LIGHTWEIGHT ROOF VENTS

FIELD OF THE INVENTION

Aspects of the invention relate to roof vents and methods for making same, and more particularly to novel roof vents (e.g., roof ridge vents, and off-ridge vents, etc) that are strong yet light weight, and methods for making same.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to United States Provisional Application Serial numbers, 60/800,811 filed 16 May 2006, and 60/801,159, filed 17 May 2006, both of which are incorporated by reference herein in their entirety.

BACKGROUND

Roof ventilators. Roof ventilators permit circulation of hot air through the roof of a building to decrease the temperature within the building and to allow for air circulation under the roof, especially desirable for the removal of moisture build-up to prevent rotting of wooden members. In their most basic form, roof ventilators minimally comprise a cover member that is supported at a distance above a rooftop by a vent, the vent typically comprising a plurality of projection elements (i.e., support members, such as support columns, support walls, louver members, etc., which project or extend from the underside and/or margins/edges of the cover member), holding the cover member a distance from the rooftop to allow for venting through the vent. Conventionally, aside from being unsightly, some of the problems with previous roof ventilators have included a projecting height that is too great, multi-piece constructions that are difficult to install, roof ventilators that are unable to adapt to various roof pitches, thereby requiring a multitude of products for different building types and roof ventilators that are generally unsightly.

Additionally, roof ventilators should preferably be of a sturdy construction to withstand pressures of shipping and handling, and resist damage during installation and service life. Moreover, other considerations for shipping and handling include the ability of a design to provide a compact ventilator (e.g., one that can be shipped in a flat position), and one that can be stored in inclement weather conditions. Further design considerations include aesthetics, propensity of air volume circulation, resistance to deterioration, ability to withstand exposure to

high winds and other inclement weather conditions, along with an ability to prevent dirt, rain and insects getting into the attic space being ventilated. Finally, weight is an important consideration, because of the attendant effects on cost and time needed to manufacture, ship and install the ventilators. Therefore, there is a particularly pronounced commercial advantage in having lightweight ventilators.

'Ridge ventilators.' Roof ventilators permit circulation of air through one or more openings of a building roof to decrease the temperature within the building and to allow for air circulation under the roof. Such ventilators are also desirable for the removal of moisture buildup within the enclosed cavity of the roof to prevent rotting of wooden and/or composite members. Typically, 'ridged' roofs will have an opening at the ridge communicating with the cavity, and the opening will be covered by a roof ridge ventilator ('ridge vent'). As discussed above for roof vents generally, and in their most basic form, typical roof ridge ventilators minimally comprise a cover member (e.g., a pair of hinged 'flaps') that is supported at a distance above a rooftop by at least one vent, the at least one vent typically comprising a plurality of projection elements (i.e., support members, such as support columns, support walls, louver members, etc., which project or extend from the underside and/or margins/edges of the cover member), holding the cover member a distance from the rooftop to allow for venting through the at least one vent. Such ridge vents are popular because they are positioned to optimally exchange or vent hot air accumulation at the peak of the roof cavity. Additionally, ridge vents generally comprise a continuous structure (e.g., formed of end-to-end joined sections) extending across and conforming to the roof ridge line, and are thus aesthetically pleasing relative to multiple separate, conspicuous and incongruous smaller vents. Moreover, with respect to at least formal satisfaction of building code clearance requirements, the areas on both sides of the peak are allowed to be used for calculating 'venting ratios,' thus allowing ridge vents to assume low profiles relative to 'off-ridge' type vents.

At least in theory, ridge vents protect the opening from the external environment by precluding unwanted infiltration (e.g. foreign matter), while simultaneously allowing air to freely circulate through the cavity. Nonetheless, unwanted infiltration of foreign matter into the ridge vent and the enclosed roof cavity to which the ridge vent is attached is a substantial long- standing problem in the industry, particularly in areas having extreme weather conditions. Building codes in particular states with severe weather require that roof ventilators prevent infiltration of foreign matter into the enclosed roof cavity to which the ventilator is attached. Additionally, like other types of roof ventilators, weight is an important consideration for roof

ridge ventilators, because of the need to manufacture, ship and install the ridge ventilators. Therefore, there is a particularly pronounced advantage in having lightweight roof ridge ventilators.

Therefore, a major obstacle and challenge in the roof venting industry in general (for all types of vents, ridge and off-ridge, etc.) has been to find a way to reduce the weight of the ventilators, while at the same time preserving structural integrity and strength and maintaining good venting efficiency over an extended service life. Such weight reduction is highly desired for several reasons including: reduction of the cost of the injection molding material (e.g., polypropylene, etc.), where such costs increase proportionately with the amount of material used in constructing the vent; the need to reduce the shipping weight of the ventilators; and the need to reduce weight with respect to carrying, lifting, placing and manipulating the ventilators on roof tops during installation. There are four primary prior art 'strategies' for weight reduction of roof ventilators.

A first prior art roof ventilator weight reduction strategy, and by far the most pervasive approach to ventilator weight reduction has been uniformly thinning the thickness (i.e., uniformly reducing the 'nominal thickness ') of the cover member material, and/or the thickness of the support members. For example in larger ridge ventilators (e.g., 18 inch, 1/150 ventilators), manufacturers have reduced the cover member thickness from a structurally preferable 0.080 inches to a value in the range of about 0.060 to 0.070 inches, and have additionally reduced the support member thickness from a structurally preferably 0.100 inches to a value in the range of about 0.060 to 0.070 inches. Likewise, for small ridge ventilators (e.g., 9 inch, 1/300 ventilators), manufacturers have reduced the cover member thickness from a structurally preferable 0.070 to 0.080 inches to a value in the range of about 0.060 to 0.070 inches, and have additionally reduced the support member thickness from a structurally preferable 0.070 to 0.080 inches to a value in the range of about 0.060 to 0.070 inches. Such thickness-minimized designs, while providing for weight reduction, nonetheless have the inherent disadvantage of being structurally compromised per se, and are susceptible to inadvertent damage, particularly during installation when being nailed and/or shingled. Therefore, while this is the most pervasive approach, it is inherently problematic.

A second strategy is represented by prior art ventilator units (e.g., Duraflo) that are constructed to have large openings (open voids or channels) in/through the cover member

portions (e.g., in the cover member portions that are covered by cap shingles). The problem with this strategy is significant, because such opened sections, while eliminating some material requirement and resulting in an associated weight reduction, allow for damaging infiltration of water and foreign matter, particularly upon cap shingle failure where water and material then gains direct access into the roof opening. Additionally such solutions are somewhat deceptive in the amount of actual weight reduction, because the openings on the vent surfaces are typically enclosed at their margins by relatively narrow and unstable cover material strips that require support member material extending between the roof and the strips to provide adequate stability to support, for example, nailing and/or cap shingles. Therefore, the weight reduction gained by manufacturing roof vents with open channels is significantly off-set by the weight of the additional support members required to support the narrow channel margins. Practically speaking, therefore, such vents, while somewhat lighter, are at least to some extent structurally and functionally compromised, or are compromised when an associated structure (e.g., cap shingle) fails.

A third strategy has been to increase the spacing between vertical support members that are longitudinally spaced along the underside of the cover member. For example, while all vertical support members are typically slightly tapered to some extent in going from the cover member to the roof to facilitate mold ejection, a majority of ventilators are now being produced with 3 inch spacing between longitudinally spaced vertical support members instead of the more structurally optimal 1.5 inch spacing. This is true in the case of both large (e.g., 18 inch, 1/150 ventilators) and small (e.g., 9 inch, 1/300 ventilators) ventilators. Unfortunately, by effectively doubling the distance between the vertical support members, these designs substantially compromise the integrity of the vent per se. Such increases in support member spacing is particularly problematic in view of the fact as stated above, that the support members themselves have already been significantly thinned, resulting in a substantially weaker structure which can, and often does result in uneven, wavy and partially collapsed vent installations, along with significantly decreased venting capacity.

Finally, a fourth strategy has been the increasingly popular elimination of louvers, with substitution of relatively lightweight filter material. As recognized in the art, vents comprising louver elements are optimal from the standpoint of excluding foreign matter and providing support, while at the same time providing for good ventilation flow over an extended service life. Unfortunately, substitution of louvers with loose filter material, while resulting in weight reduction, offers no structural support for the overall ventilator, and either becomes occluded

within a relatively short service life (typically 1 to 2 years), or disintegrates or collapses and thereby ceases to function at all as effective filters. Occluded filters do not support adequate air flow through the vent, and disintegrated or collapsed filters to not adequately function to preclude infiltration of foreign material into the ventilator.

Principals relating to 'continuity of nominal thickness' and 'projection element dimensions " in injection molding. . 'Nominal thickness' is an art-recognized descriptor for the wall thickness of a molded component. Typically, in prior art injection molded ventilators, the nominal thickness preferably does not vary by more than five or ten percent in the plastic component. Significantly, variation of nominal thickness of more than ten percent is known in the art to disrupt injection molding in a number of ways. For example, excessive nominal thickness variation makes flaws more likely. Additionally, walls that are too thick tend to use too much plastic for cost effective molding. Walls that are too thin can be too weak. Therefore, continuity of nominal wall thickness is standard and pervasive in the art in the context of plastic molds (e.g., injection molding).

The prior art strategies discussed above to reduce ventilator weight, in keeping with the prior art principal of continuity of nominal wall thickness, have primarily involved uniformly reducing the 'nominal thickness' of the ventilator cover members, and/or of the vertical support members. However, as discussed above, such uniform 'thinning' results in inherently weaker ventilators having compromised strength and/or function. Therefore, the extent of weight reduction is limited, because excessive 'thinning' (unfortunately present in many prior art vents) results in warped parts or parts that crack or break during shipping, handling, and/or installation. This is particularly true in view of prior art teachings regarding the relative thickness of any 'projection elements', where reducing the thickness of a ventilator cover member would typically call for a coordinate reduction in the thickness of the support members, thus compounding the overall strength problem of such ventilators. Specifically, a projection element is a part of the component sticking out from the nominal wall. Projection elements are a big benefit of injection molding, and can be formed to any shape and size, within functioning limits, and provide a plastic component with features that are unattainable or inefficient to create with other forms of material manipulation. Roof vents typically have such projection elements in the form of support members (e.g., support walls) that project from the lower surface of the roof vent cover member. Importantly, however, such projection elements should not be thicker than the nominal wall, or sink marks can occur. Alternatively, the projection elements can break off easily if too thin. Therefore, a major disadvantage of prior art strategies to achieve weight

reduction is that, following the art recognized principal of 'continuity of nominal thickness (i.e., uniform thickness of cover members and support walls), the support members of prior art vents have been coordinately thinned along with the cover members to avoid sink marks and broken projections. Unfortunately, this practice has resulted in lighter, but substantially weaker ventilators.

Therefore, the problem of how to reduce roof ventilator weight, while retaining adequate structural integrity and functionality over a reasonable service life represents a long-standing problem in the roof ventilator art, and there is an associated pronounced need for a realistic, viable and effective solution. Unfortunately, as discussed above, the prior art 'strategies' are not effective solutions to this long-standing problem, because each such prior art strategy, while providing weight reduction to various extents, engenders a corresponding negative consequence that significantly compromises the integrity and/or the service-life functionality of the respective prior art vents.

SUMMARY OF THE INVENTION

Aspects of the present invention represent a significant departure from the art in terms of design in view of the pervasive prior art principal of 'continuity of nominal thickness' and coordinate dimensioning of projection elements (see discussion under "Background" above).

Particular aspects provide a realistic, viable and effective solution to solve a long- standing problem in the roof ventilator arts of how to reduce roof ventilator weight, while retaining adequate structural integrity and functionality over a reasonable service life.

In preferred aspects, the inventive ventilators comprise at least one cover member surface recess area (e.g., a scalloped surface recess) in the cover member, the surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member between the two spaced support members relative to the thickness of the cover member at the respective support member extension positions to provide a selectively recessed roof ventilator affording a reduced weight while retaining structural and functional integrity.

BRIEF DESCRIPTION OF THE DRAWINGS

Figures IA and IB show top views of first exemplary embodiments of cover surface recess roof vents according to particular aspects of the present invention.

Figure 2A and 2B show expanded top view of respective sections of the exemplary cover surface recess roof vent embodiments of Figures IA and IB.

Figure 3 shows a side view and expanded side view of a section of the exemplary cover surface recess roof vent embodiments of Fi ¹ Ogu' res 1 and 2.

Figures 4A and 4B show respective end views of the exemplary cover surface recess roof vent embodiments of Figures 1, 2 and 3.

Figure 5 is an environmental view of a cover surface recess roof ridge ventilator constructed in accordance with the present invention and located over the open space at the peak of the roof;

Figure 6 is a perspective bottom view of the roof ridge ventilator of FIG. 5 with the vent and the shielded louvers at an upward incline;.

Figure 7 is a bottom plan view of a of a cover surface recess roof ridge ventilator showing the relative locations of the shielded louver openings and the location of the supports of one of the embodiments

Figure 8A is a side sectional view of the vent shown in FIG. 7, including an upwardly facing shielded louver with a center support.

Figure 8B is a side sectional view of a vent with upwardly facing shielded louver without a center support.

Figure 8C is a side sectional view of a vent with a downwardly facing shielded louver with a center support.

Figure 8D is a side sectional view of a vent with a downwardly facing shielded louver without a center support.

Figure 9 is a side sectional cut-away view showing greater detail of the shielded louver feature.

Figure 10 is an environment view of the roof ventilator shown in the middle of the roof.

Figure 11 is a perspective view of a roof ridge ventilator constructed in accordance with the present invention.

Figure 12 is a top view through a roof ridge ventilator constructed in accordance with the present invention.

Figure 13 is a partial sectional view taken along the direction of lines 3—3 in FIG. 12 to illustrate vent openings of the ventilator.

Figure 14 is a perspective view of a roof ridge ventilator constructed in accordance with the present invention illustrating positioning of the ventilator when installed.

Figure 15 is a view taken in section through roof ridge when installed, illustrating air deflection over the roof.

Figure 16 is a perspective view of a roof ventilator formed in accordance with one embodiment of the present invention.

Figure 17 is a partial bottom planar view of a roof ventilator formed in accordance with one embodiment of the present invention showing the filter device, louvers, and supports.

Figure 18 is a cross-sectional end view of a roof ventilator formed in accordance with one embodiment of the present invention, showing placement and attachment of a filter device.

Figure 19A is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing alternative attachment of the filter device.

Figure 19B is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing other alternative attachment of the filter device.

Figure 19C is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing yet another alternative attachment of the filter device.

Figure 20 is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing alternative placement and attachment of the filter device.

Figure 21A is a cross-sectional end view of a roof ventilator formed in accordance with another embodiment of the present invention, showing other alternative placement and attachment of the filter device.

Figure 21B is a cross-sectional end view of a roof ventilator formed in accordance with yet another embodiment of the present invention, showing another alternative placement and attachment of the filter device.

Figure 22 is a cross-sectional end view of a support of a roof ventilator formed in accordance with another embodiment of the present invention, showing sidewall serrations.

DETAILED DESCRIPTION OF THE INVENTION

Particular aspects provide a realistic, viable and effective solution to solve a longstanding problem in the roof ventilator arts of how to reduce roof ventilator weight, while retaining adequate structural integrity and functionality over a reasonable service life.

In preferred aspects, and with reference to FIGURES 1-4, the inventive ventilators comprise at least one cover member surface recess area 100 (e.g., a scalloped surface recess) in the cover member, the surface recess area strategically positioned between two spaced support members 102 to proportionately reduce the thickness of the cover member between the two spaced support members relative to the thickness of the cover member at the respective support member extension positions to provide a selectively recessed roof ventilator affording a reduced weight while retaining structural and functional integrity.

Selecfively/Straiezii-dlly phired surface reresses. In departing from the prior art principal of continuity ol nominal thickness, the primary function of the scalloped surface (i.e., surface recess areas) is to reduce the weight of the roof ventilator or roof ridge ventilator to a minimum without sacrificing structural integrity. Therefore, it will be appreciated that the exact shape ot ^' tbe surface recess is not critical. For example, the surfaces recess areas may be generally circular, ovoid, rectangular, square, or any shape tor that matter, with the crucial aspect being that the at least one surface recess areas are strategically positioned between two spaced support members to proportionately (e.g., proportionate with respect to the recess depth and/or effective volume) reduce the thickness of the cover member between the two spaced support members relative to the cover member thickness at the respective support member

extension positions, so as to provide for a selectively recessed roof ventilator affording a reduced weight while retaining structural and functional integrity.

Likewise the contour of the transition going into and out of the recesses (the contour of the recess margins) may vary. For example the margins (e.g., shoulders or edges) of the recess may be of a radial nature where the margin edge or vertex has been rounded, and where the exact specifications of the radial curvature may vary depending on the depth and shape/contour of the recess surface area. Radius edges (e.g., formed in a prutυmυld milling process) may transition gradually into the recess depth, may be relatively abrupt, or may provide an intermediate transition or edge. Alternatively, the contour of the recess margins may be of a vertex nature with one or more sharp, angular transitions, where the vertex angles may vary depending on the depth and shape/contour of the recess surface area, etc. Preferably, the contour of the recess margins is vertex in nature, to provide for maximal strength. Combinations of recess margin contours are encompassed (e.g., various combinations of radial and/or vertex and/or other shaped margins, and compound margins comprised of both radial and vertex features).

Preferably, the lightweight ventilators of the present invention are made by injection molding of plastic (e.g., plastic selected from the group consisting of polymers, polypropylene, nylon, thermoplastic, epoxy resins, polyurethane and the like). The resulting ventilators have covers comprising one or more selectively placed surface recesses, resulting in, despite being injection molded, a 'blind embossed' effect (this occurs when areas of one surface are recessed while the opposite side remains flat, causing the material to become thinner in those areas). Alternatively, if the vents are made of a ductile material (e.g., a metallic material such as aluminum) then 'pattern pressing' or 'blind embossing' can be used (instead of, for example injection molding) to obtain the inventive selectively placed surface recesses.

Particularly preferred embodiments:

Aspects of the present invention provide a lightweight roof ventilator, comprising: a cover member having an upper surface and a downwardly facing lower surface, the surfaces defining a cover member thickness there between, and defining respective upper and lower cover member surface areas; at least one vent channel under the lower surface of the cover member; a plurality of spaced support members extending from corresponding support member extension positions of the lower surface of the cover member, the spaced support members suitable to support the cover member at a distance from a surface (e.g., roof surface or roof top);

and at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

Additional aspects provide a lightweight roof ventilator, comprising: a cover member having an upper surface suitable for securing shingles thereover, and a downwardly facing lower surface, the surfaces defining a cover member thickness there between, and defining respective upper and lower cover member surface areas; at least one vent secured to the lower surface of the cover member, the at least one vent having a first set of louvers; a plurality of spaced support members extending from corresponding support member extension positions of the lower surface of the cover member, the spaced support members of a height substantially equal to that of the first set of louvers and suitable to support the cover member at a distance from a surface (e.g., roof surface, roof top); at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

Further aspects provide a lightweight roof ventilator, comprising: an elongate cover member having an upper surface and a downwardly facing lower surface, the surfaces defining a cover member thickness there between, and defining respective upper and lower cover member surface areas; a first set of louvers attached to the lower surface of the cover member and disposed along one side of the cover member, the first set of louvers having a height; a plurality of spaced support members extending from corresponding support member extension positions of the lower surface of the cover member, the spaced support members of a height substantially equal to that of the first set of louvers and suitable to support the cover member at a distance from a surface (e.g., roof surface, roof top); and at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective

support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

Yet further aspects provide a lightweight roof ventilator, comprising: a cover member of elongated shape including a pair of flaps, each flap having an upper surface over which cap shingles are secured and having a downwardly facing lower surface, wherein said cover member comprises a longitudinal hinge element located centrally between the two outer edges of the flaps; a pair of vents respectively secured to the lower surface of the flaps, each vent having a first set of louvers, the first set of louvers having a height; a respective plurality of spaced support members extending from corresponding support member extension positions of the lower surface of the cover member flaps, the spaced support members of a height substantially equal to that of the first set of louvers and suitable to support the cover member at a distance from a surface (e.g., roof surface, roof top); and at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

In certain embodiments, the at least one cover member surface recess area is in the lower surface of the cover member. In alternate embodiments, the at least one cover member surface recess area is in the upper surface of the cover member.

Preferably, the lightweight roof ventilator comprises an array of a plurality of surface recess areas, each recess area positioned, at least in part, between two spaced support members of a corresponding array of spaced support members. In certain aspects, the surface recess area array is an ordered array of recess areas, wherein each recess area is positioned, at least in part, between two spaced support members of a corresponding ordered array of spaced support members. In particular aspects, the cover member is elongated, and the plurality of spaced support members are longitudinally spaced on the lower surface of the cover member. In some embodiments, the at least one vent channel is positioned beneath and/or secured to the lower surface of the cover member and comprises a first set of louvers.

In preferred lightweight ventilator embodiments, the reduced weight is an amount in the range from about 5% to about 60%, or from about 10% to about 50%, or from about 15% to about 45%, or from about 20% to about 40%, or from about 25% to about 35%, or about 25% to

about 30%, relative to a comparable non-recessed ventilator. Preferably, the reduced weight is an amount in the range from about 15% to about 45%, or from about 20% to about 40%. More preferably, the reduced weight is an amount in the range from about 20% to about 40%. In particular embodiments the weight reduction is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, or at least 60%, relative to a comparable non-recessed ventilator

In particular lightweight roof ventilator embodiments, the percentage of a cover member surface area involved in recesses is an amount in the range from about 5% to about 85%, or from about 10% to about 80%, or from about 15% to about 75%, or from about 20% to about 60%, or from about 25% to about 50%, or about 30% to about 40%. Preferably, the percentage of a cover member surface area involved in recesses is an amount in the range from about 10% to about 80%, or from about 15% to about 75%. More preferably, the percentage of a cover member surface area involved in recesses is an amount in the range from about 15% to about 75%. In particular embodiments the percentage of a cover member surface area involved in recesses is at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 75%, at least 80%, or at least 85%, relative to a comparable non-recessed ventilator

In particular aspects, the lightweight roof ventilators further comprise a filter or fibrous filter disposed under the cover member, and/or a second set of louvers extending from the lower surface of each flap and located between the first set of louvers and the hinge means.

Additional embodiments of the present invention provide a roof ridge ventilator to be installed under a cap shingle, comprising: an elongate cover member including a pair of flaps, each flap having an upper surface over which cap shingles are, in operation, secured and also having downwardly facing lower surfaces; a pair of vents respectively secured to the lower surface of the flaps, each vent having a first set of louvers, the first set of louvers having a height; a plurality of longitudinally spaced support walls in each vent that extend substantially vertically, the support walls extending outwardly from under the cover member and extending beyond the cover member, thereby leaving portions of the support walls uncovered by the cap shingle and exposed, the exposed portions of the support walls including top edges which descend downwardly with respect to the upper surface; each vent having a longitudinally extending, upwardly projecting outer wall connecting said longitudinally spaced support walls; weepage openings in the outer wall at the bottom of the outer wall spaced intermediate said

outer support walls to permit collected liquids to drain there through; and at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively- recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

In certain aspects of this ventilator, the pair of vents comprises a pair of outwardly and downwardly projecting vents respectively secured to the lower surfaces of the cover member flaps; each vent having a longitudinally extending inner wall slanting upwardly and inwardly including louver openings to permit air circulation through the roof ridge. In particular embodiments the ventilator is made of plastic (e.g., selected from the group consisting of polymers, polypropylene, nylon, thermoplastic, epoxy resins and polyurethane).

Preferred ventilator embodiments further comprise an integral hinge element located between the outer edges of the cover member flaps. In certain aspects, the ventilator is formed to a length of about 5 feet, and/or the width of said cover member between the outer edges is approximately the width of a standard cap shingle. In preferred embodiments, the longitudinally extending outer wall projects inwardly and upwardly at an angle of about ten to about seventy- five degrees, or from about fifteen to about seventy-five degrees with respect to the upper surface plane of the cover member flap, thereby deflecting air flow across the upper surface of the cap shingle.

In particular embodiments, the louver openings include at least 50 louvers, and/or the louver openings are from about 0.1 to about 1.0 inches wide, and/or about 0.5 to about 5.0 inches long. Preferably, the weepage openings include at least one weepage opening between each pair of longitudinally spaced outer support walls. In particular aspects, the ventilator is made of a plastic (e.g., selected from the group consisting of polymers, polypropylene, nylon, thermoplastic, epoxy resins and polyurethane).

Yet further embodiments provide a roof ridge ventilator to be installed under a cap shingle, comprising: an elongated cover member including a pair of flaps, each flap having an upper surface over which cap shingles are, in operation, secured and also having downwardly facing lower surfaces; a pair of vents respectively secured to the lower surface of the cover member flaps, said vents including at least one pair of shielded louvers, the louvers having a

plurality of openings; a plurality of longitudinally spaced supports in each vent that extend substantially normal to the lower surface of the cover member flaps, extending between and only up to the louvers of each pair of louvers, so as to avoid obstruction of the louvers by the supports and thereby maximize the net fee area for ventilation; and at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

In particular aspects, this ventilator has at least one pair of shielded louvers having a substantially inverted V-formation for the vent portion including the plurality of openings, and wherein each support extends less than half-way across the vent such that the net free area is maximized. In particular aspects, the ventilator is made of a plastic (e.g., selected from the group consisting of polymers, polypropylene, nylon, thermoplastic, epoxy resins and polyurethane). Preferably, the ventilator comprises and integral hinge located between the outer edges of the cover member. In certain aspects, the ventilator is formed to a length of about 5 feet, and/or the width of the cover member between the outer edges is approximately the width of a standard cap shingle. In particular ventilator embodiments, the openings to permit air circulation include between about 3 and 10 louvers, or about 7 louvers, formed in the inner walls. Preferably, the louver openings are from about 0.1 to about 1.0 inches wide, and/or from about 3 inches long. In certain embodiments, the vents and cover member form a parallelepiped. In some embodiments the pair of vents are substantially mirror images of one another, and/or have a substantially V-shaped configuration for the vent portion containing the plurality of openings.

Yet additional embodiments provide a roof ridge ventilator to be installed under a shingle atop a roof surface, comprising: an elongated cover member having an upper surface over which shingles are secured and also having downwardly facing lower surface, said cover member including a longitudinally extending portion to be secured onto the roof surface; at least one vent respectively secured to the lower surface of the cover member, said vent including at least one pair of shielded louvers having a portion defining a plurality of openings, wherein the portion defining the openings in the pair of louvers is substantially configured as an inverted V- shape of fixed dimension and angle, so as to provide structural static load bearing capability to the ventilator without reducing the net free area ventilation thereof; and at least one cover

member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to reduce (e.g., proportionately reduce) the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively- recessed roof ventilator affording a reduced weight (while retaining structural and functional integrity).

In particular aspects, the ventilator is made of a plastic (e.g., selected from the group consisting of polymers, polypropylene, nylon, thermoplastic, epoxy resins and polyurethane). In particular embodiments, the ventilator is from about 6 to about 9 inches wide, and/or the longitudinally extending portion of the cover member measures about 3 inches in width to be nailed to the roof surface without impeding the net free area for ventilation. Preferably, the louver openings include about 7 louvers, and/or the louver openings are from about 0.1 to about 1.0 inches wide, and/or from about 3 inches long. In certain embodiments, the vents assume a substantially V-shaped configuration for the vent portion containing the plurality of openings.

EXAMPLE 1

(First exemplary roof ventilator embodiments having at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members; U.S. Patent 5,070,771 is incorporated herein by reference in its entirety)

A roof ridge ventilator to be installed under a cap shingle includes a one piece cover member of an elongated shape including a pair of flaps, each flap having one upper surface over which cap shingles are secured and also having downwardly facing lower surfaces, a pair of vents respectively secured to the lower surface of the cover member flaps, each vent including at least one set of shielded louvers having a plurality of openings for deflecting air flow while maintaining a minimum free area for air passage such that the air flowing there through is substantially reduced in velocity to limit the infiltration of foreign matter. A plurality of longitudinally spaced supports in each vent extend substantially vertically to permit nailing onto the roof such that the vent does not collapse during installation and such that the net free area remains intact. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight.

In another embodiment, a roof ventilator to be installed under a shingle atop a roof surface is disclosed which includes a one piece cover member of an elongated shape having an upper surface over which a shingle is secured, the cover member including a longitudinally extending portion to be secured onto the roof surface. At least one vent is secured to the lower surface of the cover member flap, the vent including at least one set of shielded louvers having a plurality of openings for deflecting the air flow while maintaining a minimum free area for air passage therethrough. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight.

In accordance with the present invention, an improved roof ventilator is provided; a selectively-recessed roof ventilator affording a reduced weight.. In addition to reduced weight, rain, insects and dirt particles are prevented from entering the ventilated space while retaining compact size, low cost, ease of manufacture, ease of installation, sturdiness, and longevity. Essentially, the present roof ventilator may either be used as a singular ventilator to be installed in the lower portion of the roof or as a roof ridge ventilator including a pair of vents adapted to extend longitudinally on a roof ridge covering the peak of the roof ridge. The single roof ventilator is installed by cutting a slot in the roof, in the area of the roof over which the roof ventilator is being installed, and nails or other fastening means are directed through the ventilator to secure it to the roof. The roof ridge ventilator is placed into position by merely laying the ventilator over the peak of the roof, and nailing through the ventilator into the materials below.

The singular roof ventilator which may be installed in a lower portion of the roof includes a one-piece cover member with an upper surface over which a shingle is to be secured and at least one vent secured to the lower surface of the cover member. The cover member includes a longitudinally extending portion to be secured onto the roof surface and may include a plurality of longitudinally spaced support in the vent that extend substantially vertically to permit nailing onto the roof such that the vent will not collapse during installation and such that the net free area remains intact. The vent includes at least one set of shielded louvers with a plurality of openings for deflecting air flowing therethrough.

Specifically, the present invention for the roof ridge ventilator includes a one-piece cover member of an elongated shape which includes a pair of flaps, each flap having an upper surface over which the cap shingles are secured and a downwardly facing lower surface which has a pair of vents secured thereto for deflecting air flow while maintaining a minimum free area for air passage such that the air flowing therethrough is substantially reduced in velocity to limit the infiltration of foreign matter. Each vent may also have longitudinally spaced-apart supports that extend substantially vertically to permit nailing onto the roof such that the vent does not collapse during installation and such that the net free area remains intact. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively- recessed roof ventilator affording a reduced weight. These vents run substantially perpendicular to the line of the roof and to limit the entry of dirt, insects and other foreign particles into the ventilated space, as well as providing structural support.

In another embodiment, the ventilator may be used as a roof ventilator to be installed in the lower portion of the roof. The roof ventilator may be used mid-roof in order to aid in ventilation, and is intended to be installed underneath the shingles. For installation, a hole is cut in the roof, the vent is nailed on top of the hole, and a shingle is nailed on top of the vent.

The objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.

With combined reference to FIGS. 5 and 6 of the drawings, the first embodiment of the invention is shown as a roof ridge ventilator constructed in accordance with the present invention and is generally indicated by reference number 10, having particular utility in the construction of residential and commercial buildings. Roof ridge ventilator 10 includes a one- piece cover member 12 of an elongated shape including a pair of flaps 14 and a hinge 16 unitary with the flaps and furthermore includes a longitudinal groove there between. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a

selectively-recessed roof ventilator affording a reduced weight. The construction of the cover member 12 permits use of the ventilator 10 on roof ridges of varying pitches and angles. The ventilator may be any length, but it is preferably about 4 to 5 feet long. Cover member 12 has an upper surface 18 over which cap shingles (not shown) are secured. The securement is normally provided by nailing through both the cap shingles and the ventilator 10 and is hereinafter more fully described.

Roof ridge ventilator 10 also includes a pair of vents 22 respectively located beneath the pair of cover member flaps 14. As hereinafter more fully described, each vent 22 has at least one vent wall 24 having a plurality of vent openings 26 as illustrated in FIGS. 5 through 9 to permit air circulation through the ventilator. Preferably, the openings 26 have a louver configuration, and include at least two louvers extending upwardly. The louvers are approximately from 0.1 to 1.0 inches wide, and from 0.5 to 5 inches long but may be of different dimensions if the application warrants. The vent includes at least one set of shielded louvers having a plurality of openings for deflecting air flow while maintaining a minimum free area for air passage such that the air flowing therethrough is substantially reduced in velocity to limit the infiltration of forei 'g6'n matter.

As shown in FIGS. 5 and 6, the louvers are preferably molded into the vent walls 24 and have from 3 to about 10 louvers, preferably about 7 louvers. The louver openings are preferably about 0.15 inches high and about 3 inches long. It is preferable to have 2 shielded louvers which are essentially a mirror image of one another about the center of vents 22. Openings 26 act to change the direction of air flow through the roof ventilator so that the velocity of the air within the vent is reduced to substantially zero under normal conditions, which limits the infiltration of any foreign matter back into the residential or commercial building. It is anticipated that more than one set of louvered openings may be utilized in the vent for other various applications. The side sectional configuration of the louver basically lends itself to a parallelpiped shape. Each vent may also have support walls 28 which have top edges 30 for supporting the vent and the cap shingle secured thereto. Vents 22 are secured to lower surface 20 of flaps 14.

The ventilator 10 may be made of materials such as polymers, polypropylene, nylon, thermoplastic, epoxy resins, polyurethane or any other plastic inherent to various manufacturing methods although other metallic materials may be used. Both the cover member 12 and the vents 22 of the ventilator are preferably made from these materials, although it is possible to utilize a suitable metal such as aluminum or sheet steel. The most preferred plastic is

polypropylene because it emits bug repelling odors so that insects and bugs are discouraged from nesting or entering the roof through the ventilator.

Cover member 12 is designed to provide a roof ridge ventilator with a lateral width that is substantially the same as the width of a standard cap shingle which is to be placed over the ventilator. Upon installation, the cap shingle should conform to the shape of the ventilator and thereby have the same pitch as the pitch of the roof, providing an aesthetically appealing appearance. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight.

FIG. 6 shows a perspective view from the bottom of the vent and shows the relative placement of the inner wall 24 which has louvered openings 26 as well as the placement of the support walls 28. It is preferable that support walls 28 are located in as few places as possible, in order to increase the net free area for air flow there through. As illustrated in FIG. 6, each vent 22 of the ventilator includes a longitudinally extending inner wall 24 in which the vent openings 26 are provided. The louvered construction may be formed by slicing the sheet material of inner wall 24 and pressing the material into a louvered design. Alternatively, the louver openings may be formed during the injection molding process. Other fabricating techniques known to manufacturers are contemplated.

Inner wall 24 acts as an interior baffle structure to prevent foreign particles and debris from entering the roof of the building, while allowing a substantially increased net free flow area for exhausting air through the roof. Suitable connections for securing the flaps 14 to support walls 28 may include many conventional means and methods, including rivets, heat deformation, and adhesive securing methods or, if the piece is injection molded, it can be molded as a unitary piece. The shielded louver openings 26 are from about 0.1 to about 1.0 inches wide, and from about 0.5 to about 5.0 inches long. Preferably, there are at least 50 louvers extending upwardly in each roof ridge ventilator. Various designs for different embodiments are shown in FIGS. 8a through 8d.

Looking now to FIG. 7, a bottom plan view of one-half of the roof ridge ventilator is shown, showing one-half of the longitudinal groove defining hinge 16. In such a roof ridge ventilator application, a mirror image of the vent and cover member shown in FIG. 7 is attached

to the other side of hinge 16. The vent 22 is shown attached to lower surface 20 of the cover member. Inner wall 24 is shown with its relative placement to support walls 28, and includes shielded louvered openings 26.

Moving now to FIGS. 8a through 4d, FIG. 8a illustrates the vent portion taken along lines 4a of FIG. 7. As can be seen in FIG. 8a, cover member 14 has a lower surface 20 to which the vent 22 is attached. In some means of manufacture, the vent 22 is a separate piece from cover member 14, although FIG. 8a shows an embodiment where it has been injection molded as a unitary piece. Inner wall 24 is shown with openings 26. The shielded louvers are between openings 26 which help to deflect the air flow as it travels there through. As the air is deflected, the velocity of the air is reduced to substantially zero under normal circumstances before it reaches the area under the cover member 14 closest to the groove 16, which is in communication with the air inside the building as can be seen in FIG. 5. Although FIG. 8a shows a support wall 28 in the diagram, yet another embodiment of the invention as shown in FIG. 8b is the same as 4a, but without support wall 28. Similarly, FIG. 8c illustrates a vent with the inner walls 24 shown in an inverted position, and includes a support wall 28. FIG. 8d illustrates the inverted vent design without a support wall. FIG. 9 shows a close-up detail of the louvered openings 26 within inner wall 24.

FIG. 10 shows a singular roof ventilator as it is installed in the lower portion of a conventional roof. The roof ventilator 32 has vent portions contained therein similar to those illustrated for the roof ridge ventilator 10 above, but only has one-half of the ventilator generally shown in FIGS. 5 through 8 for the roof ridge ventilator. As this is not designed to put onto a roof ridge, a longitudinally extending portion 34 is included for nailing down onto the roof by and through extending openings 36. For installation, a hole is cut into the roof as shown by numeral 38 and vent 32 is placed thereon. Longitudinally extending portion 34 is secured to the top of the roof by any fastening means through openings 36 for securement. Thereafter, a shingle (not shown) is placed over the ventilator and flashings may be used, if desired. As can be seen by the drawing, air rising through opening 38 from within the residential or commercial building is exhausted by the roof ventilator. Such a construction may provide at least one cubic foot of circulating air flow per minute per 100 cubic feet of attic space when the ventilator 32 is utilized with a conventional roof. The size of the louvered openings (not shown in this embodiment) are sufficiently small to prevent most foreign articles from passing there through or clogging the vents. As above, roof ventilator 32 may be made of any material, including polypropylene or other plastics which may be injection molded. The added advantage of using

polypropylene is that it emits odors which repel bugs and the like. Roof ventilator 32 may be installed at any place along the roof and may of any length. Although alternative methods for securing the vent 32 may become apparent to one of ordinary skill in the art, the preferred embodiment includes longitudinally extending portion 34 for securing. Preferably, the longitudinally extending portion 34 measures approximately 3 inches in width. The ventilator may be any length but is preferably from about 6 to about 9 inches wide.

While the best mode for constructing the invention has been herein described in detail, those familiar with the art to which this invention relates will recognize various alternative ways of carrying out the invention as defined by the following claims. Significantly, however, according to aspects of the present invention, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight.

EXAMPLE 2

(Second exemplary roof ventilator embodiments having at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members; U.S. Patent 4, 4,903,445 is incorporated herein by reference in its entirety)

A roof ridge ventilator (10) comprises a one-piece cover member (12) including a pair of flaps (14) and a hinge (16) unitary with the flaps to permit pivotal movement there between in order to allow use of the ventilator on roof ridges of different angles and pitches, the cover member being designed to be placed under the standard cap shingle such that the shingle extends over the cover member and down the top edges of longitudinally spaced outer support walls. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. A pair of vents (22) are located below the pair of cover member flaps (14), and each vent has openings (26) to permit air circulation through the roof ridge. Each vent (22) also has an upwardly projecting outer wall angled toward the cover member, and including weepage openings at the bottom of the outer

wall spaced between the outer support walls to permit collected liquids to drain there through. The angle of the outer walls is designed to deflect air flow over the roof ridge ventilator and across the top of the cap shingle secured to the upper surface of the cover member, thereby substantially preventing foreign particle entry through the roof ridge ventilator into the building. The ventilator easily accomplishes building code requirements for air flow while providing an attractive, nearly undetectable roof ridge ventilator having substantially reduced weight in view of the inventive cover surface recesses.

In accordance with the present invention, an improved roof ventilator is provided; a selectively-recessed roof ventilator affording a reduced weight. In addition to reduced weight,. rain, insects and dirt particles are prevented from entering the ventilated space while retaining compact size, low cost, ease of manufacture, ease of installation, sturdiness, and longevity. Essentially, the present roof ridge ventilator is adapted to extend longitudinally on a roof ridge covering the peak of the roof ridge. The ventilator is placed into position by merely laying the ventilator over the peak of the roof, and nailing through the ventilator into the materials below.

Specifically, the present invention includes a one-piece cover member of an elongated shape which includes a pair of flaps, each flap having an upper surface over which the cap shingles are secured and downwardly facing lower surface which has a pair of vents secured thereto. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. Each vent has a longitudinally extending inner wall with an upward slant and openings to permit air circulation through the roof ridge. In the preferred embodiment, the openings are of a louvered design. Each vent also has longitudinally spaced-apart support walls which run perpendicular to the peak of the roof that extend substantially vertically to limit the entry of dirt, insects and other foreign particles into the ventilated space. The support walls extend outwardly from under the cover member and extend beyond the cover member to leave portions of the support walls uncovered by the cap shingle and exposed to the outer elements. The exposed portions of the support walls have top edges which slope downward underneath the cap shingles and it is intended that the exposed portions of the support walls will be partially covered by the outermost edges of the cap shingle after installation. In addition, the outer walls have weepage openings to permit collected liquids to drain there through.

In order to deflect air over the cap shingle after it has been installed, each vent of the present invention has a longitudinally extending, upwardly projecting outer wall which connects the longitudinally spaced support walls and acts as a deflection means. The outer wall is angled toward the center of the ventilator and is made of a solid piece of material, with the exception of weepage openings at the bottom of the outer wall. The weepage openings are spaced between the outer support walls to permit collected liquids to drain therethrough.

With reference to FIG. 11 of the drawings, a roof ridge ventilator constructed in accordance with the present invention is generally indicated by reference number 10, having particular utility in the construction of residential and commercial buildings. Roof ridge ventilator 10 includes a one-piece cover member 12 of an elongated shape including a pair of flaps 14 and a hinge 16 unitary with the flaps and furthermore includes a longitudinal groove therebetween. The construction of the cover member 12 permits use of the ventilator 10 on roof ridges of varying pitches and angles. Cover member 12 has an upper surface 18 over which cap shingles are secured. The securement is normally provided by nailing through both the cap shingles and the ventilator 10 and is hereinafter more fully described. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively- recessed roof ventilator affording a reduced weight. Roof ridge ventilator 10 also includes a pair of vents 22 respectively located beneath the pair of cover member flaps 14. As hereinafter more fully described, each vent 22 has a slanted inner wall 24 which extends inwardly and upwardly. Inner wall 24 has a plurality of vent openings 26 as illustrated in FIGS. 11 through 14 to permit air circulation through the ventilator. Preferably, the openings 26 have a louver configuration, and include at least two louvers extending upwardly. The louvers are approximately from 0.100 to 1.0 inches wide, and from 0.5 to 5 inches long. Each vent also has support walls 28 which have top edges 30 for supporting the vent and the cap shingle secured thereto. Vents 22 are secured to lower surface 20 of flaps 14, preferably by attaching to the support walls 28. Each vent has a longitudinally extending, upwardly projecting outer wall 32 connecting the longitudinally spaced support walls 28, and angling toward the center of the cover member 12. Angled outer walls 32 have weepage openings 34 at the bottom which are spaced between the support walls to permit collective liquids to drain there through. The ventilator 10 may be made of plastic such as polypropylene, nylon, thermoplastic, epoxy resins, polyurethane or any other plastic inherent to various manufacturing methods. Both the cover member 12 and the vents 22 of

the ventilator are preferably made from these materials, although it is possible to utilize a suitable metal such as aluminum or sheet steel. The most preferred plastic is polypropylene because it emits bug repelling odors so that insects and bugs are discouraged from nesting or entering the roof through the ventilator.

Cover member 12 is designed to provide a ventilator with a lateral width that is substantially the same as the width of a standard cap shingle which is to be placed over the ventilator as illustrated in FIG. 14. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. Upon installation, the cap shingle should conform to the shape of the ventilator and thereby have the same pitch as the pitch of the roof, providing an aesthetically appealing appearance.

Turning now to FIG. 12, a top plan view of the roof ridge ventilator of the present invention is illustrated showing the relative location of louver openings 26, support walls 28 and weepage openings 34. With combined reference to FIG. 12 and FIG. 3, the special construction and angle of the angled outer wall 32 is illustrated. Flap 14, having an upper surface 18 and a lower surface 20, is shown having vent 22 attached to the lower surface of the flap. As illustrated, inner wall 24 includes louver openings 26. The top surface 30 of support wall 28 includes a descending portion 29 adapted to receive and be partially covered by the outermost edges of the cap shingle secured to the upper surface of the cover member, as better seen in FIG. 14. Support walls 28 are shown approximately 1/2 inch to 3 inches apart.

As shown in FIG. 13, the angled outer wall 32 extends upwardly and inwardly at an angle of approximately ten to seventy-five degrees with respect to the upper surface plane of the cover member flap. The angled outer wall extends upwardly from the top surface 18 of flap 14 by a distance denoted by numeral 40. Distance 40 may range from 0.001 to about 2 inches depending upon the application. Preferably, distance 40 is about 0.125 inches or the height of a standard shingle used in residential applications. This additional upward extension of the angled outer wall 32 is useful in deflecting the air flow over the roof ridge ventilator and across the top of the cap shingle. By deflection over the angled outer wall, the air is thrust onto the shingle body which has been attached to the vent. The advantage realized is the air is directed neither

above nor below the shingle, but rather, across it thereby substantially preventing foreign particle entry through the roof ridge ventilator into the building. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight.

With reference now to FIG. 14, the roof ridge ventilator described hereinabove is shown in a perspective view placed underneath shingles 21 and illustrates the placements of the upper cap shingle 21 as installed over the roof ridge ventilator 10. Shingle 21 extends beyond the outermost dimension of flap 14 slightly and rests on the downwardly sloped descending portion 29 of top edge 30. Flaps 14 of roof ridge ventilator 10 are formed such that a cap shingle 21 will extend laterally across the roof ridge ventilator and hang slightly into the open exposed area as shown in FIG. 14. The roof ridge ventilator 10 preferably has a length of about five feet, but may be any convenient length.

As illustrated in FIG. 14, each vent 22 of the ventilator includes a longitudinally extending inner wall 24 in which the vent openings 26 are provided. The louvered construction may be formed by slicing the sheet material of inner wall 24 and pressing the material into a louvered design. Alternatively, the louver openings may be formed during the injection molding process. Inner wall 24 acts as an interior baffle structure to prevent foreign particles and debris from entering the roof of the building, while allowing a substantially increased net free flow area for exhausting air through the roof. Suitable connections for securing the flaps 14 to support walls 28 may include many conventional means and methods, including rivets, heat deformation, and adhesive securing methods. When ventilator 10 is made from plastic or polyethylene, adhesives or rivets are preferable. The louver openings 26 have openings from about 0.1 to about 1.0 inches wide, and from about 0.5 to about 5.0 inches long. Preferably, there are at least 50 louvers extending upwardly in each roof ridge ventilator. Weepage openings 34 include at least one opening between each pair of longitudinally spaced support walls. The weepage openings are intended to allow liquids which collect in the inner recess of the ventilator to drain therethrough. Weepage openings 34 are preferably from about 0.25 to about 1.0 inches in length.

Turning now to FIG. 15, a roof ridge ventilator constructed in accordance with the present invention is shown installed on a conventional roof. As can be seen from the drawing,

the air rising to the top of the roof is exhausted by the roof ridge ventilator through the recesses between support walls 28. Such a construction may provide at least about 3 cubic feet of circulating air flow per minute per 100 cubic feet of attic space when the ventilator 10 is utilized with a conventional roof. Furthermore, the size of the openings 26 is nevertheless sufficiently small to prevent most foreign particles from passing there through or clogging the vents. The angled outer walls 32 act to deflect air flow up over the cap shingle 21 so that air flow across the roof is not impeded. The design of the present invention is intended to aid ventilation through the ventilator without regard to the orientation of the building.

While the best mode for constructing the invention has been herein described in detail, those familiar with the art to which this invention relates will recognize various alternative ways of carrying out the invention as defined by the following claims.

EXAMPLE 3

(Third exemplary roof ventilator embodiments having at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members; U.S. Patent 4, 6,491,581 is incorporated herein by reference in its entirety)

A roof ridge ventilator with filtering device to be installed under a cap shingle includes a one piece cover member of an elongated shape including a pair of flaps, each flap having one upper surface over which cap shingles are secured and also having downwardly facing lower surfaces, a pair of vents respectively secured to the lower surface of the cover member flaps, each vent including at least one set of shielded louvers having openings for deflecting air flow while maintaining a minimum free area for air passage such that the air flowing there through is substantially reduced in velocity to limit the infiltration of foreign matter. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. Longitudinally spaced supports extend substantially vertically to permit nailing onto the roof such that the vent does not collapse during installation and such that the net free area remains intact. A band of fibrous material positioned inboard of the vent to further prevent foreign matter for entering the attic.

In accordance with the present invention, a roof ventilator is provided. The roof ventilator includes a cover member having a flap with a first surface over which shingles are secured and a second surface. Additionally, there is at least one cover member surface recess

area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. The roof ventilator also includes a first set of louvers for deflecting airflow and reducing airflow velocity while maintaining minimum free area for air passage. Supports and a filter device are coupled to the cover member second surface. The supports extend from the second surface of the cover member flap at a height substantially equal to that of the first set of louvers to minimize interference with the first set of louvers by the supports. The filter device filters external air passing through the first set of louvers.

In accordance with other aspects of this invention, the filter device is a band of fibrous material and has a thickness that is substantially equal to the height of the supports.

In accordance with additional aspects of this invention, the filter device includes slits cut so as to be aligned with the supports when the filter device is attached to the cover member. The filter device is attached over the supports by the supports fitted into slits of the filter device.

In accordance with still yet other aspects of this invention, the roof ventilator further includes a second set of louvers located inboard of the supports. The second set of louvers have openings for further deflecting and reducing air flow velocity while maintaining a minimum free area for air passage.

A roof ventilator formed in accordance with the present invention has several advantages over roof ventilators used in the past. First, the filter device minimizes the passage of rain, insects, and dirt particles from entering the ventilated space while retaining the compact size and low cost of the roof ventilator. Second, the louvers deflect airflow while maintaining a minimum free area for air passage, such that the air flowing through the roof ventilator is substantially reduced in velocity to further limit the infiltration of foreign matter. Finally, because of its integrated design, a roof ventilator formed in accordance with the present invention can easily be manufactured and installed.

FIGS. 16 and 17 illustrate one embodiment of a roof ventilator 20 constructed in accordance with the present invention. The roof ventilator 20 includes a cover member 22, first and second louvers 24A and 24B, supports 26, and a filter device 28. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess

area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively- recessed roof ventilator affording a reduced weight. Except for filter device 28 (described further below), roof ventilator 20 is suitably formed from a thermal plastic, such as polypropylene, or other materials such as nylon, epoxy resin, polyurethane or other plastics. Alternatively, roof ventilator 20 may be formed from a suitable metal such as aluminum or sheet steel.

The cover member 22 includes first and second flaps 3OA and 3OB and a hinge 32 extending longitudinally between the first and second flaps 3OA and 3OB. The hinge 32 is suitably integrally formed with the first and second flaps 3OA and 3OB to form a unitary body.

The construction of the cover member 22 permits use of the roof ventilator 20 on roof ridges of varying pitches and angles. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. The roof typically contains an opening for venting the roof cavity. The roof ventilator

20 may be of any length, but is suitably four to five feet. In one embodiment, the roof ventilator 20 may be secured to a roof ridge by a cap shingle (not shown) by a well-known fastener (e.g., a nail, screw, tack, staple or other types of fasteners) extending through both the cap shingle and the roof ventilator 20.

The first and second set of louvers 24A and 24B are suitably integrally formed with the cover member 22 and include openings 34. Each opening 34 permits air circulation through the roof ventilator 20. Further, each opening 34 deflects airflow while maintaining a minimum free area for air passage, such that air flowing through the louvers 24A and 24B is substantially reduced in velocity to limit the infiltration of foreign matter. The openings 34 change the direction of airflow through the roof ventilator 20, such that airflow velocity within the roof ventilator 20 is reduced to substantially zero under normal conditions.

Still referring to FIGS. 16 and 17, the supports 26 will now be described in greater detail.

Each of the supports 26 are substantially rectangular and are integrally formed with the lower surface of the cover member 22, such that, in this embodiment, each support 26 is substantially

normal to the cover member 22. Additionally, there is at least one cover member surface recess area in the cover member, the at least one surface recess area positioned, at least in part, between two spaced support members to proportionately reduce the thickness of the cover member within the surface recess area relative to the cover member thickness at the respective support member extension positions, to provide for a selectively-recessed roof ventilator affording a reduced weight. The supports 26 are spaced at predetermined locations along the length of the roof ventilator 20 to minimize their impact on air flowing through the roof ventilator 20. In this embodiment, at least one side of the roof ventilator 20 includes two rows of aligned supports, such that an inboard and outboard row of supports are disposed in space relationship on the lower surface of the cover member 22. As configured, filter device 28 may be disposed between the spaced inboard and outboard rows of supports. Although in this embodiment, the supports 26 are rectangular in shape and extend normally from the surface of the cover member 22, in other embodiments, the supports can extend from the cover member at any suitable angle or shape so long as the configuration does not interfere with the roof ventilator 20 being properly mounted to the roof.

The filter device 28 is suitably formed from various fibrous materials, such as fiberglass, plastic fibers, natural fibers and coated natural fibers. The fibers may be loosely woven, or may be unwoven and held together with a binding material. In one embodiment, the fibrous material is the same as that used in SPEEDVENT vent products available from Northwest Building Products, Madison Heights, Mich. The fibrous material may include a backing or mesh on one or both sides to provide additional structural support for the filter device to hold its shape. In this particular embodiment, the filter device 28 is substantially rectangular in shape and may be adhesively or mechanically fastened between the inboard and outboard rows of the supports 26. As fastened between supports of the supports 26, the filter device 28 extends the length of the roof ventilator 20. The filter device 28 further minimizes infiltration of foreign matter into the roof to which the roof ventilator 20 is mounted, while still allowing ventilation. In this embodiment, the filter device 28 is advantageously placed away from the opening in the roof ridge so that the fibrous material will not sag or otherwise fall into the roof ridge opening.

Operation of the roof of ventilator 20 may be best understood by referring to FIG. 18. For clarity, this description is for one half of the ventilator (i.e., the half containing louvers

24A), with the operation for the other half (i.e., the half containing louvers 24B) being essentially identical. In ventilation operation (i.e., when conditions tend to allow air to flow out of the ventilator), air tends to flow from the roof ridge opening toward the cover member 22.

This airflow is typically caused by convection and/or external airflow over the roof (i.e., the shape of the ventilator along with the orientation of the louvers can cause a pressure differential that facilitates airflow out of the ventilator). In normal ventilation, air flows through the filter device 28 as indicated by the arrow 52. The air passes through the filter device 28 and then through the louvers 24, as indicated by an arrow 50.

Because the airflows and pressure differentials involved with ventilation are relatively small compared to those experienced during extreme weather conditions, it is desirable that the filter device impedes the ventilation airflow as little as possible while still providing the desired infiltration protection. Therefore, in accordance with the present invention, filter device 28 is formed into a relatively narrow band or strip of fibrous material. In conjunction with the internal louvers (e.g., louvers 24A), the relatively narrow width of the band is sufficient to achieve infiltration performance to meet current extreme weather building codes while minimizing obstruction of ventilation airflow out of the roof. In one embodiment, the band is about 1.25 inches wide, but the width can be smaller or larger, depending on the density of the filter material, louver performance, and building code infiltration requirements. In view of the present disclosure, those skilled in the art can determine the suitable filter parameters to meet these requirements. The filter thickness preferably matches the height of the louvers. One advantage of this embodiment is that the louvers tend to filter out solid matter so that the filter device will not become clogged. Under extreme weather conditions when water may leak past the louvers, the filter device prevents this water from leaking into the roof ridge opening.

In infiltration operation (i.e., when conditions tend to cause air to flow into the roof ventilator), as air passes through the openings 34 of the louvers 24A, this air is deflected upward, following a course in the opposite direction of the arrow 50. As a result, the free area through which air is permitted to pass is minimized, thereby substantially reducing both the velocity and infiltration of foreign matter of air passing through the louvers 24A.

After air passes through the louvers 24A, this air passes through the filter device 28, following a course that is opposite that of the arrow 52. The filter device 28 further reduces passage of airborne foreign matter through the roof ventilator 20. As a result, airborne matter within air passing through the roof ventilator 20 is filtered out through the louvers 24A and the filter device 28. As previously described, the louvers 24A and the filter device 28 operate together to meet current extreme weather building codes while minimizing obstruction of ventilation airflow out of the roof.

Referring now to FIG. 19, an alternate embodiment of a roof ventilator 120 formed in accordance with the present invention is illustrated. The roof ventilator 120 of this alternate embodiment is substantially identical in materials and operation as roof ventilator 20 (FIG. 18) described above, except that roof ventilator 120 includes a retainer 136. Except for retainer 136, the reference numbers used in describing features and elements of roof ventilator 120 are the same as those of roof ventilator 20 (FIG. 18), but preceded by a numeral " 1" so that the description of roof ventilator 20 can be easily applied to roof ventilator 120. Attachment of the filter device 128 may be had by a retainer 136 extending normally from the free end of the inboard row of supports 126. The retainer 136 extends outboard from the free end of the inboard row of supports 126 to further assist in retaining the filter device 128 within the roof ventilator 120.

FIG. 19A illustrates a roof ventilator 120A that is substantially similar to roof ventilator 120 (FIG. 19), except that roof ventilator 120A has a retainer 166 that extends to the opposite support 126 (adjacent to louver 124a) instead of the shorter retainer 136 (FIG. 19). Support 126A includes a fitting 168 that fits into a slot (not shown) on retainer 166. In this embodiment, the fitting 168 has the shape of a tapered or angled flange and is formed from a substantially rigid yet resilient material. The flange is formed so that one side is tapered toward the distal end of the fitting 168 but the other side facing cover member 122 is flat. The resilient material and tapered side of the flange allows the fitting 168 to be fitted through the slot in retainer 166, while the flat side of the flange prevents the retainer 166 from being moved away from support 126A. This feature further aids in retaining filter device 128 in roof ventilator 120A. Further, this feature can advantageously eliminate the need for adhesive to bond filter device 128 to the cover member 122. Alternatively, the fitting 168 and the slot may be formed on the retainer 166 and support 126A, respectively.

FIG. 19B shows another alternative embodiment similar to that of FIG. 19A except that the retainer 155 does not overlap the support 126A. Instead, in this embodiment, the retainer 166 is formed as integrally with support 126 and is folded over so that the end of the retainer 166 contacts the support 126A. In this embodiment, a lip 170 is formed on the support 126A. In this embodiment, the lip 170, the retainer 166, and the supports 126 and 126A are formed from a resilient material, such as a plastic or polymer, that allows the retainer 166 to be bent over past the lip 170 after the filter device 128 is placed between the supports 126 and 126A. That is, the end of the retainer 166 is forced past the lip 170 to be "snapped" into place,

contacting and flush with the support 126A. The retainer 166 together with the lip 170 serve to hold the filter device 128 in place.

Referring now to FIG. 20, a second alternate embodiment of a roof ventilator 220 formed in accordance with the present invention is illustrated. The roof ventilator 220 is identical in materials and operation as the embodiment described above with the following exceptions described below. Except for the second set of louvers 270, the reference numbers used in describing features and elements of roof ventilator 220 are the same as those of roof ventilator 20 (FIG. 18), but preceded by a numeral "2" so that the description of roof ventilator 20 (FIG. 18) can be easily applied to roof ventilator 220.

In this alternate embodiment, a second set of louvers 270, a mirror image of the first set of louvers 228a, is located in a V-shaped configuration, such that the second set of louvers 270 extend from the base of the outboard set of supports at a predetermined angle to intersect the inboard set of supports. In this embodiment, the angle is about 25 degrees but any angle up to 90 degrees can be used depending on the height and intersection point of the outboard set of supports. In this embodiment, the band of fibrous material for the filter device 228 includes slits 248 that are cut to a depth that is substantially equal to the height of the support, or deeper, or even all the way through the filter device 228. The slits 248 run longitudinally and are suitably cut at a distance spaced from each other equal to the distance between each support. The filter device 228 is attached over the supports, with the slits 248 fitting snugly over each support 226. Alternatively, the filter device may be attached to the cover member adjacent to or in the second set of louvers so that airflow into the roof ventilator must pass through two sets of louvers before flowing through the filter device.

FIG. 21 illustrates a roof ventilator 320 formed in accordance with another embodiment of the present invention. The roof ventilator 320 is identical in materials and operation as roof ventilator 220 (FIG. 20) described above except that the single row of supports 226 adjacent to louvers 224A is replaced with two rows of supports 326A and 326B. Except for these supports, the reference numbers used in describing features and elements of roof ventilator 320 are the same as those of roof ventilator 220 (FIG. 20), but incremented by 100, so that the description of roof ventilator 220 (FIG. 20) can be easily applied to roof ventilator 320.

In this alternate embodiment, the row of supports 326A is formed on part of the first set of louvers 324A while the other row of supports 326B is formed on the second set of louvers 370. In this embodiment, the band of fibrous material for the filter device 328 is disposed

between the rows of supports 326 A and 326B. The filter device can be attached to the roof ventilator 320 by adhesive or mechanical fasteners. In a further refinement, retainers (not shown) as described above in conjunction with FIGS. 8 and 8B can be added.

FIG. 21A illustrates a refinement of the embodiment of FIG. 21, with the supports 326A and 326B placed closer together. In this embodiment, the supports 326A and 326B are about 0.5 inches apart, although other distances can be used in other embodiments as required to match the width of the filter device. The fibrous material of the filter device 328 is placed between the supports. It is believed that the two sets of louvers in this embodiment allow the filter device 228 to be relatively narrow while still achieving the desired infiltration protection.

FIG. 22 illustrates a support 426 formed in accordance with another embodiment of the present invention. As shown in FIG. 22, support 426 includes serrations 480 along a sidewall. The serrations 480 can have a spine-like, barb-like, spike-like shape, etc., with sharp points directed generally toward the cover member 422. When the roof filter is assembled, the filter device (omitted for clarity) is adjacent to and contacting the serrations 480 of the support 426. The serrations 480 tend to allow the filter device to move towards cover member 422 during assembly. In addition, the serrations 480 tend to prevent the filter device from moving away from cover member 422 by becoming enmeshed in the fibrous material of the filter device, thereby helping to fasten the filter device securely to the support 426. These serrations can be provided in one or more of the supports of the embodiments depicted in FIGS. 18-21.

From the foregoing descriptions, it may be seen that a roof ventilator formed in accordance with the present invention incorporates many novel features and offers significant advantages over currently available roof ventilators. While the presently preferred embodiments of the invention have been illustrated and described, it is to be understood that within the scope of the appended claims, various changes can be made therein without departing from the spirit and scope of the invention.