting  36 ) on the underside of the central section  18  of the intermediate member  14 . Skilled artisans will recognize that a wide variety of different types of fittings are possible for connecting the stack vent connector  12  to the intermediate member  14 . 
     The lower portions  46  of the different connectors  12  can connect to interchangeable adapters. In some embodiments, the adapters may be integral with the lower portion  46  so that different connectors  12  can integrally include adapters of varying sizes to facilitate connection to a variety of different stack vents. Alternatively, the lower portion  46  can have a standard size, with an additional adapter being provided between the stack vent and the connector  12 . Such adapters may be provided in a variety of sizes to facilitate connection with a variety of different sizes and types of stack vents. The adapters may be configured to provide a sealed connection between the stack vent and the connector  12 .  FIG. 8  shows one embodiment of an adapter  50 . The adapter  50  includes an upper opening  54  that receives the lower portion  46  of the stack vent connector  12 , and a lower opening  56  in a portion  58  received within a stack vent  52 . Other types of adapters  50  are possible within the scope of the invention. 
     In use, air flows up through the stack vent, into the connector  12 , through the central section  18  of the intermediate member  14 , and then around the edges of the cover  16  and/or through the openings  34 . In certain embodiments, a gap  15  between the cover  16  and the intermediate member  14  defines a ventilation gap to the outside. The ventilation gap is in ventilating communication with the stack vent through the connector  12 , and thus permits airflow therebetween. In such embodiments, the cover  16  may have a downwardly depending baffle or flange at its lower edge. The flange may be configured to allow airflow underneath it to ventilation gap while preventing ingress of rain or snow. Note that the vent  10  can be used with a manifold so that multiple stack vents terminate at the single vent  10 . 
       FIG. 9  illustrates a cross-sectional view of a roof  100  having a roof vent according to one embodiment. The illustrated roof  100  includes a roof supporting structure  101 , a layer of tiles  109 , a roof vent  110 , and a stack vent  108 . 
     The illustrated roof supporting structure  101  comprises rafters  102 , a roof deck  103  over the rafters  102 , and optionally battens  104  over the roof deck  103 . The rafters  102  extend substantially perpendicular to a ridge and an eave (not shown) of the roof  100 . The rafters  102  run substantially parallel to one another. The rafters  102  may be formed of, without limitation, a metal or wood. The roof deck  103  is directly supported on the rafters  102 . The roof deck  103  is typically formed of plywood or sheet metal. The battens  104  extend substantially perpendicular to the rafters  102 , and run substantially parallel to one another. In other embodiments, at least one of the rafters  102 , the roof deck  103 , and the battens  104  may be omitted or replaced with a different roof supporting element. It will be appreciated that the roof supporting structure  101  can have various other configurations depending on the design of the roof. 
     The layer of tiles  109  is mounted over the roof supporting structure  101 . The illustrated tile layer  109  resides directly on the battens  104 . The tiles may be formed of, without limitation, clay, a metal, or a plastic material. In the illustrated embodiment, a lower end of a tile  109  lies on an upper end of an immediately lower tile. An upper end of the tile  109  directly resides on one of the battens  104  while supporting a lower end of an immediately upper tile directly thereon. 
     The roof vent  110  is positioned within the layer of tiles  109 . The roof vent  110  comprises a cover  116 , an intermediate member  114 , and a stack vent connector  112 . The configurations of the foregoing elements can be as described above with respect to the roof vent  10 . 
     As shown in  FIG. 9 , the cover  116  and intermediate member  114  of the roof vent  110  are positioned between immediately lower and upper tiles  109   b ,  109   c . In addition, the cover  116  and intermediate member  114  are interposed between two horizontally neighboring tiles (not shown). The roof vent  110  can advantageously be mounted on the roof supporting structure  101  in a manner substantially the same as that in which the tiles  109   a - 109   d  are mounted. 
     The stack vent connector  112  includes an upper fitting  147  and a lower tubular portion  146 . The upper fitting  147  is positioned between the intermediate member  114  of the roof vent  110  and the roof deck  103 . The lower portion  146  extends from the upper fitting  147  to below the roof deck  103 . 
     The stack vent  108  extends from a living space or drain of the building to immediately below the roof deck  103 . The illustrated stack vent  108  includes a flexible tube  108   a  and a pipe  108   b  connected to each other. The upper end of the flexible tube  108   a  is connected to the lower portion  146  of the connector  112 . In certain embodiments, the stack vent  108  may extend through the roof deck  103 . In such embodiments, the stack vent  108  may be connected to the connector  112  in or above the roof deck  103 . A skilled artisan will appreciate that the configuration and position of the stack vent  108  and connector  112  can vary depending on the ventilation needs and the roof design. 
     Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.