U.S. patent application number 10/695041 was filed with the patent office on 2005-11-03 for ridge cap closure system.
This patent application is currently assigned to ATLAS BOLT & SCREW CO.. Invention is credited to Ridenour, Randall D..
Application Number | 20050241248 10/695041 |
Document ID | / |
Family ID | 34522698 |
Filed Date | 2005-11-03 |
United States Patent
Application |
20050241248 |
Kind Code |
A1 |
Ridenour, Randall D. |
November 3, 2005 |
Ridge cap closure system
Abstract
A roof closure system for use with corrugated panel roofs having
a ridge cap and ventilated or non-ventilated foam closures
permanently attached thereto, the ridge cap and the foam assembled
as a ready-to-use single unit. The foam closure is formed a highly
mallable foam material such that the closure may be used with any
style of corrugated metal roof panels.
Inventors: |
Ridenour, Randall D.;
(Mansfield, OH) |
Correspondence
Address: |
Thomas W. Ryan
PIPER RUDNICK LLP
P.O. Box 64807
Chicago
IL
60664-0807
US
|
Assignee: |
ATLAS BOLT & SCREW CO.
|
Family ID: |
34522698 |
Appl. No.: |
10/695041 |
Filed: |
October 28, 2003 |
Current U.S.
Class: |
52/198 |
Current CPC
Class: |
E04D 3/40 20130101; E04D
13/174 20130101 |
Class at
Publication: |
052/198 |
International
Class: |
E04D 003/36 |
Claims
I claim:
1. A pre-assembled closure system for a corrugated roof, the
closure system comprising a ridge cap having a plurality of
dependent ledges, each of said dependent ledges having a foam
closure permanently attached thereto.
2. The pre-assembled closure system of claim 1 wherein the foam
closure is formed of a malleable foam material whereby the foam
closure can conform to a wide variety of patterns of corrugated
panels.
3. The pre-assembled closure system of claim 1 wherein the foam
closure is selected from the group comprising ventilating foams and
non-ventilating foams.
4. A manufacturing method of forming a pre-assembled closure
system, the method comprising: a) forming a ridge cap for a peaked
corrugated roof building, said ridge cap having a plurality of
dependant ledges; b) permanently attaching a foam closure to said
ridge cap, wherein said attachment is undertaken by automated
means.
5. The method of claim 5 wherein forming the ridge cap and
attaching the foam closure are undertaken concurrently on a
manufacturing line.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention finds use in the field of ridge or roof caps
for freestanding structures. More particularly, this invention
relates to a ridge or roof cap for structures having corrugated
metal roofs and vented or non-vented foam closures.
[0003] 2. Background
[0004] Many types of freestanding structures, particularly
commercial buildings, are constructed with roofs formed from
corrugated metal panels or sheets. In a building having a peaked or
pitched roof, as opposed to a flat roof, a roof or ridge cap is
placed at the peak. Depending on the requirements of the building,
the ridge cap may serve to assist ventilation in the building in
combination with ridge vents in the eaves.
[0005] By its very nature, the surface of a corrugated metal panel
has a series of repeating troughs and crests. When an object, such
the flat attachment portions of a ridge cap are placed on top of
such troughs and crests, gaps are formed between the object and the
corrugated metal panel. Such gaps are not welcome due to issues of
insulation, moisture weathering, and wear from debris collecting in
the gaps. It is therefore custom practice to place a strip of foam
between the ridge cap attachment portions (flaps) and the
corrugated roof panels. The foam is usually contoured on one side
to the pattern of the corrugated roof panel and contains an
adhesive backing. At the construction site, the adhesive backing on
the foam is exposed and the foam is attached to the roof panels.
The ridge cap is lined up with the foam closure on the corrugated
roof and fastened using conventional means known in the art such as
screw, nails, or bolts.
[0006] While there is no doubt that prior art foam closure systems
are functional, they present several usability problems which can
interfere with an otherwise smooth installation in the field. The
adhesive backing can sometimes be difficult to expose and, upon
exposure, can pick up dirt, dust and other debris from the job
site, leading to problems with adhesion and possible premature wear
of the foam or the ridge cap. It can also be difficult to line up
the exposed adhesive portions of the foam with the roof panels,
leading to possible waste of materials and manpower to correct
misaligned pieces of foam. Finally requiring corrugated metal
panels, foam closures needing to correspond to the shape of the
corrugations, and ridge caps, all possibly from separate
manufacturers, complicates the ordering and delivery process and
leads to clutter on the job site
[0007] It is therefore an object of the present invention to
provide a roof ridge cap and foam closure that is easy and
economical to install in the field.
[0008] It is another object of the present invention to provide a
roof ridge cap and foam enclosure that reduced the likelihood of
collecting unwanted dust, dirt and debris.
[0009] It is yet another object of the present invention to provide
a foam closure that is able to mate to a wide variety of
corrugation styles of metal roof panels so as not to be profile
sensitive.
[0010] These and other objects of the invention will be apparent to
those skilled in the art for the following detailed description of
the preferred embodiments of the invention.
SUMMARY OF INVENTION
[0011] The invention comprises roof closure system for use with
corrugated panel roofs having a a ridge cap and ventilated or
non-ventilated foam closures permanently attached thereto,
manufactured as a single unit. In the preferred embodiment of the
invention, the foam closure is formed a highly mallable foam
material such that the closure may be used with any style of
corrugated metal roof panels. It is also contemplated that the foam
closures attached to the ridge caps may be formed of a shaped foam
that corresponds to a particular pattern or style of a corrugated
metal roof panel.
BRIEF DESCRIPTION OF THE DRAWING
[0012] Specific embodiments of the invention have been chosen for
purposes of illustration and description, and are shown in the
accompanying drawing, forming a part of the specification
wherein:
[0013] FIG. 1 is a cross-sectional view of the inventive ridge cap
closure system on a metal paneled roof.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] The ridge cap closure system according to the present
invention will be described herein by reference to the accompanying
drawing wherein FIG. 1 shows a cross-sectional view of of the
inventive ridge cap closure system on a metal paneled roof.
[0015] As described in further detail, below, the subject ridge cap
closure system 10 is generally comprised of a ridge cap 20 having
two or more dependant ledges 22 runing the entire length of both
sides of the ridge cap and foam closure strips 24 attached to each
of said dependant ledges 22. The ridge cap 20 portion of closure
system 10 is constructed of metal conventionally used in metal
panel roof buildings, such as galvanized steel, aluminum or copper
and is available pre-formed from numerous suppliers or can be bent
in situ during the manufacturing process of the entire closure
system 10. As shown in FIG. 1, the ridge cap 20 generally is formed
in a triangular or peaked shape although a rounded or flatened
shape may used, as dictated by the project. Ridge caps normally
sold and used in 10' sections.
[0016] In the preferred embodiment of the invention, the foam
closure strips 24 are generally formed from a flexible, semi-rigid,
cross-linked polyethylene foam, such as is produced by Hibco
Plastics, Inc. (Yadkinville, N.C.) or any other foam material used
in the art. Depending on the building application, the foam
closures 24 can be non-ventilating or ventilating, closed or
open-celled. In the preferred embodiment of the invention, the foam
closure 24 is formed in a convoluted, egg-crate style and is highly
mailable, such that it can conform to any pattern of corrugation of
the corrugated roof panels 28. One advantage of using a mailable
foam closure 24 over the prior art is that a contractor need only
be concerned about ordering the closure system 10 having the
appropriate type of ridge cap 20 and not being concerned with
ordering the appropriate type of contoured foam to match the style
of corregated panels being used on the building project. Futher,
mailable foam 24, as used as part of the inventive system 10,
offers the added advantage of being able to use different
corrugation styles of corruguated panel 28 on the same roof with a
continous strip of foam 24. Of course, the closure system 10 of the
instant invention functions, albeit less preferrably, using
specifically contoured foam matching the contours of the specific
corrugated panel 28, as is currently practiced in the art.
[0017] The inventive closure system 10 is formed at a factory or
other manufacturing facility as a single component rather than a
ridge cap 20 and foam strips 24 separately ordered and transported
to a construction site and assembled by workers exposing an
adhesive backing the foam 24 and adhering the foam to the roof
panels. The closure system 10 may be formed as part of a unitary
assembly process where the ridge cap 20 and the foam are assembled
on the same line with automated means, such as a manufacturing
line, or otherwise with minimal human intervention. In an
alternative embodiment of the assembly process, the ridge cap 20
and the foam 24 are manufactured in separate facilities, possibly
by unrelated manufacturers, brought together at another
manufacturing line, an adhesive is applied to the back of the foam
24 which is then precisely mated to the ridge cap 20. In either
manufacturing embodiment, the complete closure system 10 is then
ready to be transported to a construction site and used, without
concern of lining up the foam 24 with the roof panels 28 and
subsequently lining up the cap 20 with the roof panels 28 and the
foam 24.
[0018] Referring again to FIG. 1, a building roof is formed of a
series of beams or struts 26, two of which are shown in the
cut-away view. A series of corrugated panels 28, typically metal,
are affixed to and between the struts 26. The closure system 10 is
placed upon the metal panels 28 such that the peak of the ridge cap
20 is aligned with the peak of the roof. The closure system is then
attached to the metal panels 28 and the struts 26 by way of
fastening means 30 such as screws, bolts, nails, and rivets. Upon
attachment, the malleable foam 24 conforms to and fills the various
troughs and crests of the corrugated panels 28, forming a tight
seal between the ridge cap 20 and the roof panels 28.
[0019] In addition to the use with ridge caps 20, the instant
invention is adaptable to base plates and eave struts. It should
also be noted that the foam may be placed underneath the ridge cap
20 or on top of the base plates or eave struts, depending on the
needs of the contractor.
[0020] In addition to the structures, sequences, and uses
immediately described above, it will be apparent to those skilled
in the art that other modifications and variations can be made the
method of the instant invention without diverging from the scope,
spirit, or teaching of the invention. Therefore, it is the
intention of the inventors that the description of instant
invention should be considered illustrative and the invention is to
be limited only as specified in the claims and equivalents
thereto.
* * * * *