Patent Publication Number: US-2003233800-A1

Title: Elevated batten system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
     [0001] This application is a continuation application of pending application Ser. No. 09/653,116, which was filed on Aug. 31, 2000. Through application Ser. No. 09/653,116, the present application claims the full benefit and priority to provisional U.S. Application No. 60/151,642, filed Aug. 31, 1999. The entirety of both applications noted above is incorporated into the present invention. 
    
    
     
       FIELD OF THE INVENTION  
       [0002] The present invention relates generally to roofing, and particularly relates to a system for installing tile roofing.  
       BACKGROUND OF THE INVENTION  
       [0003] Tile roofing has been around for thousands of years continues to be the most common roofing material used throughout the world. Since tile installations predate the introduction of plywood by centuries, it is noteworthy that, except in America where tile is a relative newcomer, most tile roofs are installed on open spaced sheathing. Most commonly, the tiles are attached to 2″×2″ battens that are spaced in accordance with the size of the tile. In some cases a draped underlayment or sarking system may be installed over the rafters prior to batten installation but often times the tiles themselves are that stand-alone roof system.  
       [0004] This method of installation has worked well for hundreds of years due to the fact that the roofs are installed in such a manner that the water is prevented from entering through the tile assembly. By sealing all hips, ridges, and walls with proper flashing materials and directing water off the roof, tile roofs provide trouble free service for decades.  
       [0005] Since most of the roofs in America are installed over solid roof sheathing, tile installations have been modified to suit the culture. While tile roofs installed over solid decking can be made to work, this application creates a number of problems that do not occur with tile roofs over spaced sheathing. One method of tile application that works well over solid roof decks and provides the advantages of old world installations is the counterbatten system.  
       [0006] Counterbatten systems are created by installing wood strips in vertical direction up the roof on 16 or 24 inches on center and then fastening the horizontal or anchor battens directly through these vertical battens. The size of these batten strips will vary according to spacing and load factors but the minimum dimensions are typically ⅜ inch thick for the vertical strips and nominal 1 by 3 inch for the horizontals. Nominal 1 by 2 inch battens are usually avoided for these applications and should never by used if the vertical strips are spaced greater than 16 inches on center.  
       [0007] Counterbatten or strapping systems provide an effective, long lasting method of roof tile installation. Elevating the anchor battens and tiles above the roof surface optimizes most aspects of the tile roof installation. Any concern about wind-driven rain is diminished because any water beneath the tile can course off the roof without encountering resistance from battens or tile. By preventing water ponding, all components of the system can be expected to last longer and perform better. Nail penetrations are minimized and those nails that do not penetrate the underlayment are less likely to ever by exposed to water since they only penetrate the vertical strips that run parallel to water flow.  
       [0008] This method has long been the standard for low slope installations and tile installations in regions subject to severe winter weather but provide significant advantage to tile installations universally.  
       [0009] The air space between the roof deck and the installed tile forms a highly effective thermal barrier that ventilates and cools in hot climates and helps prevent ice dams in cold regions. The strapping system optimizes this effect in both cases. In recent thermal studies performed by the Florida Department of Energy, it was shown that a typical tile roof installation reduces ceiling level heat flux by 38% compared to the same roof with a black asphalt shingle. With the counterbatten system that figure jumps to 48% reduction.  
       [0010] In cold weather regions, a major cause of ice damming is the heat lost through the roof that melts snow on the surface that runs down and freezes when it reaches the eaves. With the counterbatten system under the tile roof, even if attic ventilation is ineffective, the air space beneath the tile is usually sufficient to dissipate the heat before it is able to melt the snow.  
       [0011] Attention should be paid to flashing and edge treatments since the thickness of the vertical batten must be considered to maintain an even plane and proper flow pattern. Additional nailer boards and edge metals will usually be required at rake edges. For full details on counterbatten installations, please refer to the WSRCA/NTRMA Design Criteria Manual for Cold and Snow Regions.  
       [0012] Although such counterbatten systems include advantages, disadvantages still exist, and there is always room for improvement.  
       SUMMARY OF THE INVENTION  
       [0013] The present invention overcomes deficiencies in the prior art by providing an improved batten system which includes an improved installation technique as well as improved operating characteristics due to the provision of a preassembled batten assembly.  
       [0014] Generally described, the present invention provides an elevated batten assembly for use atop a roof supporting surface and for supporting tiles above the roof supporting surface, the elevated batten assembly comprising an elongate horizontal batten strip having an underside for generally facing the roof supporting surface, and a plurality of support pads spaced apart and attached to the underside of the batten strip, the support pads configured to be located between the batten strip and the supporting roof surface, and also configured to contact the roof supporting surface and to support the batten strip above the roof supporting surface.  
       [0015] Therefore it is an object of the present invention to provide an improved roofing system.  
       [0016] It is a further object of the present invention to provide an improved roofing system which is easy to install.  
       [0017] It is a further object of the present invention to provide an improved roofing system which is easy to manufacture.  
       [0018] It is a further object of the present invention to provide an improved roofing system which is reliable in operation.  
       [0019] It is a further object of the present invention to provide an improved roofing system which is easy to transport prior to installation.  
       [0020] Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of the preferred embodiment of the invention when taken in conjunction with the drawing and the appended claims. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0021]FIG. 1 is a side elevational view of an elevated batten assembly  10  according to the present invention, which includes a length of lumber  12  and a plurality of discrete, spaced apart, plywood pads  14  attached to the underside of the length of lumber  12 .  
     [0022]FIGS. 2A and 2B are related. FIG. 2A is a lower plan view of the elevated batten assembly  10  according to the present invention, which includes a length of lumber  12  and a plurality of plywood pads  14  attached to the underside of the length of lumber  12 . FIG. 2B shows the flow of water  13  (shown by the use of two lines  13 ) around and exemplary pad. Options #1 and #2 show slightly different pad locations, with no functional differences claimed or known.  
     [0023]FIG. 3 is an illustrative view showing one set of dimensions of the length of lumber  12 , namely dimension A which is two and one-half inches, and dimension B which is three-quarters inches.  
     [0024]FIG. 4 is an illustrative view showing one set of dimensions of plywood pads  14 , namely dimension C which is one and one-half inches, and dimension D which is two and one-half inches.  
     [0025]FIG. 5 is a pictorial view showing the outline of an exemplary group of tiles  100  as they would be installed atop the installed batten assemblies  10 , shown installed atop an exemplary roof surface  200 . This view is looking up the roof surface (viewing from beneath the crest of the roof).  
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0026] The elevated batten system according to the present invention is a one-step version compared to the prior art systems described above. The prior art method of installing a counterbatten system requires that the roofer start by attaching the vertical strips (typically ⅜ inch lath) at 12-inch to 24-inch on center depending on the size of the horizontal batten to be used. Once the vertical strips are in place, the prior art horizontal battens are then attached to the vertical strips at increments determined by the tile coursing layout, usually at 13 to 14 inch spacing. The tiles are attached to the batten strips in a conventional manner.  
     [0027] The elevated batten system according to the present invention is designed to eliminate the need to install the vertical and horizontal battens in separate steps. By pre-attaching ⅜ inch thick blocks  14  to the underside of the horizontal battens  12  at the lumber mill or other assembly facility, the function of the vertical strips is contained in the resulting batten assembly  10  itself. The 2-inch square blocks  14  made from ⅜ inch plywood are attached at 16-inch increments to the 1-inch by 3-inch battens  12  with stapling, glue, or other suitable means prior to bundling at the production source. The elevated batten system according to the present invention may then be installed similarly to normal batten installation but will provide additional advantages.  
     [0028] The elevated batten system according to the present invention includes various features and benefits. The horizontal battens  14  are made of 1″×3″ nominal lumber in standard lengths of 8 feet (2.44 m). Lengths other than standard (8 feet lengths) may be special ordered. However the standard 1″×2″ batten that represents the current standard can also be used. It is a universal piece that can be used with any profile of tile and in a variety of load conditions. The battens can be untreated or can be treated with pressure treating or other weather resistant properties as desired. 1″×3″ lumber is generally straighter and less apt to warp than 1″×2″. This makes it more practical to consider aligning the battens with coursing marks rather than having to chalk lines for guidance.  
     [0029] The plywood blocks  14  (a.k.a. “pads”), which in one embodiment measure 1¾″×1¾″×⅜″, are attached by mechanical attachment (e.g., stapling, screws or nails), adhesion (e.g., glue), or other suitable means to one side of the horizontal batten  14  at selected distances on center (e.g., 12 inches on center, 16 inches on center, 24 inches on center, or other selected distances on center). The thickness of the pads serve to elevate the batten above the roof deck and provide adequate support to prevent deflection. The elevation of the battens  12  allows for water to pass freely beneath the batten. This prevents damming that can typically result in roof leaks or premature deterioration of the felt, batten and fasteners. These pads can be subjected to moisture treatment as desired prior to attachment.  
     [0030] The blocks  14  are aligned onto the batten in a diagonal direction as shown in FIG. 2B to minimize water resistance. The blocks can also be 1 inch square or other dimensions as desired, and can be made from a variety of suitable materials, including wood, rubber, plastic, or recycled material.  
     [0031] Alignment of the support blocks  14  is such that each end represents a “male” or “female” configuration, which allows for solid support at each end of adjoining battens, and at the same time allows for improved stacking as a male-female pair may be stacked with their respective block sides cofacing, with the blocks nesting between each other in an alternating fashion. The batten assemblies  10  can be aligned and bundled with plastic strapping, 12 battens per bundle which provides fastening for approximately one square (100 sq. ft.) of roofing tile.  
     CONCLUSION  
     [0032] Therefore it may be seen that the present invention overcomes deficiencies in the prior art by providing an improved batten assembly which includes improved performance, reduces assembly time of the battens at the construction site, and allows for adjustability of the system to meet particular site installation needs.  
     [0033] While this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims.