Cross-Reference to Related Applications

[0001] This application claims priority of both United States Provisional Patent Application No. 63/045,089, filed 27 June 2020, and United States Provisional Patent Application No. 63/137,017, filed 13 January 2021.

Technical Field

[0002] This invention relates to battens for use as support structures on surfaces such as roofs

Background

[0003] Roofs used to be little more than some kind of more or less waterproof surface on a frame. Examples of such roofs include thatch, palm fronds, split wood shakes, and even, in Viking times, peat, turf or sod on a layer of birch bark. Modern roofs are naturally much more complicated and use both techniques and materials that are more suitable to mass production and are intended to be more efficient and long-lasting.

[0004] Modern roofs usually still have a frame, including such bearing members as rafters or trusses, which support some sheathing material such as boards, plywood or composite, but typically often have additional exterior structures or layers to provide greater waterproofness, insulation, ventilation, and support for the outermost protective covering of metal, shingles, shakes, tiles, etc.

[0005] Battens, also referred to as slats, form one such supporting structure. Battens are usually a set of lengths of wood or other material that are attached to an immediately underlying structure and to which the final roof covering is secured. The distance between adjacent battens is often specified by the manufacturer of the roof covering so that fasteners will be in the proper positions. For example, measured in the direction perpendicular to the roof ridge, the proper distance between battens for shingles may be different than that for tiles, which may in turn be different than that for metal sheets. Properly placing battens therefore usually requires repeated and precise measurements to ensure proper spacing and, in many installations, that the battens are parallel. This can be time-consuming, and also requires frequent movement by one or more roofers working to install the roof.

[0006] An additional consideration when it comes to installing a roof is that, to reduce the risk of condensation and moisture damage there should preferably be an air gap for ventilation between roof battens that support the outer roof covering and the underlying roof surface. At present, to the extent this is done at all, an additional set of batten-like strips are secured to the underlying roof surface perpendicular to the supporting battens. This leads not only to the need for additional material, but also to greater installation complexity.

Brief Description of Drawings

[0007] Figure 1 is a bottom view of one embodiment of a batten arrangement.

[0008] Figure 2 is a top view of the batten arrangement of Figure 1. Note that the concepts "top" and "bottom" may be reversed depending on the installation.

[0009] Figure 3 shows an end view of the batten arrangement of Figures 1 and 2 in a non-extended configuration, viewed in the length-wise direction of the batten arrangement.

[0010] Figure 4 is a side view of the batten arrangement of Figures 1 and 2 in a non-extended configuration, viewed perpendicular to the length-wise direction of the batten arrangement.

[0011] Figure 5 illustrates one way in which a connecting strap can be attached to a batten.

[0012] Figure 6 is a perspective view of the batten arrangement of Figures 1 and 2 in the non-extended configuration.

[0013] Figure 7 illustrates the embodiment of the batten arrangement of Figures 1 and 2 on a roof, in the non-extended configuration.

[0014] Figure 8 illustrates the embodiment of the batten arrangement of Figures 1 and 2 on a roof, in an extended configuration. [0015] Figure 9 shows an embodiment of a batten arrangement with battens of unequal length.

[0016] Figure 10 illustrates an embodiment of a batten arrangement with non parallel battens.

[0017] Figure 11 is a perspective view of the batten arrangement provided with spacing elements.

[0018] Figures 12 and 13 are views from underneath and above, respectively, of the batten arrangement with the spacing elements.

[0019] Figures 14A-14E show different views of one embodiment of a spacing element.

[0020] Figure 14F shows an embodiment of the spacing element with a hole through it.

[0021] Figure 15 illustrates the batten arrangement, with spacing elements, in the non-extended configuration.

[0022] Figure 16 is an end view of the batten arrangement, that is, a view in the direction of extension of the connecting straps, when the batten arrangement in the non-extended configuration.

[0023] Figure 17 shows the batten arrangement with the spacing elements, viewed from the side in the direction of lengthwise extension of the battens.

[0024] Figures 18-20 shows a perspective, top, and bottom view of an embodiment of the batten arrangement, with spacing elements, in the non- extended configuration.

Description of Embodiments

[0025] In broad terms, different embodiments of the invention provide a batten arrangement 100 that can be easily manufactured and quickly installed, and that ensures proper batten spacing with no need for time-consuming, repeated, individual measurements for proper placement. Spacing elements ("spacers") are also disclosed that may be used in some embodiments to provide spacing between battens and an underlying building surface, such as a roof. [0026] Figure 1 illustrates a basic embodiment of the batten arrangement for use on a simple roof, that is, a roof that is substantially rectangular. Just for the sake of reference, x-y axes are indicated in the figure. In this embodiment, two or more battens 100a, 110b, ..., 110h (referred to below collectively by the common reference number 110) are intended to be parallel, with a separation b, an overall length L (of the batten arrangement as a whole), and a width w (also of the batten arrangement as a whole). In the figures, L and W correspond to the length and width of the roof on which the battens are to be mounted; the battens themselves will typically each be as illustrated, that is, longer than they are wide, extending mostly in their own lengthwise direction (here, the x-direction). The battens may be made from any conventional material such as wood that is suitable for being fastened on an underlying surface and for having coverings such as shingles, tiles, asphalt roofing paper, metal, etc., attached to them, usually by nails, screws, rivets, etc. To maintain this separation, the battens 110 are connected by two or more substantially non-stretch connecting elements such as straps 120a, 120b, 120c (referred to below collectively by the common reference number 120), which, in this embodiment, extend parallel to each other and perpendicular (in they direction) to the lengthwise (x) direction of the battens 110, and with a separation 5.

[0027] In Figure 1 , eight battens and three connecting straps are shown, where each batten has a width of bw. This is purely by way of example. The number of battens and their spacing b, and the number of straps and their spacing 5, are design choices that will depend on, among other things, the shape and size of the roof the battens are to be mounted on, the required spacing of the outer covering (shingles, tiles, metal, etc.) that are to be secured to the battens, etc. Moreover, as is illustrated below, in other embodiments, any or even all of the parameters bw, b, s, L and W need not be constants, that is, not the same for all the battens and straps.

[0028] The straps 120 should be made of a material that is bendable, but substantially lengthwise inelastic. By "substantially" is meant that, over the total length L of the batten arrangement, under the tensile force of the arrangement itself as it is laid and extended on a roof, the greatest increase due to strap stretch in the separation of adjacent battens should not exceed the tolerance for positioning and attaching the intended roof covering on the battens. The material chosen for the straps should also allow for easy attachment, such as by stapling or the like, to the battens, without tearing under expected loads.

[0029] One suitable material for the connecting elements (here, the strap members 120) is a relatively inelastic polymer such as polyester, such as for cargo straps commonly used to secure goods to pallets, to secure cardboard boxes for large and heavy items, etc. Such strapping has the additional advantages of high tensile strength, split resistance, low cost, ease of application, ease of attachment to itself (so as to enable end loops), and flatness, such that it will not interfere with the lay of the battens or of any covering. It also does not have a sharp edge, which increases the safety of the workers working with it. It would, however, also be possible to use other materials such as metal wires, relatively inelastic cord (such as polypropylene or carbon fiber-based), etc., as long as they fulfill the requirement for substantial lengthwise inelasticity. All these alternatives are referred to here as "straps" for the sake of succinctness. Although it is preferable from the viewpoint of ease of manufacture and installation, each strap 120 is preferably a single element that extends from one end batten to the other. It would also be possible, however, to use multiple, but shorter straps that, together, make up a single connecting member for the battens.

[0030] In many cases, the batten arrangement 100 may be installed with the straps 120 either on the under side or the top side of the battens. Figure 2 shows the batten arrangement with the straps 120 underneath the battens. The choice will depend on the underlying structure and the outermost roof covering. Once the battens are secured to the underlying surface, in any conventional manner such as with nails or screws, the straps will no longer be needed, although, if they are on the top side of the battens, they may provide some extra support for some parts of roof coverings such as metal roof sheets, or aid in vertical alignment of such sheets.

[0031] Figure 3 shows the batten arrangement 100 as it might be delivered from a manufacturer, or during transport. Flere, the batten arrangement is "compact", that is, the battens are "undeployed", packed together, such that the straps 120 stick up between them in loops. One end of each strap, or at least some of the straps, may be made into a loop 122 that forms a handle so that workers can easily pull the battens into the correct position on a roof. Figure 4 shows the batten arrangement viewed in the plane of and perpendicular to the lengthwise direction of the battens 110.

[0032] Figure 5 illustrates one example of how a strap 120 may be attached to a batten 110 using any conventional fastener 300 such as a staple, which has the advantage of ease of manufacture and low cost. Other fasteners may be used, however, such as rivets, tacks, screws, nails, etc., or even glue. Moreover, embodiments may also use the spacing elements described below, which also function to secure the straps to battens. The main requirements are that whatever connection arrangement is used should not allow the strap to shift more than negligibly and should not cause it to split or tear.

[0033] Figure 6 is a perspective view of the batten arrangement (the Figure 1 embodiment) in its compact, "stowed" (undeployed, non-extended) configuration, in which the battens 110 lie against or immediately adjacent to each other, separated only by the loops of the straps and any other unrelated features that designers might choose to put on the edges of the battens.

[0034] Figure 7 illustrates one example of the Figure 1 embodiment of the batten arrangement 100 in the undeployed configuration on a roof 200. In some countries, battens 110 are mounted directly onto the roof sheathing 220. In other countries, the horizontal (extending lengthwise in the x-direction) battens 110 are in turn attached to additional vertical (extending lengthwise in the y-direction) battens 230, which allows for ventilation between the batten arrangement 100 and the roof sheathing 220. Embodiments of the invention may be used in both cases.

Moreover, an arrangement is disclosed below that may eliminate the need for the battens 230 through the use of spacers 400 that allow for ventilation under the horizontal battens 110.

[0035] As Figure 7 shows, the batten arrangement 100 may be laid on the roof 200 such that the lowermost batten aligns with the lower edge of the roof, with whatever spacing from the edge is needed for the given installation. For example, grasping the end loops 122, workers can then pull the batten arrangement upwards into the position shown in Figure 8, in which the straps 120 are taut and the battens are "automatically" spaced at the correct distance b. Note that another advantage of the straps 120 is that, given sufficiently small relative spacing, they will also tend to help hold the battens straight, that is, to prevent the battens from "sagging" in between the endpoints, when they are deployed on the roof. The battens may then be fastened to the underlying supporting structure (vertical battens 220, if included, or directly on the sheathing 230) in any conventional manner. Note that it would also be possible to start with the compact batten arrangement at the roof ridge and pull it downward instead.

[0036] Figures 7 and 8 show a single batten arrangement 100 on the roof 200. In some cases, if the roof is so wide that a single batten arrangement isn't wide enough, it would of course be possible to mount two or more batten arrangements on the roof, each with the batten spacing b.

[0037] As Figure 9 illustrates, the battens and straps may be arranged to be suitable for mounting on roofs that have other than the simple, unobstructed, rectangular shape shown in Figures 7 and 8. For example, the batten arrangement may be needed for a roof with extending structures such as chimneys that are too big for the batten arrangement to be simply placed over, or with a geometry that includes different planes. In the batten arrangement illustrated in Figure 9, at least two of the battens 110 have different lengths (x-direction). The straps 120 may also have different spacing as needed so that all the battens are properly supported, with a strap near enough each end of each batten that it will not tend to twist out of position and proper spacing. Thus, in the illustrated example, bl ¹b2 and sl¹s2.

[0038] In most anticipated implementations, the battens 110 will have the same width. This is, however, not necessary and may also be made a selectable parameter for each or for one or more of the battens. The size or type of roof covering might vary, for example, over the surface of the roof, so as to give it a deliberately less uniform appearance, or because some portions of the roof have a different geometry or requirements than others. For example, in Figure 9, the topmost batten is shown as having a width bwl, whereas all the battens below it are shown as having the width bw2 ¹bwl. Flaving different batten widths may affect the batten spacing b, but since it will in most cases be so that the batten arrangement 100 is made according to a predetermined specification, this will be something the manufacturer can easily account for using known methods, or simple pre-configuration. [0039] Figure 10 illustrates yet another embodiment, suitable for mounting on irregular roof structures such as hips or valleys, non-rectangular, overhanging porch roofs, etc. In this case, the battens 110 are not parallel, but rather the lengths of the straps are chosen such that the battens assume the proper geometry when the straps are taut. In implementations such as the one shown in Figure 10, the straps 120 are not in a straight line over their entire length, but for the best stability, they still expend primarily perpendicular, that is, with the largest directional component, relative to the battens to which they are attached. In the illustrated case, when mounting the batten arrangement on the roof, an initial reference might be, for example, a line of curvature of the bottom of the roof or roof section. Once the lower ends of the battens are properly positioned, with or without being fastened, the batten arrangement may be "fanned out" into the desired configuration and position. Alternatively, the end battens may be held in place where they should be, and the battens between may be adjusted so that they lie in the correct positions; the straps will in either case ensure the proper spacing once the reference battens are secured.

[0040] Embodiments of the invention lend themselves well to the efficient and cost-effective manufacture of batten arrangements for not only roofs with standard dimensions and shapes, such as pre-fabricated houses, but also for roofs with more complicated geometries. Given the desired number of battens, their spacing, possibly different widths and their geometry, a manufacturer may easily determine the number and positioning of the straps to ensure that the arrangement will have the proper configuration when fully extended. This could be done by actually laying out and connecting battens according to the specification, or to form a template for additional batten arrangements.

[0041] Designing, and even manufacturing, a batten arrangement according to user- or customer-specified parameters, received as inputs, may also be done using a software routine and known mathematical techniques. The inputs will typically include the dimensions (such as L and W, or other dimensions sufficient to define a non-quadrilateral surface) of the roof or portion thereof that the batten arrangement is to cove. Unless the values are standardized and thus already known, the desired separation profile of the battens may also be made a user- selectable input parameter (which, as Figure 9 illustrates, need not be uniform), as well as batten widths (b or bwl, bw2, etc.) other than any pre-determined standard, optionally strap separation ( s , or si, s2, ... etc.), and any other optional information the user may be allowed to input, such as type of materials used. Note that a suitable number of straps and their separation(s) may instead be computed by the manufacturer based on a maximum preferred per-strap load and/or degree of allowable bending of the battens. With such a specified geometry, the points of attachment for the straps and the battens (using, for example, the elements 300 or spacers 400 below) may be modeled as points of connection for lines that represent the straps 120. Especially for implementations with constant-width battens bw, the battens may be modeled either as rectangles, or, if the points of attachment are assumed to be at the center of each batten, as lines. This geometry could then be transferred to the machine that cuts the selected battens to length(s) and attaches the straps to them with the elements 300 or spacers (see below). The arrangement may then be conveniently delivered to a customer in the stowed configuration. Custom-made batten arrangements may in such cases be at most negligibly more difficult to manufacture than the "standard" arrangement shown in Figure 1.

[0042] Battens are used on other building surfaces than roofs. For example, battens may also be used for walls. The different embodiments of this invention may of course be used in such projects as well.

[0043] Batten Arrangement with Integrated Spacing Elements

Figure 11 is a perspective view that illustrates an embodiment of the batten arrangement 100 in which spacers 400 (only one of which is numbered, to avoid clutter in the figure) are provided as a means of not only attaching the straps 120 to the battens 110, but also to raise the battens 110 off of the underlying surface and thus to provide better ventilation. Figure 12 shows this arrangement from the underneath as it would be mounted on a roof, and Figure 13 shows it from above.

[0044] Figures 14A-E illustrate an embodiment of the spacer 400, which is preferably manufactured as a unit, but could also be assembled from component parts, for example, by gluing or other means. The material from which each spacer is manufactured should be able to withstand the lateral forces that will arise when the batten arrangement is extended on a roof. In implementations in which the batten arrangement is to be secured on the roof with screws, nails, or the like, it should also be possible to screw or nail down through the spacer without it cracking. (An embodiment is described below that in most cases will avoid this risk.) Many different kinds of plastic are therefore suitable for manufacturing the spacers 400, as well as composites, some woods, certain types of rubber or other elastomers, etc. The thickness of each spacer, that is, its extent in the z-direction as shown in Figure 14B, will be chosen depending on how big a gap is desired under the battens

[0045] When in place, a batten will rest on an upper surface 410 of the spacer, between opposing side walls 412. The upper surface 410 is recessed at least enough to prevent lateral movement of a batten when the batten rests on it, and the distance between the lateral walls 412 is preferably approximately the same as the width of a batten, again, so that the batten will be secured laterally.

[0046] A "track" or groove 414 extends vertically (the z-direction as shown in the figure) between opposing edge portions 415 of the spacer 400 and receives the strap 120 when the arrangement is in the non-extended configuration, which is illustrated from the side in Figure 15. The depth of the track 414 is preferably at least as great as the thickness of the strap so that adjacent portions of the strap don't rub against each other in the non-extended configuration. As Figure 15 shows, in this configuration, the strap 120 will extend upward as a "loop" between adjacent battens 110 and extend under each spacer 400, perpendicular to the battens. (If the battens themselves are not parallel, then the strap will extend under the spacers accordingly.) By making the track 414 at least as deep as the strap is thick, the strap will therefore not rub against itself, and the spacers will sit flush against each other, when the arrangement is in the non-extended configuration.

[0047] Figure 14E is a bottom view of the embodiment of the spacer, that is, of the bottom surface 420 of the spacer, which will lie against the underlying roof surface or covering. As illustrated, a groove/track 421 extends in the direction of the strap, to receive the strap between two relatively raised side portions 422. As can also be seen in Figure 14D, the groove 421 should also preferably be at least as deep as the strap is thick, so that the spacer will lie flush on the underlying surface. This not only ensures good contact, but is also a safety feature for the worker, since it helps prevent slipping and rolling of the spacer. To further reduce the risk of slippage, and to help hold the batten arrangement in place when it is first deployed on a roof, before it is permanently secured, it would also be possible to abrade the bottom surface of the side portions 422, or to affix or apply a non-skid strip or material to them.

[0048] The strap 120 is secured immovably within the groove 421 of the bottom surface 420 of each spacer in its "row" using any suitable method, such as glue, partial melting (when the spacer and strap are made of compatible plastics), with fasteners, or any other chosen means.

[0049] It would also be possible to manufacture a slot through the spacer, in the y- direction, through which the strap is threaded, such that the strap runs through rather than under each spacer; even in this case, the strap should be secured so that it does not slide relative to the spacer and thus to the corresponding batten.

[0050] When the batten arrangement is deployed on a roof, as mentioned above, it will be secured using nails, screws, etc. In embodiments that include the spacers 400, this will mean having to nail, screw, or otherwise drive the chosen fastener through not only the batten, but also through the spacer and down into the roof surface. If the spacers 400 are made of a suitable plastic, elastomer, or other material that can withstand penetration by the fastener without cracking, then it may be acceptable simply to do so. In other cases, or to avoid all risk of cracking, a hole 430 (Figure 14F) may be pre-drilled vertically (z-direction) through the spacer. The hole is preferably larger than the expected diameter of the fastener so as to allow for a margin of error when driving the fastener down through the approximate center of the batten and of the spacer.

[0051] Figure 16 shows, viewed in the y-direction, how the straps extend up between the battens 110 when the arrangement is stowed. Figure 17 shows how, when the batten arrangement is then extended, the straps extend essentially without bend under the spacers, and thus under the battens. The embodiment of the batten arrangement with the spacers 400 may therefore be deployed just as in Figures 7 and 8.

[0052] Figures 18-20 show the batten arrangement in the non-extended, ready-to- deploy configuration, in a perspective view, a view from above, and a view from underneath, respectively. Note that, even with the spacers 400, the arrangement may be made compact and easy to transport. The battens, although separated laterally a bit by adjacent spacers, will still be held securely, without the straps rubbing against themselves, since adjacent spacers may rest flush against each other.

[0053] Once the batten arrangement with spacers is deployed on a roof, it may be secured in place as usual. Fasteners such as nails or screws will then pass through the strap-batten "intersections" as before, but in this embodiment this will typically mean that they should pass through not only the batten, but also the spacer, that is, into surface 414 and out surface 421 into the underlying roof structure. Note that it will not matter if the fastener also punctures the strap underneath the spacer since, at that point, the batten/spacer assembly will be secured to the underlying surface anyway; moreover, if the strap is made from, for example, web-reinforced polyester, then it will generally not break or stretch even if punctured.