Patent Publication Number: US-11649635-B2

Title: Roof vent with secure attachment mechanisms

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of, and claims priority to, U.S. patent application Ser. No. 16/676,897 filed Nov. 7, 2019 titled ROOF VENT WITH SECURE ATTACHMENT MECHANISMS, the disclosures of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to vents for covering openings on roofs. More particularly, the invention relates to vents that cover openings on metal roofs, preventing moisture and objects from entering the opening while allowing air to pass therethrough. The vents disclosed herein also prevent moisture from entering the building through openings that can be created when the vents are attached to a roof. The vents include a cap, a collar, and a flashing configured to contact the roof. The vents can also include a screen placed between the cap and the collar. The collar can have arms formed on an upper portion thereof to facilitate connection of the collar to the cap. Feet can be formed on a bottom portion of the collar. Once the vent is fully assembled, the feet can be positioned underneath the flashing and can be the main connection point of the vent to a roof. 
     BACKGROUND 
     Vents are often used on roofs, both commercial and residential, to release indoor steam and other gases to the atmosphere. Some examples are vents for agricultural and industrial buildings, bathroom vents, laundry room exhaust vents, and kitchen range vents. These vents may include a cap; a screen to prevent rain, insects, and other pests from entering the vent; and a flashing to interface with the roof. Various materials are used to form such vents, including various plastics, metals, and rubber materials. Securely attaching such vents to a metal roof presents several challenges. For example, the attachment method must be secure enough to withstand wind and other environmental factors. More problematic, the vent must be attached to the roof in a manner that prevents moisture, etc., from entering the building through the points at which the vent is secured to the roof. 
     Pre-existing roof vents designed for shingle roof applications are difficult to install on metal roofs and perform poorly when they are installed because they are designed to integrate with a shingle roof system. In a shingle roof system, a portion of the vent is installed underneath roofing shingles. Pre-existing adapters allow these shingle-roof vents to be installed on a metal roof, but the adapters are large and create an unsightly appearance with their expanded footprint on top of the decorative metal roof. These adapter flashings are also expensive and can drive up the cost of the project. In fact, such adapters can also cost much more than the vent itself. 
     Pre-existing vents designed for metal roof applications do not have a means of securely fastening the vent directly to the metal roof or the roof deck. Instead, the vents attach to a penetration through a roof, such as an exhaust vent pipe. Therefore, there is no way to securely fasten the vent over an opening in the roof deck without such penetrating members present. More specifically, preexisting vents designed for metal roofing do not attach to the structure of the roof itself. Instead, the vent is designed to attach to the protruding end of a pipe. Some vents do include a flashing made of an elastomeric material which is also fastened to the surface of the roof, but, again, the main structure of the vent is not attached to the roof surface. Because such flashings are usually made of a flexible elastomeric material, they do not provide any structure or support. It is solely used to cover the opening in the roof through which a pipe or similar penetration could pass. Due to the lack of structural stability in this design, such vents are unstable on top of a roof and can potentially even be torn away from the roof in windy conditions. Even if the vent does not detach from the roof, vents attached to a roof only by their rubber flashings will move around significantly on windy days and can be damaged over time from that movement. 
     SUMMARY 
     The present invention resolves the several problems associated with prior roof vents. The vents described herein include features that allow the more rigid main structure of the vent to be attached directly to a metal roof. Specifically, a collar of the vent is formed with feet that attach directly to a metal roof. The collar extends through the flashing, which is also attached to the metal roof Arms are provided on an upper portion of the collar, and a cap or top of the vent is attached to the arms, thereby creating a substantially rigid attachment from the cap to the metal roof attachment point. The present invention therefore provides a vent for a metal roof that attaches more securely to the roof, and is therefore more durable, while eliminating the need for special adapters to modify existing shingle roof vents for use on a metal roof. The vents described herein therefore lower installation time and cost while providing a more secure and weather resistant attachment to a roof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a side view of a roof vent according to the present invention; 
         FIG.  2    is an exploded side view of the roof vent of  FIG.  1   ; 
         FIG.  3    is an exploded top view of the roof vent of  FIG.  1   ; 
         FIG.  4    is an exploded bottom view of the roof vent of  FIG.  1   ; 
         FIG.  5    is a is an exploded side view of another roof vent according to the present invention; 
         FIG.  6    is a side view of the roof vent of  FIG.  5   , fully assembled. 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  1    shows a vent for a roof, preferably a metal roof. Vent  100  covers openings on a metal roof and prevents moisture from entering through the opening on the metal roof. As shown in  FIG.  1   , vent  100  includes a cap  102  that covers the top of the vent. Cap  102  can be formed of a variety of metals or other materials. For example, cap  102  can be formed of plastic, nylon, aluminum, steel, or various other rigid materials. Slits  103  can be formed in cap  102 . As described herein, slits can allow for more efficient airflow through vent  100 , although primary airflow through vent  100  occurs through the bottom of cap  102  between cap  102  and collar  104 . Cap  102  can also be formed without slits  103 . Although slits  103  as shown in  FIG.  1    are in a rectangular shape, it is understood that slits  103  can be formed in a variety of shapes, including circular, square, etc. More or fewer slits can also be used depending on desired supplemental airflow. 
     Underneath the cap  102  is a collar  104  that extends between the cap  102  and the neck  107  of flashing  106 . Neck  107  and flashing  106  can be formed as a single unit, preferably of one piece of rubber. As shown in  FIG.  1   , flashing  106  is flat except for neck  107 . Flashing  106  and neck  107  can be formed from an elastomeric material, for example silicone, neoprene, or ethylene propylene diene monomer (EPDM). Neck  107  can be formed of the same piece of material as flashing  106 , or can be formed separately and then attached to the main body of flashing  106 . Forming flashing  106  with a large generally flat section can provide a more weather-tight seal against a roof. However, flashing  106  and neck  107  can be formed of a single unit that is a cone shaped instead of having the flat flashing  106  with a neck  107  extending therefrom. That is, the entire flashing  106  could be in a general conical shape. Flashing  106  can also be formed with a larger conical section while still preserving a sufficiently sized flat portion to insure a weather-tight seal to a roof. 
     As will be explained in further detail with respect to other figures, vent  100  shown in  FIG.  1    is designed to be attached to a pitched roof. As visible in  FIG.  1   , collar  104  has a first height towards the lower edge  108  of vent  100  and has a second height which is smaller than the first height towards the upper edge  110  of vent  100 . This design allows cap  102  to be generally parallel relative to the ground while flashing  106  is flush against the surface of the pitched metal roof. As will be described herein in further detail, vent  100  can also be formed with a collar that has a uniform or near uniform height around its circumference. It is also understood that the height of collar  104  at lower edge  108  and upper edge  110  can be adjusted to match roofs having a variety of pitches such that, whatever the pitch of a roof, cap  102  is flat or generally flat relative to the ground. While the vents herein are described with reference to metal roofs, for which they are particularly suited, it is understood that aspects of the vents described herein can be used in shingle and flat roof applications where more secure attachment methods are desired. Moreover, the vents shown in  FIGS.  1 - 5    show vertical lines around the perimeter of the vent collars and necks. Those lines merely represent the curvature of the collars and necks. The collars and flashing necks of the vents depicted in  FIG.  105    preferably have a smooth perimeter surface, such that when viewing an assembled vent there are no breaks or sharp bends. However, it is understood that it would be possible to form the curvature of the collars with a plurality of small bends instead of a smooth curvature, in which case the collar could have vertical lines as depicted in the figures. And, while the flashing necks are generally constructed from an elastomeric material, lines could be formed on the perimeter of flashing necks according to the present invention for aesthetic purposes or to add rigidity to the flashing necks. 
       FIG.  2    shows an exploded side view of vent  100 . As with  FIG.  1   ,  FIG.  2    shows cap  102  with optional slits  103 . Screen  201  is also shown in  FIG.  2   . Screen  201  was not shown in  FIG.  1    but can be placed between cap  102  and collar  104 . Screen  201  is preferably formed of a metal material such as a galvanized mesh metal. Screen  201  could also be formed of a variety of other materials that can withstand the environment of an outdoor metal roof, for example, various plastics, nylon, metals, rubbers, or fibrous materials such as fiberglass or even some plant based fibers such as rope, twine, or hemp could be used (metal screen is preferred). Screen  201  prevents animals, bugs, and other objects from entering under the cap  102  and through the collar  104 , and thereby prevents those animals, bugs, and other objects from entering in the building on which the vent  100  is placed. Screen  201  can be placed flush against the top portion  202  of collar  104 . Screen  201  is shown in a generally square shape, but it is understood that screen  201  could be formed in a round shape to match the outline of the top  202  of collar  104 . Whether screen  201  is a square, circular, or other shape, it can extend to the end of arms  203  or can extend only around the top portion  202  of collar  204 . Screen  201  could also wrap down around the outside of collar  104  to provide a secure attachment to collar  104 . 
     Also shown in  FIG.  2    is a more detailed rendering of collar  104 . As shown in  FIG.  2   , collar  104  has a top portion  202  and a bottom portion  204 . A plurality of arms  203  extend from the top portion  202  of collar  104 . Because of the angle of the illustration in  FIG.  2   , only two arms  203  are shown, but it is understood that any number of arms could be used to achieve the goals of the invention. For example, a single large arm could be used, or more preferably three or four arms could be used to provide a solid base to which cap  102  can be attached. Collar  104  can also be formed with one or more feet  205 . As with arms  203 , any number of feet  205  can be formed to extend from the bottom portion  204  of collar  104 . As described in more detail with respect to other figures, four feet can be formed to provide secure attachment to a metal roof around the circumference of the vent. When assembled, the feet can be configured such that each foot extends toward one of four corners of the generally rectangular or square shaped flashing. Flashing  106  can be formed in a variety of other shapes, including round, rectangular, or with multiple sides. Whatever the shape of flashing chosen, the feet  205  can be of a sufficient length to extend outward past the point where the cap  102  ends such that the feet  205  can be easily attached to the roof. 
       FIG.  2    also illustrates the built-in pitch of collar  104 , which is designed to allow the vent  100  to be used on a pitched roof while maintaining a generally level cap  102 . As seen in  FIG.  2   , a lower portion  207  of collar  104  has a height between the top portion  202  of collar  104  and the bottom portion  204  of collar  104  that is higher than the height between top  202  and bottom  204  of the collar  104  at an upper portion  210  of the collar  104 . As described with respect to  FIG.  1   , this increased height at lower portion  207  of collar  104  is placed on the downslope of the roof on which vent  104  is placed. As a result, the top portion  202  of collar  104  is generally flat when compared to a ground plane, and cap  102  is also generally flat relative to the ground. Forming vent  100  such that, when installed, the cap  102  is generally parallel with a ground plane can reduce the risk of moisture from blowing into the vent while increasing airflow through the vent when compared with vents in which the cap is parallel with the roof slope after installation. The flashing  106  lays flat on the pitched metal roof to provide sufficient contact surface for weatherproofing. For a lower profile appearance, vent  100  can be formed such that cap  102  is generally parallel to the roof when vent  100  is installed. 
       FIG.  2    also shows flashing  106  and collar  107 , which is attached to flashing  106 . Flashing  106  and neck  107  can be formed of the same material as one unit. Flashing  106  and neck  107  can also be formed in a conical shape instead of having a flat base with a neck extending therefrom, as shown in  FIG.  2   . Flashing  106  and neck  107  can be formed of an elastomeric material such as silicone rubber, EPDM, or any other substance with similar properties. 
       FIG.  3    illustrates an exploded top perspective view of vent  100 . As can be seen in  FIG.  3   , vent  100  includes all components referred to in  FIG.  1    and  FIG.  2   .  FIG.  3    shows vent  100  with four arms  203 . Each arm  203  includes a protrusion  206  extending down at approximately a right angle towards flashing  106 , while these protrusions  206  are shown at a right angle it is understood that other angles can be used. Protrusions  206  allow cap  102  to be secured to the protrusions  206  while the under-surface of the cap  102  is spaced above the top portion  202  of collar  104 . Spacing the under-surface of cap  102  above the top portion  202  of collar  104  allows air to exit the vent between the cap and the collar. As discussed previously, screen  201  prevents debris, small animals, and bugs from accessing the opening in the top portion  202  of collar  104 . Feet  205  of collar  104  are designed to attach directly to a metal roof or to the roof deck if the metal roof panel has been cut away. 
     Flashing  106  and neck  107 , which can be formed of a rubber material, are stretchable. 
     During assembly, feet  205  are placed through neck  107  and under flashing  106 . Neck  107  of flashing  106  rests securely around the circumference of collar  104 . The entire vent assembly  100  can then be attached to the metal roof simply by attaching feet  205  to the roof. The cap and screen are secured to the collar  104 , and the feet  205  of collar  104  are secured to the roof. Neck  107  of flashing  106  is held in place by chemical bonding against collar  104 . Silicone caulk, liquid rubber, or other similar substances can also be used around the edges of flashing  106  to provide additional attachment strength and weatherproofing. Vent  100  can be preassembled, sold, and delivered to customers in the form shown in  FIG.  1   . To attach vent  100  to a metal roof, the feet  205 , which have already been placed fully through neck  107  such that they are underneath flashing  106  while collar  104  protrudes from neck  107 , are attached directly to the metal roof or roof deck. After attaching feet  205  to metal roof or roof deck, the flashing  106  can be brought down to cover the feet  205  and fastened to the metal roof by means of screws penetrating the flashing through a reinforcement material around the outer perimeter of the flashing  106 . Although not shown in the figures, the reinforcement material can be a rigid or semi-rigid material, such as a metal or rigid or semi-rigid plastic. The reinforcement material assists in keeping flashing flat against the roof as it can be formed to match the contours of a metal roof panel. 
       FIG.  4    is a bottom exploded perspective view of vent  100 . As can be seen in  FIG.  4   , cap  102  includes lips  401 . The lips  401  fit over protrusions  206  of arms  203  and are attached thereto. Also, as seen in  FIG.  4   , collar  104  includes four feet  205 , although as described herein fewer or more feet could be used to secure the vent  100  to a roof. 
       FIG.  5    shows a roof vent  500  that is designed to have a low profile which is situated approximately parallel to the plane of the roof no matter the pitch. Roof vent  500  is largely identical to roof vent  100  as described with respect to  FIGS.  1 - 4   , except that the collar  504  for roof vent  500  has a uniform or generally uniform height around its circumference. As a result, as shown in  FIG.  6   , when roof vent  500  is attached to a flat roof, cap  102  is generally parallel to the surface of the metal roof. While not shown in  FIG.  5   , vent  500  can also be provided with a screen as shows in  FIGS.  2 - 4   . 
     Systems, methods and apparatus are provided herein. References to “preferred embodiments,” “another embodiment,” “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art how to implement the disclosure in alternative embodiments. 
     Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element is intended to invoke 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.