Abstract:
A ridge vent comprising a pair of opposing vent parts each fabricated from a plurality of stacked, interconnected layers of a corrugated plastic sheet material and a top panel extending between and connected to the opposing vent parts, with the entire assembled ridge vent being rolled into a spiral or coil, and secured in that configuration for later installation on a roof. The assembled ridge vent is rolled into the spiral configuration from an initially planar configuration by engaging a leading end of the ridge vent and rolling the ridge vent onto a drum or mandrel to form a tight, uniform spiral. The rolled vent can then be labeled and banded or packaged. The fabrication process from bulk rolls of sheet material to packaged roof vents can be substantially continuous and automated. Roof vents of various lengths or widths can be manufactured with only minor adjustments or substitutions in the fabrication equipment. The ridge vent is installed by placing the roll on the peak of the roof with the free end of the spiral extending over the top of the spiral and oriented away from the direction of installation. The blank is unrolled to expose a portion of the ridge vent, which is fastened to the roof. This process is repeated until the desired length is installed. Foam end caps and air deflectors optionally may be installed.

Description:
RELATED APPLICATIONS 
     This is a continuation-in-part of application Ser. No. 08/570,656 filed on Dec. 11, 1995, U.S. Pat. No. 5,651,734. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to ridge cap roof ventilators folded from a blank of corrugated plastic sheet material having two vent parts and an intermediate top panel, and particularly to such an assembled roof ventilator that is rolled into a spiral or coiled configuration. 
     2. Discussion of the Prior Art 
     The art is relatively well defined relating to ridge cap roof ventilators fabricated from corrugated plastic sheet material and folded to form two vent parts disposed on opposing sides of an opening in a roof peak and an intermediate top panel. 
     U.S. Pat. No. 4,803,813 to Fiterman and U.S. Pat. Nos. 5,04,041 and 5,331,783 to Kasner describe various methods for scoring, folding, and routing blanks of corrugated plastic sheet material to form the roof vents, as well as their method of installation and use. 
     These folded roof ventilators and similar designs were traditionally made and sold in lengths of approximately four feet. However, a hinged double-length roof vent was developed as disclosed in U.S. Pat. No. 5,304,095 to Morris which enhanced the shipping and installation of such roof vents. 
     In comparison, other types of highly flexible roof covering products such as shingles, tar paper, and some roof ventilation products fabricated from open celled foam or other pliable materials are distributed in roll form, which permits longer lengths of product to be installed in one operation without transitions, and eliminates some potentially undesirable features such as seams or gaps. 
     U.S. patent application Ser. No. 08/570,656 filed on Dec. 11, 1995 discloses a multi-layer, corrugated plastic ridge cap roof ventilator having two opposing vent parts (of the type shown in the Fiterman &#39;813, Morris &#39;095, and Kasner &#39;041 and &#39;783 patents) which is fabricated from a cut and scored blank of double-faced corrugated plastic sheet material that is rolled into a spiral configuration and secured for shipping. The blank is subsequently unrolled, and the scored panels are sequentially folded and secured to the roof to form the opposing vent parts during installation. The roof vent embodiments and fabrication process described in this application increases manufacturing efficiency and substantially reduces waste from trimming and fitting shorter sections of 4&#39; or 8&#39; roof vents, however the process of folding and fastening the roof vents is still time consuming for the installers, and the rolled blanks can sometimes be difficult to carry or handle when climbing a ladder or in windy conditions due to their respective length and width. 
     It may be appreciated that those skilled in the art have heretofore been required to select between the advantages of assembled multi-layer double-faced corrugated plastic roof ventilators which cannot be rolled, rolled roofing products which do not provide the advantages of a multilayer double-faced corrugated plastic product, or additional steps which must be taken during installation to convert a rolled blank of double-faced corrugated plastic sheet material into an assembled multi-layer roof ventilator. 
     BRIEF SUMMARY OF THE INVENTION 
     It is therefore the goal of the present invention to provide an assembled, multi-layer, corrugated plastic ridge cap roof ventilator in which the layers or panels of each vent part are interconnected or secured together in a stacked orientation, and the assembled product is rolled into a spiral configuration for shipping and installation. 
     Briefly described, the roof vent of this invention comprises a pair of opposing vent parts connected by a top panel--with each vent part being formed from a plurality of layers of double-faced corrugated plastic sheet material that are hingedly connected or fastened to one another in a stacked orientation--which is rolled longitudinally along its length to form a tight spiral or coiled configuration and secured for shipping. 
     The roof vent is rolled into the spiral configuration by engaging the leading end of a section of the roof vent, passing the generally planar section between a pair of pinch-type tensioning rollers or alternately along a nonlinear path across a plurality of tensioning rollers which cause the section to flex or bend longitudinally, and then rolling the section around a drum or mandrel. 
     The roof vent is installed by placing the roll on the peak of the roof covering the pre-cut ventilation opening, with the free end of the roll disposed extending over the top of the roll and oriented away from the direction of installation. A length of the section is unrolled and fastened to the roof in a conventional manner. The section is further unrolled and fastened to the roof, with the process continuing until the desired length has been installed. Alternately, the entire length may first be unrolled and then fastened to the roof. Foam end caps and air deflectors may optionally be installed if desired. 
     The roof vent in spiral or coiled roll form is easier and safer to carry when climbing a ladder or moving about a roof compared with either straight vent sections or the prior rolled vents discussed above, particularly in windy conditions, and the flat toroidal rolls can be stacked or placed &#34;on end&#34; on a moving pallet or an angled roof roll without rolling away. 
     The rolled roof vent disclosed herein may therefore be fabricated in a substantially continuous and automated process starting with the extrusion of large bulk rolls of single- or double-faced corrugated sheet material, the rolls being fed through the appropriate dies and machinery to cut, trim, score, fold, and fasten the panels to form a continuous web of the folded roof vent, the continuous web being cut into sections of the appropriate length which are rolled into the spiral configuration (or alternately the web may be rolled and sections cut during the rolling process), with the spiral rolls then being labeled and banded or packaged. Such a fabrication process permits the fabrication of sections of roof vent having differing lengths and widths with only minor adjustment or substitutions in the fabrication equipment or machinery. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the spiral rolled roof vent of this invention being partially installed on the peak of a roof; 
     FIG. 2 is a cross sectional view of one vent part and the top panel of the roof vent, taken through line 2--2 in FIG. 1, showing the double-faced corrugated plastic sheet material, hinged interconnections between the panels, and use of a fastener to secure the panels together in a vertically aligned stacked orientation; 
     FIG. 3 is a diagrammatic representation of a section of the roof vent being passed along a non-linear path between tensioning rollers and rolled onto a cylindrical drum or mandrel to form a tight spiral; 
     FIG. 4 is a broken away perspective view showing the leading edge of the section of FIG. 3 being engaged by the cylindrical drum, and the multiple layers of double-faced corrugated plastic sheet material forming the panels of one vent part and top panel; and 
     FIG. 5 is a perspective view of the roof vent rolled in a tight spiral or coiled configuration, with a label wrapped about the circumference of the roll, and the roll secured using a pair of bands. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The apparatus and method of this invention are illustrated in FIGS. 1-5 and referenced generally therein by the numeral 10. 
     The prior art disclosures relating to the fabrication and structure of roof vents using corrugated plastic sheet material having a convoluted intermediate ply, the nick-scoring and cut-scoring procedures utilized to construct folded roof ventilators, and the various other features, optional components, improvements, and methods of fabrication and use associated with these products are incorporated into this specification by reference as though fully recited herein, including but not limited to the disclosures contained in U.S. Pat. No. 4,803,813 to Fiterman; U.S. Pat. Nos. 5,094,041 and 5,331,783 to Kasner; U.S. Pat. No. 5,304,095 to Morris; and U.S. patent application Ser. Nos. 08/570,656 now U.S. Pat. No. filed on Dec. 11, 1995 relating to a rolled ridge ventilator; 08/127,005 filed on Sep. 24, 1993 relating to an adjustable air deflector for a roof ventilator; and 08/126,307 filed on Sep. 24, 1993 relating to a foam end closure or intermediate support for a roof ventilator and method of making and using the same. 
     While the particular embodiment of the roof vent 10 described herein and shown in FIGS. 1 and 2 is discussed below with particular reference to a three-ply or double-faced corrugated plastic sheet material, it is understood that roof vents 10 of this type and configuration may alternately be fabricated and constructed in the same manner using two-ply or single-faced corrugated plastic sheet material, as well as corrugated sheet materials of other types to the extent they are sufficiently impervious to weather, heat, moisture, decay, and other environmental conditions prevalent in the locations where the roof vents 10 will be installed and used. 
     Referring particularly to FIGS. 1 and 5, the rolled roof vent 10 of this invention is shown in its tightly-rolled spiral or coiled configuration for shipping, and in the process of installation. The roof vent 10 is shown as a section 12 having a finite length on the order of 20&#39;, however the respective length and width of the section 12 may be readily varied according to the needs of a particular application discussed further below. The section 12 has a leading edge 14 prior to being rolled, a free end 16 after being rolled, and a pair of opposing sides 18, 20 which extend parallel with the longitudinal axis of the section 12 the length of the section 12. 
     The construction or fabrication of the section 12 from a blank of sheet material is shown in detail in FIG. 2, as well as in FIGS. 1 and 4. The sheet material is an polyethylene plastic, and may include any percentage of recycled plastic resin that is suitable for the intended use. The section 12 defines a top panel 22 that extends in an uninterrupted manner the length of the section 12 generally parallel with and bisected by a longitudinal centerline. Extending from and hingedly connected to the top panel 22 are a plurality of panels 24, with three such panels 24 being shown. The top panel 22 and plurality of panels 24 are preferably fabricated from a double-faced corrugated plastic sheet material having a pair of planar plies 26 connected to a convoluted intermediate ply 28 to create a multiplicity of air passages 30 and a grain extending generally perpendicular to the longitudinal axis of the section 12. 
     Each panel 24 is hingedly interconnected to the adjacent panels 24 or to the outer edges of the top panel 22 by a hinge member 32 formed by one of the planar plies 26 which is not entirely cut or severed during the cutting and scoring process. The panels 24 are accordion folded into a generally stacked orientation beneath the top panel 22 to form a pair of opposing vent parts 34, in each of which the panels 24 have approximately the same shape and size and the peripheral edges of each are in generally vertical alignment with one another. A center route 36 may be formed into the underside of the top panel 22 in a conventional manner as described in the Kasner &#39;041 patent identified above. The route 36 permits the top panel 22 to be folded or conform to any pitch or angle, as well as rounded peaks, while maintaining a uniform and straight fold or bend. The route 36 permits the top panel 22 to provide additional ventilation. The panels 24 of the opposing vent parts may optionally be cut and scored to form a staggered, tapered, stepped, or other patterns or configurations other than vertical stacked alignment along same-sized concentric peripheral borders. The blank of sheet materials may optionally be fabricated from single-faced corrugated material having a single planar ply attached to a convoluted ply. 
     Referring to FIGS. 1 and 2, it may be seen that the panels 24 of the vent parts and the top panel 22 are fastened together (at approximately 2&#39; intervals in a 20&#39; section 12) with staples 38 or similar fasteners. It may be appreciated that the vent parts may also be fabricated by cutting entirely through the blank to form a plurality of panels 24 which are separate and disconnected from one another, stacking those panels 24 to form the vent parts, and fastening them together (and to the top panel) in stacked alignment or a staggered pattern to form the vent parts and the roof vent 10. In the preferred embodiment, the panels 24 and top panel 22 are interconnected both by the cut- or nick-scoring process which provides integral hinges 32 between the plurality of panels 22 and the top panel 24, as well as the fasteners 38. 
     The process of rolling the section 12 into the spiral configuration is shown diagrammatically in FIGS. 3 and 4. The leading edge 14 of the section 12 is engaged on a generally cylindrical drum 42 in any suitable manner, such as by a bar-type clamp (not shown) which extends parallel with and grips the leading edge 14 of the section 12, U-shaped connectors 44 which are received within the air passages 30 of the section 12, or other types of gripping mechanisms conventionally used with single- or double-faced plastic sheet material. 
     The pair of generally U-shaped connectors 44 shown in FIGS. 3 and 4 as one of the available gripping mechanisms is suited to corrugated sheet materials, each connector 44 having a pair of prongs 46 and an intermediate bridge 48, one of the prongs 46 being received within an aperture 50 in the side of the drum 42, and the other prong 46 received within and engaging one of the multiplicity of air passages 30 defined by the corrugated sheet material. The prong 46 received within the aperture 50 of the drum 42 may be elongated relative to the other prong 46, and be spring biased toward the midpoint of the drum 42 so that the connector 44 may be pulled laterally away from the drum 42 to disengage the section 12, and biased back into engagement with another section 12 by the spring force. 
     Referring particularly to FIG. 3, the drum 42 is mounted for rotation in the direction that the section 12 is to be rolled into a spiral configuration, and may be rotated manually or by a suitable motor or drive mechanism (not shown). In addition, the drum 42 is mounted to move upwardly and downwardly between a lower and a raised position, as shown in solid lines and phantom lines, respectively, in FIG. 3. As the drum 42 is rotated and the section 12 rolled onto the drum 42, the drum 42 will rise proportionately, such that the upper or raised position corresponds to a change in height equal to the radial thickness of the roof vent 10 in the rolled configuration, measured between the inner and outer diameters. 
     The section 12 being rolled is initially passed between a pair of pinch-type tensioning rollers 40 disposed on opposing top and bottom sides of the section 12 which maintain the proper alignment and longitudinal tensioning of the section 12 as it approaches the drum 42, and serves to prevent the trailing end of the section 12 from flipping upwardly or around the drum 42 as it rotates due to natural stiffness or rigidity of the fabricated section 12. The tensioning rollers 40 also exert sufficient rearward tension or force to ensure that the section 12 rolls into a reasonably tight and uniform spiral. Alternately, in situations where the section 12 is especially thick or the corrugated sheet material is particularly stiff or rigid and a suitably tight and uniform spiral roll cannot be achieved using just pinch-type tensioning rollers 40, the section 12 may be passed along a non-linear path between and across a plurality of tensioning rollers 40 disposed above and below the section 12, and onto the drum 42 or mandrel as shown in FIG. 4. In this process, the tensioning rollers bend or flex the section from its normally planar configuration to an angled position, and thereby prepare the section 12 for rolling into a spiral configuration. The tensioning rollers may be disposed to gradually increase the angle of flexure of the section 12, for example the first roller 40 generating an obtuse bend of between 90° and 180°, and the second roller 40 creating a bend of a lesser obtuse angle or approaching or achieving a right or acute angle. Subsequent angles may be the same or progressively sharper, depending upon the thickness of the section, stiffness of the corrugated sheet material, the engagement between the panels 24 and top panel 22, and the eventual diameter of the spiral to be formed. 
     It will be readily appreciated by those skilled in the art that the weight of the drum 42, the rotational force or torque exerted on the section 12 by the drum 42, the longitudinal tension applied by the tensioning rollers 40, the spacing of the tensioning rollers 40 and the non-linear path and angles of flexure formed therebetween, and the angular velocity of the drum 42 will depend upon the thickness and stiffness of the section 12, which in turn depends upon the particular construction and materials utilized. It has proven suitable to roll a 20&#39; section 12 constructed using nick-scored accordion folded panels 24 stapled along the center of each vent part at 2&#39; intervals having a thickness of 5/8&#34; into a tight spiral on an approximately 12&#34; diameter drum 42. It should be noted that to produce a uniform tight spiral without significant creases or puckers, it is important to maintain generally uniform longitudinal tension along each side edge 18, 20 of the section 12 as the section 12 traverses the non-linear path, at least through the last few or final pair of tensioning rollers 40. 
     Once the section 12 has been rolled into the tight spiral as shown in FIG. 5, a label 52 or other placard may be wrapped around a portion of the roof vent 10, and the roof vent 10 may be secured in the spiral configuration for shipping or storage using a pair of welded plastic bands 54 or similar fasteners. The roof vent may also be shrink-wrapped, taped, or secured in any other suitable manner. Labeling information may optionally be printed or applied directly to the outer surface of the rolled roof vent 10. 
     It may be readily appreciated that the length of the section 12 may vary anywhere between a minimum length shorter than which it would not be practical to roll the section 12 into a spiral configuration to facilitate transport or storage, and a maximum length beyond which the spiral roll 10 could not practically be carried, lifted, or handled by a worker installing the roof vent 10 on a roof 58. However, in some applications (such as buildings having very long peaks or adjacent buildings having commonly aligned peaks) it may be suitable to fabricate extremely large spiral rolls 10 which are lifted to the roof 58 and deployed using mechanical assistance, such as a fork lift or boom crane. It may also be appreciated that the roof vent 10 may be fabricated in a variety of widths, thicknesses, and other dimensional variances. 
     Referring again to FIG. 1, the method of installing the roof vent 10 is shown. The installation site provides a house or other building structure having a generally peaked roof 58 defining a ridge opening 60 extending therethrough for ventilation. All or a portion of the roof 58 may be covered with shingles 62, and the roof 58 will usually include planar underlayment 64 supported by joists 66 and a central beam (not shown). 
     The rolled roof vent 10 is placed on top of the peak of the roof 58 with the free end 16 extending across the top of the roll and oriented facing the end of the roof 58, or conversely facing away from the direction of installation. When viewed from the side elevation, the rolled roof vent 10 will have a free end 16 extending over the top of the roll 10 when the direction of installation is from right to left and the spiral of the roll 10 has a counter-clockwise orientation, as shown in FIG. 1. In this manner, the rolled roof vent 10 may be handled and installed by one individual without the roll 10 inadvertently unrolling as sequential portions of the section 12 are unrolled and secured to the roof. 
     The free end 16 of the rolled roof vent 10 is positioned adjacent the edge of the roof 58 or at another desired starting point with the roll disposed above the roof opening 60, and the section 12 is then unrolled a short distance along the peak of the roof 58 to feed or expose a manageable portion, as shown in FIG. 1. The free end 16 of the section 12 is then fastened to the roof 58 in a conventional manner using fasteners (not shown) such as nails or staples, and an intermediate portion between the fee end 16 and the roll may similarly be secured to the roof 58. 
     The section 12 is then further unrolled to expose another subsequent portion of the section 12, which is similarly secured to the roof 58. This process is repeated until the desired or entire length of the section 12 has been unrolled and secured to the roof 34. Any excess length of the section 12 may be but away and discarded or used on a separate section of the roof 58. It may be appreciated that the roof vent 10 is generally very flexible across the centerline of the top panel 22, but a sufficient length of the section 12 may need to be unrolled to allow enough distance or clearance from the remaining portion of the roll to permit the top panel 22 to be flexed or bent so that the vent parts will contact the roof 58. 
     Alternately, the entire section 12 may be unrolled onto the peak of the roof 58 at one time, generally aligned along the ridge or peak of the roof 58, and then folded across the peak of the roof 58 and secured to the roof 58 using fasteners in a conventional manner traversing progressively from one end of the section 12 to the other. 
     Foam end caps 68 or intermediate supports and adjustable air deflectors (not shown) may optionally be installed in a conventional manner if desired, either during or subsequent to the installation of the rolled roof vent 10. A pair of the foam end caps 68 which conform to the shape or pitch of the roof 58 may be packaged between wrapped layers of the rolled vent 10, and additional foam segments 68 may be included if intermediate support for the top panel 22 may be desired in a particular application. More than one section 12 of the roof vent 10 may be butted together with no special fasteners or connectors, or an installer may prefer to adhere the foam end caps 68 into each of the adjacent abutting sections 12 and then adhere or caulk the end caps 68 and corresponding abutting portions of the top panels 22 together to provide a moisture-proof or leak-resistant seal. 
     Although the present invention has thus been described in detail with reference to the preferred embodiments for practicing that invention, other embodiments, modifications, alterations, or substitutions deemed within the spirit and scope of the present invention may suggest themselves to those skilled in the art depending upon the particular applications involved. It is therefore intended that the present invention be limited only by the properly attributable scope of the attached claims below.