U.S. patent application number 14/987482 was filed with the patent office on 2016-04-28 for above-deck roof venting article.
This patent application is currently assigned to 3M Innovative Properties Company. The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to James N. Dobbs, John S. Edwards, Jon A. Kirschhoffer, Frank W. Klink.
Application Number | 20160116176 14/987482 |
Document ID | / |
Family ID | 47557501 |
Filed Date | 2016-04-28 |
United States Patent
Application |
20160116176 |
Kind Code |
A1 |
Edwards; John S. ; et
al. |
April 28, 2016 |
ABOVE-DECK ROOF VENTING ARTICLE
Abstract
A roofing system and article for installation on a roof deck.
The roofing article includes a body having an upper portion and an
underside. A first channel is defined within the upper portion. The
first channel includes an inlet. A second channel is defined
intermediate the underside of the body and the roof deck. The
second channel is operably connected to the first channel through
an orifice, such that the outside air can enter the second channel
through the orifice.
Inventors: |
Edwards; John S.; (Hudson,
WI) ; Klink; Frank W.; (Oak Park Heights, MN)
; Dobbs; James N.; (Woodbury, MN) ; Kirschhoffer;
Jon A.; (Stillwater, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
47557501 |
Appl. No.: |
14/987482 |
Filed: |
January 4, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14366291 |
Jun 18, 2014 |
9228356 |
|
|
PCT/US2012/070034 |
Dec 17, 2012 |
|
|
|
14987482 |
|
|
|
|
61579297 |
Dec 22, 2011 |
|
|
|
Current U.S.
Class: |
52/199 |
Current CPC
Class: |
E04B 1/947 20130101;
E04D 1/24 20130101; E04D 1/28 20130101; E04D 13/172 20130101; E04D
13/17 20130101; F24F 7/02 20130101; E04D 13/002 20130101; E04D 1/30
20130101; E04D 2001/307 20130101; E04D 2001/309 20130101 |
International
Class: |
F24F 7/02 20060101
F24F007/02; E04D 13/17 20060101 E04D013/17 |
Claims
1. A roofing article for installation on a roof deck, said roofing
article comprising: a body comprising an upper portion and an
underside; a first channel defined within said upper portion, said
first channel comprising an inlet through which outside air can
enter said first channel; and a second channel defined intermediate
said underside of said body and the roof deck, wherein said second
channel is operably connected to said first channel through an
orifice such that the outside air can enter said second channel
through said orifice.
2. The roofing article of claim 1, wherein said second channel is
in airflow communication with an unconditioned space and wherein
unconditioned air from the unconditioned space can enter said
second channel.
3. The roofing article of claim 2, wherein the unconditioned air
entering said second channel can mix with outside air entering said
second channel through said orifice to form mixed air.
4. The roofing article of claim 2, wherein the unconditioned space
is an attic.
5. The roofing article of claim 1, further comprising insulation
presented intermediate said first channel and said second
channel.
6. The roofing article of claim 1, wherein said first channel
comprises an first channel upper internal surface and a first
channel lower internal surface, wherein one or more of said first
channel upper internal surface and said first channel lower
internal surface comprises a radiant barrier presented
therewith.
7. The roofing article of claim 1, wherein said second channel
comprises an second channel upper internal surface and a second
channel lower internal surface, wherein one or more of said second
channel upper internal surface and said second channel lower
internal surface comprises a radiant barrier presented
therewith.
8. The roofing article of claim 1, further comprising an air
director presented in said first channel proximate said orifice to
direct outside air into orifice.
9. The roofing article of claim 1, wherein said airflow interrupter
comprises an intumescent material.
10. The roofing article of any claim 1, wherein a ratio of a cross
section of said inlet to a cross section of said orifice is between
about 2 to about 48.
11. The roofing article of claim 1, wherein a ratio of a cross
section of said inlet to a cross section of said orifice is between
about 1 to about 12.
12. The roofing article of claim 1, wherein said roofing article is
operably coupled to one or more rails presented on a roof deck.
13. A roofing system comprising at least two roofing articles, each
roofing article comprising: a body comprising an upper portion and
an underside; a first channel defined in said body, said first
channel comprising an inlet through which outside air can enter
said first channel; a second channel defined intermediate said
underside of said body and the roof deck, wherein said second
channel is operably connected to said first channel through an
orifice such that the outside air can enter said second channel
through said orifice, wherein the second channels of each of the at
least two roofing articles are in airflow communication so as to
create an airflow path between the at least two roofing
articles.
14. The roofing system of claim 13, wherein the second channel of
each of the at least two roofing articles is in airflow
communication with an unconditioned space and wherein unconditioned
air from the unconditioned space can enter said second channel.
15. The roofing system of claim 13, wherein the unconditioned air
entering said second channel of each of the at least two roofing
articles can mix with outside air entering said second channel of
the at least two roofing articles through said orifice to form
mixed air, wherein said mixed air can exit said second channel of
the at least two roofing articles.
16. A roofing system for installation on a roof deck comprising: at
least two roofing articles, each roofing article comprising: a body
comprising an upper portion and an underside; a first channel
defined in said body, said first channel comprising an inlet
through which outside air can enter said first channel; a second
channel defined intermediate said underside of said body and the
roof deck, wherein said second channel is operably connected to
said first channel through an orifice such that the outside air can
enter said second channel through said orifice; and at least one
rail presented on roof deck, wherein said at least two roofing
articles are configured to be operably serially coupled to rail,
such that said second channel of said at least two roofing articles
is substantially aligned to create an airflow path.
17. The roofing system of claim 16, wherein said rail is integrally
formed with a rail sheet that can be operably coupled to the roof
deck.
Description
FIELD
[0001] The present disclosure generally relates to roofing
materials. More particularly, the present disclosure relates to a
roofing system having an airflow path therein.
BACKGROUND
[0002] It can be desirable to use construction articles that
provide energy conservation advantages for buildings and housing
structures. Absorbed solar energy increases cooling energy costs in
buildings, particularly in warm southern climates, which can
receive a high incidence of solar radiation. An absorber of solar
energy is building roofs. It is not uncommon for the air
temperature within an attic or unconditioned space that is adjacent
to or under a roof, to exceed the ambient air temperature by
40.degree. F. (about 22.2.degree. C.) or more, due in part to
absorption of solar energy by the roof or conduction of the solar
energy through the roof This can lead to significant energy costs
for cooling the interior spaces of a building to a comfortable
living temperature.
SUMMARY
[0003] The subject matter of the present disclosure, in its various
combinations, either in apparatus or method form, may be
characterized by the following non-exhaustive list of exemplary
embodiments:
[0004] 1. A roofing article for installation on a roof deck, said
roofing article comprising:
[0005] a body comprising an upper portion and an underside;
[0006] a first channel defined within said upper portion, said
first channel comprising an inlet through which outside air can
enter said first channel; and
[0007] a second channel defined intermediate said underside of said
body and the roof deck, wherein said second channel is operably
connected to said first channel through an orifice such that the
outside air can enter said second channel through said orifice.
[0008] 2. The roofing article of embodiment 1, wherein said second
channel is in airflow communication with an unconditioned space and
wherein unconditioned air from the unconditioned space can enter
said second channel.
[0009] 3. The roofing article of embodiment 2, wherein the
unconditioned air entering said second channel can mix with outside
air entering said second channel through said orifice to form mixed
air.
[0010] 4. The roofing article of any of embodiments 2 or 3, wherein
the unconditioned space is an attic.
[0011] 5. The roofing article of any of embodiments 1-4, further
comprising insulation presented intermediate said first channel and
said second channel.
[0012] 6. The roofing article of any of the preceding embodiments,
wherein said first channel comprises an first channel upper
internal surface and a first channel lower internal surface,
wherein one or more of said first channel upper internal surface
and said first channel lower internal surface comprises a radiant
barrier presented therewith.
[0013] 7. The roofing article of any of the preceding embodiments,
wherein said second channel comprises an second channel upper
internal surface and a second channel lower internal surface,
wherein one or more of said second channel upper internal surface
and said second channel lower internal surface comprises a radiant
barrier presented therewith.
[0014] 8. The roofing article of any of the preceding embodiments,
further comprising an air director presented in said first channel
proximate said orifice to direct outside air into orifice.
[0015] 9. The roofing article of any of the preceding embodiments,
further comprising an airflow interrupter for at least partially
closing at least one of said first channel or said second channel
when said airflow interrupter is exposed to temperatures at or
greater than about 350 degrees Fahrenheit.
[0016] 10. The roofing article of embodiment 9, wherein said
airflow interrupter comprises an intumescent material.
[0017] 11. The roofing article of any of the preceding embodiments,
further comprising a cover presented with said inlet, said cover
enabling outside air to flow therethrough into said first
channel.
[0018] 12. The roofing article of embodiment 11, wherein said cover
inhibits mold or algae growth.
[0019] 13. The roofing article of any of embodiments 11 or 12,
wherein said cover comprises at least one of copper-containing
materials, zinc-containing material, or photocatalytic
material.
[0020] 14. The roofing article of any of embodiments 11-13, wherein
said cover is meltable so as to at least partially close said inlet
in the event of a fire.
[0021] 15. The roofing article of any of embodiments 11-14, wherein
said cover comprises polyester.
[0022] 16. The roofing article of any of the preceding embodiments,
wherein a ratio of a cross section of said inlet to a cross section
of said orifice is between about 2 to about 48.
[0023] 17. The roofing article of any of the preceding embodiments,
wherein a ratio of a cross section of said inlet to a cross section
of said orifice is between about 1 to about 12.
[0024] 18. The roofing article of any of the preceding embodiments,
wherein said roofing article is operably coupled to one or more
rails presented on a roof deck.
[0025] 19. A roofing system comprising at least two roofing
articles, each roofing article comprising:
[0026] a body comprising an upper portion and an underside;
[0027] a first channel defined in said body, said first channel
comprising an inlet through which outside air can enter said first
channel; and
[0028] a second channel defined intermediate said underside of said
body and the roof deck, wherein said second channel is operably
connected to said first channel through an orifice such that the
outside air can enter said second channel through said orifice,
[0029] wherein the second channels of each of the at least two
roofing articles are in airflow communication so as to create an
airflow path between the at least two roofing articles.
[0030] 20. The roofing system of embodiment 19, wherein the second
channel of each of the at least two roofing articles is in airflow
communication with an unconditioned space and wherein unconditioned
air from the unconditioned space can enter said second channel
[0031] 21. The roofing system of any of embodiments 19-20, wherein
the unconditioned air entering said second channel of each of the
at least two roofing articles can mix with outside air entering
said second channel of the at least two roofing articles through
said orifice to form mixed air, wherein said mixed air can exit
said second channel of the at least two roofing articles.
[0032] 22. The roofing article of any of embodiments 19-21, further
comprising an airflow interrupter presented with said airflow path
for at least partially closing at least one of said first channel
or said second channel when said airflow interrupter is exposed to
temperatures at or greater than about 350 degrees Fahrenheit.
[0033] 23. The roofing article of embodiment 22, wherein said
airflow interrupter comprises an intumescent material.
[0034] 24. A roofing system for installation on a roof deck
comprising:
[0035] at least two roofing articles, each roofing article
comprising: [0036] a body comprising an upper portion and an
underside; [0037] a first channel defined in said body, said first
channel comprising an inlet through which outside air can enter
said first channel; and [0038] a second channel defined
intermediate said underside of said body and the roof deck, wherein
said second channel is operably connected to said first channel
through an orifice such that the outside air can enter said second
channel through said orifice; and
[0039] at least one rail presented on roof deck, wherein said at
least two roofing articles are configured to be operably serially
coupled to rail, such that said second channel of said at least two
roofing articles is substantially aligned to create an airflow
path.
[0040] 25. The roofing system of embodiment 24, wherein said rail
is integrally formed with a rail sheet that can be operably coupled
to the roof deck.
[0041] 26. The roofing system of any of embodiments 24 or 25,
wherein the rail sheet comprises a plurality of rails.
[0042] 27. The roofing system of any of embodiments 24-26, wherein
the roofing article comprises a plurality of first channels.
[0043] 28. The roofing system of any of embodiments 24-27, wherein
the roofing article comprises a plurality of second channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The disclosed subject matter will be further explained with
reference to the attached figures, wherein like structure is
referred to by like reference numerals throughout the several
views.
[0045] FIG. 1 is a cross-sectional schematic side view of a roofing
article according to a first embodiment.
[0046] FIG. 2 is a second cross-sectional schematic side view of a
roofing system including the roofing article of FIG. 1.
[0047] FIG. 3 is a fragmentary cross-sectional schematic side view
of a sloped roof having a roofing system of FIG. 2 with four
roofing articles of FIG. 1 thereon.
[0048] FIG. 4 is the fragmentary cross-sectional schematic side
view of FIG. 3 depicting air flow.
[0049] FIG. 5 is the fragmentary cross-sectional schematic side
view of FIG. 3 depicting air flow.
[0050] FIG. 6 is a cutaway schematic top view of the roofing
article of FIG. 1 in panel form.
[0051] FIG. 7 is a cross-sectional schematic view of the roofing
system of FIG. 2, further depicting the thermal energy transfer of
the roofing article.
[0052] While the above-identified figures set forth several
embodiments of the disclosed subject matter, other embodiments are
also contemplated, such as those noted in the disclosure. In all
cases, this disclosure presents the disclosed subject matter by way
of representation and not by limitation. The figures are schematic
representations, for which reason the configuration of the
different structures, as well as their relative dimensions, serves
illustrative purposes only. Numerous other modifications and
embodiments can be devised by those skilled in the art, which other
modifications and embodiments fall within the scope and spirit of
the principles of this disclosure.
DETAILED DESCRIPTION
[0053] When in the following terms such as "upper" and "lower",
"top" and "bottom", "right" and "left", or similar relative
expressions are used, these terms only refer to the appended
figures and not necessarily to an actual situation of use.
[0054] The present disclosure broadly relates to a roofing article
with an airflow path for use in an above-deck roof ventilation
system, and methods of installing such roofing articles. Various
exemplary embodiments of the disclosure will now be described with
particular reference to the Drawings. Embodiments of the present
disclosure may take on various modifications and alterations
without departing from the spirit and scope of the disclosure.
Accordingly, it is to be understood that the embodiments of the
present disclosure are not to be limited to the following described
exemplary embodiments, but is to be controlled by the limitations
set forth in the claims and any equivalents thereof.
[0055] Thus, reference throughout this specification to "one
embodiment," "embodiments," "one or more embodiments" or "an
embodiment," whether or not including the term "exemplary"
preceding the term "embodiment," means that a particular feature,
structure, material, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
exemplary embodiments of the present disclosure. Therefore, the
appearances of the phrases such as "in one or more embodiments,"
"in embodiments," "in one embodiment" or "in an embodiment" in
various places throughout this specification are not necessarily
referring to the same embodiment of the exemplary embodiments of
the present disclosure. Furthermore, the particular features,
structures, materials, or characteristics may be combined in any
suitable manner in one or more embodiments.
[0056] Referring to FIG. 1, a roofing article 100 according to a
first embodiment of the present disclosure can include a body
having a bottom sheet 104 and a top sheet 106 overlaying at least a
portion of bottom sheet 104, and one or more first air channels 108
defined or presented in an upper portion of said body intermediate
top sheet 106 and bottom sheet 104. First air channel 108 includes
a first channel upper internal surface 107 and a first channel
lower internal surface 109. Referring to FIG. 2, as described in
detail below, one or more second air channels 110 are defined or
presented below bottom sheet 104 and intermediate a roof deck 12.
Referring to FIG. 2, second channel 110 includes a second channel
upper internal surface 111 and a second channel lower internal
surface 113. First channel 108 and second channel 110 can be
interconnected or otherwise in fluid or airflow communication by an
aperture 120 or orifice, which is described in further detail
below.
[0057] Depending on the climate, the roofing articles can be
designed so as to ensure or optimize that mixed air stays in the
second channel path. This can be done by minimizing the size of the
aperture between the first and second channels--so as to increase
the resistance through the aperture relative to the resistance of
the second channel pathway. Some climates where it can be desirable
to ensure or optimize that mixed air stays in the second channel
path include colder climates. By retaining the mixed, warmer air in
the second channel path, it can help to heat the entire roof and,
as a result, melt the snow on the entire roof.
[0058] Also, the roofing articles can be designed so as to allow
for air to back out of an air inlet included on one of the roofing
articles. This can be done by maximizing the size of one or more
apertures between the first and second channels--so as to decrease
the resistance through the aperture relative to the resistance of
the second channel pathway. Some climates where it can be desirable
to release air from the second channel path include warmer
climates. By enabling air to be released, it can help to keep the
roof cooler.
[0059] In embodiments wherein it is desired to maintain air flow
along an entire length (from bottom to top) of a roof, i.e., so
that any air exiting the roofing articles is inhibited, the
cross-sectional area of the aperture 120 can be between about 0.05
square inches and about 0.70 square inches (wherein a ratio of the
air inlet 124 cross-sectional area to the cross-sectional area of
the aperture 120 is about 2.0 to about 48.0). Preferably, the
cross-sectional area can be between about 0.15 square inches and
about 0.35 square inches (wherein a ratio of the cross-sectional
area of the air inlet 124 to the cross-sectional area of the
aperture 120 is about 5.0 to about 16.0). Optimally, the
cross-sectional area can be between about 0.15 square inches and
about 0.25 square inches (wherein a ratio of the cross-sectional
area of the air inlet 124 to the cross-sectional area of the
aperture 120 is about 8.0 to about 16.0). Such embodiments can be
used, for example, in cooler or cold climate zones 4-7.
[0060] In embodiments wherein it is desired to vent air flow along
one or more points along a length (from bottom to top) of a roof,
the cross-sectional area can be between about 0.20 square inches
and about 1.25 square inches (wherein a ratio of the air inlet 124
cross-sectional area to the cross-sectional area of the aperture
120 is about 1.0 to about 12.0). Preferably, the cross-sectional
area can be between about 0.30 square inches and about 0.80 square
inches (wherein a ratio of the cross-sectional area of the air
inlet 124 to the cross-sectional area of the aperture 120 is about
2.0 to about 8.0). Optimally, the cross-sectional area can be
between about 0.45 square inches and about 0.70 square inches. Such
air flow is described in greater detail below (wherein a ratio of
the cross-sectional area of the air inlet 124 to the
cross-sectional area of the aperture 120 is about 2.0 to about
5.5). Such embodiments can be used, for example, in warm or hot
climate zones 1-4.
[0061] In embodiments, aperture 120 can be circular in shape,
although other shapes can be used without departing from the spirit
and scope of the present disclosure. Bottom sheet 104 and top sheet
106 can be formed of various high temperature and fire retardant
materials, such as thermoplastic polymers, such as thermoplastic
polyolefin, or fluoro or chloro polymers, such as polyvinylidene
fluoride, fluorinated ethylene propylene, polytetrafluoroethylene,
and polyvinyl chloride using various forming methods, such as, for
example, injection molding or thermoforming, although other
materials, such as polycarbonate, acrylonitrile butadiene styrene,
steel (for example, galvanized), concrete, clay, and treated
wood-based products, can be used to form each these components.
Other forming methods can include, for example, metal stamping,
press forming, pan forming, and various component and piece
assembly methods. Additionally, bottom sheet 104 and top sheet 106
can be integrally formed or formed separately and then attached,
affixed, or otherwise coupled together. Top sheet 106 can include a
layer or layers of roofing granules presented thereon, such as, for
example, those described in U.S. Pat. Nos. 7,455,899, 7,648,755,
and 7,919,170, each of which is incorporated by reference herein in
its entirety. Top sheet 106 and/or layer or layers of roofing
granules presented thereon can be replaceable, such that this
portion can be replaced without the other portions of roofing
article 100.
[0062] Portions of body, including bottom sheet 104 and/or top
sheet 106 can be formed using a dark material, such as black, or
otherwise coated so as to give a dark appearance. Color, in
general, can be defined by "Lab color space or component color" or
CIE 1976 (L*, a*, b*), where L* is 0 for black and 100 for white (a
is + positive for red and - negative for green, b is + positive for
yellow and - negative for blue). This method is a three dimensional
way of defining coloring. In general, a "dark" color can be from 0
to about 30 on the L* scale.
[0063] Referring to FIG. 1, a thermal insulation layer 112 can
optionally (depending, for example, on climate zone) be included on
roofing article, such as on or adjacent to, or incorporated with or
adhered to, an underside of bottom sheet 104. Insulation layer 112
can be formed of extruded polystyrene foam (XPS), although other
materials, such as expanded polystyrene foam (EPS),
polyisocyanurate, polyurethane, or other type of insulation
material that has a R value in the range of 2-8 per inch of
thickness, can be used.
[0064] Referring to FIGS. 1 and 2, roofing article 100 includes a
first post member 114 and a second post member 116, each including
one or more rail bushings or rail huggers 118. Referring to FIG. 2,
bushings are shaped so as to mate with a rail having rail head with
a circular cross section, although those skilled in the art will
understand that other shapes can be used without departing from the
spirit and scope of the present disclosure.
[0065] In embodiments, rail huggers 118 can be omitted from first
post member 114 or second post member 116, wherein an edge of
roofing article 100 is operably coupled to an adjacent roofing
article 100 by, for example, a tab and slot attachment mechanism or
other attachment mechanism. This can facilitate ease of design
and/or assembly and reduce the number of rail huggers 118 used.
[0066] Referring to FIG. 1, first channel 108 can comprise an air
inlet 124 at a first end thereof. Air inlet 124 can include a cover
126, such as a perforated rigid material with a fire protective
type covering , a screen, scrim, nonwoven web, or other structure
to inhibit the ingress of snow, insects, birds, small animals,
debris, precipitation (e.g., rain, snow, sleet, hail) from entering
air inlet 124. Cover is preferably UV stable. In embodiments, cover
126 can be formed with a meltable material, such as a polyester
fabric, so as to close the air inlet, and, therefore, any airway
path or funnel, such as in the event of a fire. In embodiments,
cover 126, such as a screen, can include, for example, a
copper-containing material (such as, for example, cuprous oxide) or
a zinc-containing material, such as in the form of a strip,
particles, or other form in the screen, such that copper or zinc
ions released from the strip can inhibit the growth of algae and
other fungus material in cover. In other embodiments, cover 126 can
include photocatalytic particles, such as, for example, TiO2, ZnO,
WO3, SnO2, CaTiO3, Fe2O3, MoO3, Nb2O5, TiXZr(1-x)O2, SiC, SrTiO3,
CdS, GaP, InP, GaAs, BaTiO3, KNbO3, Ta2O5, Bi2O3, NiO, Cu2O, SiO2,
MoS2, InPb, RuO2, CeO2, Ti(OH)4, combinations thereof, or inactive
particles coated with a photocatalytic coating. U.S. Pat. No.
7,922,950, issued Apr. 12, 2011, entitled, "Monolithic building
element with photocatalytic material," is incorporated by reference
herein in its entirety for its teaching of, for example,
photocatalytic materials, particles, and coatings and uses for such
photocatalytic materials, particles, and coatings.
[0067] Cover 126 can be integrally formed with top sheet 106 and
bottom sheet 104 or formed separately and then attached, connected,
or otherwise coupled to top sheet 106 and/or bottom sheet 104. The
first end of first channel 108, including air inlet 124 and cover
126, can comprise a color chosen for aesthetic purposes. As
discussed herein, darker colors are oftentimes preferred. This can
be accomplished by using a relatively dark color for first end of
first channel 108, including air inlet 124 and cover 126, so as to
give a roof a darker appearance when viewed by someone standing
below the roof deck surface. As can be seen in FIG. 5, when
assembled, there are two general exposed surfaces--the top surface
of top sheet 106 and the first end of first channel 108, including
air inlet 124 and cover 126. When the roof is viewed by someone
standing below the roof deck surface, that person largely sees the
first end of first channel 108.
[0068] Referring to FIG. 6, first channel 108 can further include
one or more ribs 128 or air guides (one depicted) that can direct
free and force convection. The ribs 128 can extend between top
sheet 106 and bottom sheet 104 to provide further structural
integrity to roofing article 100. Referring again to FIG. 1, first
channel 108 can also include an air director 130 positioned
proximate aperture 120 that can guide or route incoming outside
intake airflow down through aperture into second air channel Air
director 130 can be formed of various materials, such as, for
example, the materials and formation methods described above with
respect to bottom sheet 104 and top sheet 106, although other
materials, such as a plastic-coated intumescent material for fire
protection, ceramics, and other non corrosive materials, can be
used. Also, air director 130 can be integrally formed within first
channel 108, such as with top sheet 106. Alternatively, air
director 130 can be formed separately and then attached, connected,
or otherwise coupled within first channel 108, such as with top
sheet 106, using, for example, adhesives, snap lock, hook and loop,
thermal weld, and other mechanical fasteners. Further, while air
director 130 is depicted as being shaped as a cutoff sphere, other
three-dimensional shapes can be used without departing from the
spirit and scope of the present disclosure. In embodiments, a
screen made with a meltable material, such as polyester, can be
provided over aperture 120 such that, in the event of a fire, the
screen would melt and close, at least in part, aperture 120.
[0069] Referring to FIGS. 2 and 3, second channel 110 can be formed
when roofing article 100 is connected to one or more rails 202
operably attached to a roof Rails 202 can include a rail base 204
and a rail post 206 extending from rail base 204 and a rail head
208 operably coupled to rail post 206. Rails 202 can be formed
integrally with or operably coupled to a rail sheet 210. Rail sheet
210 can be, for example, formed of dimension so as to facilitate
assembly to a roof deck, such as in sheets that are four feet by
eight feet in size. Rail sheets 210 can include one or more rails
202 operably coupled thereto, such as formed integrally therewith.
Rail sheets 210 can comprise one or more radiant barrier film
layers 146 or low emissivity surfaces. Radiant barrier film layers
can be formed of a thin layer of a highly reflective material, such
as aluminum, a silver metalized weatherable acrylic film (for
example, film commercially available as 3M.TM. Solar Mirror Film
1100), or of a black body. In embodiments, the emittance of radiant
barrier film layers is less than about 0.1 as measured by ASTM
C1371. Rails 202 and rail sheets 210 can be formed of various high
temperature and fire retardant materials, such as thermoplastic
polymers, such as thermoplastic polyolefin, or fluoro or chloro
polymers, such as polyvinylidene fluoride, fluorinated ethylene
propylene, polytetrafluoroethylene, and polyvinyl chloride using
various forming methods, such as, for example, extrusion, injection
molding, or thermoforming, although other materials, such as
polycarbonate, acrylonitrile butadiene styrene, aluminum, steel
(for example, galvanized), and treated wood-based products, can be
used to form each these components. Other forming methods can
include, for example, metal stamping, press forming, pan forming,
and various component and piece assembly methods.
[0070] Referring to FIG. 1, one or more radiant barrier film layers
146 or low emissivity surfaces can be included on roofing article
100 or, as described above, on rail sheet 210. Radiant barrier film
layers can be formed of a thin layer of a highly reflective
material, such as aluminum, a silver metalized weatherable acrylic
film (for example, film commercially available as 3M.TM. Solar
Mirror Film 1100), or of a black body. In embodiments, the
emittance of radiant barrier film layers is less than about 0.1 as
measured by ASTM C1371. As depicted, first channel 108 includes a
radiant barrier film layer 146 on an underside of top sheet 106 and
another on an upper side of bottom sheet 104. Second channel 110
includes a radiant barrier film layer 146 on an underside of
insulation layer 112 and another on an upper side of rail sheet
210.
[0071] While not depicted, roofing article can further include
intumescent material portion in or proximate to first channel 108
or in or proximate to second channel 110. Such intumescent material
portion can undergo a chemical change when exposed to heat or
flames to expand into a heat-insulating form to function as an
airflow interrupter. This enables containment of fire and toxic
gases and inhibits flame penetration, heat transfer, and movement
of toxic gases. As used throughout this disclosure, "intumescent
material" refers to a substance that when applied to or
incorporated within a combustible material, reduces or eliminates
the tendency of the material to ignite when exposed to heat or
flame, and, in general, when exposed to flame, the intumescent
substance induces charring and liberates non-combustible gases to
form a carbonific foam which protects the matrix, cuts off the
oxygen supply, and prevents dripping. Such heat can be at or about
350 degrees Fahrenheit. Intumescent materials can comprise an acid
source, a char former, and a blowing agent. Examples of intumescent
material include 3M.TM. Fire Barrier Wrap Ultra GS and REOGARD 1000
from Chemtura (formerly from Great Lakes Chemical Corporation).
[0072] Additionally, a phase change material (PCM) can be included
at one or more locations in roofing article 100, such as, for
example, in insulation layer 112. Such PCMs can undergo a
solid/solid phase transition with the associated absorption and
release of large amounts of heat. Like the intumescent material
portion, can undergo a change when exposed to heat or flames to
expand into a heat-insulating form or shape. Examples of PCMs
include those commercial available from PCM Products Limited.
[0073] FIG. 3 depicts four roofing articles 100 arranged and
installed on a roof (on top of roof deck 12 and felt 16). In this
configuration: first post member 114 of the right-most roofing
article 100 is adjacent to and abuts second post member 116 of the
roofing article 100 second from the right; first post member 114 of
the roofing article 100 second from the right is adjacent to and
abuts second post member 116 of the roofing article 100 third from
the right; and first post member 114 of the roofing article 100
third from the right is adjacent to and abuts second post member
116 of the left most roofing article 100. This arrangement enables
air to flow through the second channel 110 created by an underneath
each of the roofing articles. As will be described in greater
detail below, air can also enter the second channel 110 of each of
the roofing articles 100 from the first channel 108 of each through
each of their respective apertures 120.
[0074] FIG. 7 depicts the thermal energy transfer of the roofing
article 100 according to the various embodiments herein (first
embodiment depicted). Each of the energy components, "q," are as
follows:
TABLE-US-00001 Energy Item Component Energy Description 1 q.sub.s
Solar and Spectrum Radiation 2 q.sub.1 Reflective Radiation and
Convection 3 q.sub.2 Conduction Into First Channel 4 q.sub.3 Free
Convection 5 q.sub.4 Net Radiation of First Channel 6 q.sub.5
Convection (Free and/or Force) 7 q.sub.6 Free Convection 8 q.sub.7
Convection (Free and/or Force) Through Aperture 9 q.sub.8
Conduction Into Second Channel 10 q.sub.9 Free Convection 11
q.sub.10 Net Radiation of Second Channel 12 q.sub.11 Free
Convection 13 q.sub.12 Convection (Free and/or Force) 14 q.sub.13
Convection (Free and/or Force) 15 q.sub.14 Conduction Through Roof
Deck Into Attic Space
[0075] The energy balance equation is as follows:
q.sub.s-q.sub.1-q.sub.2-q.sub.3-q.sub.4+q.sub.5-q.sub.6-q.sub.7-q.sub.8--
q.sub.9q.sub.10-q.sub.11+q.sub.12-q.sub.13-q.sub.14=0
[0076] Referring to FIG. 7, q.sub.s represents the solar energy
from the sun. Of this energy, some of the energy (q.sub.2) is
transferred by conduction into first channel 108 and some of the
energy (q.sub.1) is transferred, by reflection and convection, back
into the atmosphere. Additional energy may enter roofing article
100 through air inlet 124 (q.sub.5) due to free and/or force
convection. Of the energy that is in first channel 108, some may
move due to free convection (q.sub.3 and q.sub.6), i.e., flow
driven by the presence of a temperature gradient and/or density
differences. The net radiation in first channel is transported as
q.sub.4. Of this, some is transferred by conduction into second
channel 110 (q.sub.8) and some by free and/or force through
aperture 120. Additional energy may enter second channel 110
(q.sub.12) due to free and/or force convection. Of the energy that
is in second channel 110, some may move due to free convection
(q.sub.9 and q.sub.11). The net radiation in second channel is
transported as q.sub.10. Of this, most is transferred by conduction
out of second channel 110 (q.sub.13) (to an adjacent roofing
article or up and out of a ridge vent). The remainder (q.sub.14)
may be is transferred by conduction into an attic or unconditioned
space.
[0077] FIG. 4 depicts air flow through a series of roofing articles
100. Air is depicted as entering the left-most roofing article 100
in two ways. First, outside air enters air inlet 124 and moves
upwardly in first channel 108 towards aperture 120. When this air
encounters air director 130, air director 130 directs or routes air
downwardly through aperture 120 into second channel 110. Air can
also enter left-most roofing article through second channel 110
(which can come from attic or unconditioned space). This air mixes
with the air that has been directed into second channel through
aperture 120. This mixed air then travels upwardly along the series
of roofing articles 100 in their respective second channels 110
until the final, uppermost roofing article 100. At this point, air
exits out second channel 110 of the right-most roofing article (to
an adjacent roofing article or up and out of a ridge vent). In each
of the roofing articles, air that enters air inlet 124 and then
routed downwardly through aperture 120 into second channel 110 is
mixed with the air traveling travels upwardly along the series of
roofing articles 100 in their respective second channels.
[0078] FIG. 6 depicts the airflow mechanism through roofing
articles in another view (top plan cutaway schematic view). Outside
air (depicted in broken lines) enters roofing article 100 though
air inlet 124. This air either travels between or around rib 128
towards aperture 120. Airflow director (not depicted) directs or
routes air downwardly through aperture 120 into second channel This
outside air can mix with the air flow of second channel 110 (now
depicted in thick solid lines). The mixed airflow travels though
second channel 110. Eventually, additional air is directed into
second channel 110 through apertures on subsequent, adjacent
roofing articles and is mixed with this air to create channel mixed
air.
[0079] FIG. 5 also depicts air flow through a series of roofing
articles 100, but in an alternative fashion wherein some air backs
out of an air inlet 124 of one of the roofing articles 100 (second
roofing article 100 from right). As above, air is depicted as
entering the left-most roofing article 100 in two ways. First,
outside air enters air inlet 124 and moves upwardly in first
channel 108 towards aperture 120. When this air encounters air
director 130, air director 130 directs or routes air downwardly
through aperture 120 into second channel 110. Air can also enter
left-most roofing article through second channel 110. This air
mixes with the air that has been directed into second channel
through aperture 120. This mixed air then travels upwardly along
the series of roofing articles 100 in their respective second
channels 110. When the resistance to this mixed air continuing
through the second channel 110 path becomes greater than of natural
buoyancy, the mixed air flow will find the path to less resistance
and begin flowing back out of aperture 120 between the second
channel 110 and first channel 108 (i.e., the resistance against the
incoming outside air in first channel 108 is less than that of
continuing up second channel 110 path), the air will take the path
of least resistance and back out of that first channel 108 and air
inlet 124. As depicted in FIG. 5, this occurs on the third roofing
article 100 from the left (or second roofing article 100 from the
right). Factors that can affect whether the mixed air will continue
to travel in the second channel path or back out of the air inlet
include the size of the orifices, wind, barometric pressure, and
the resistance of the fluid (air) inside second channel 110. For
example, if the cross sectional area is increased and the
bend/turns are minimized, the air flow will have or meet less
resistance as the fluid travels up second channel 110.
[0080] As described above, depending on the climate, the roofing
articles 100 can be designed so as to ensure or optimize that mixed
air stays in the second channel 110 path. This can be done by
minimizing the size of aperture 120 between the first channel 108
and second channel 110--so as to increase the resistance through
the aperture 120 relative to the resistance of the second channel
110 pathway. Some climates where it can be desirable to ensure or
optimize that mixed air stays in the second channel 110 path
include colder climates. By retaining the mixed, warmer air in the
second channel 110 path, it can help to heat the entire roof and,
as a result, melt the snow on the entire roof.
[0081] Also, the roofing articles can be designed so as to allow
for air to back out of an air inlet 124 included on one or more of
the roofing articles 100. This can be done by maximizing the size
of one or more apertures 120 between first channel 108 and second
channel 110--so as to decrease the resistance through aperture 120
relative to the resistance of the second channel 110 pathway. Some
climates where it can be desirable to release air from the second
channel path include warmer climates. By enabling air to be
released, it can help to keep the roof cooler.
[0082] Installation of the roofing articles on a roof can be as
follows for the various embodiments of the present disclosure.
While described with respect to the first embodiment, the
installation method can be used for any of the various embodiments
described herein.
[0083] Making reference to FIGS. 1-7, after the felt 16 or another
covering material is installed on roof deck 12, a plurality of rail
sheets 210 can be fastened or otherwise coupled to roof deck. For
example, rail sheets 210 can be fastened to roof deck 12 using any
of a number of mechanical fasteners, including nails or screws. For
a left-handed roofing portion (i.e., sloping from left upwards to
right), working from left to right for installation of roofing
article 100, once rails sheets 210 have been fastened to roof deck
12 so as to create a plurality of rails 202, which can extend
substantially continuously from a lower left edge of roof deck 12
to an upper edge of roof deck 12, such as at a ridge, a first
roofing article 100 can be positioned on the lower left edge of
roof deck 12 and, thus, rails 202. In embodiments, rails 202 can be
operably coupled to a prepared deck from lower to upper edge of
roof deck. Such a prepared deck can include radiant layer 146
operably coupled to roofing felt 16. Rails 202 can be operably
coupled to the deck over radiant layer 146. An installation jig or
the like can be used to ensure proper rail spacing.
[0084] Roofing articles 100 can be coupled to rails 202 by sliding
bushing or rail huggers 118 along rail heads 208 until roofing
article 100 operably abut a serially adjacent roofing article 100.
Rails 202 can include one or more cutouts (not depicted) along a
length thereof, such as in rail heads 208, so that roofing articles
100 can be coupled to rails 202 at intermediate positions thereof
so that the assembly does not all have to start at an upper end of
roof deck 12 (such as at the ridge end of the rails 202). This step
can be repeated for other roofing articles 100 such that, for each
roofing article 100, first post member 114 can operably abut second
post member 116 of a serially adjacent roofing article 100 (see,
for example, FIGS. 3-5). In embodiments, rail huggers 118 can
comprise some flexibility and can snap or otherwise be attached
directly to rails 202 and, in embodiments, rail huggers can be
formed on the bottom side of article 100. A ridge vent cap can be
placed over the ridge-side roofing article 100.
[0085] While the specification has described in detail certain
exemplary embodiments, it will be appreciated that those skilled in
the art, upon attaining an understanding of the foregoing, may
readily conceive of alterations to, variations of, and equivalents
to these embodiments. For example, international patent application
number PCT/US2011/050664, filed Sep. 7, 2011, entitled "ABOVE-DECK
ROOF VENTING ARTICLE," is incorporated by reference herein in its
entirety, including, for example, the description of the various
embodiments of the roofing article therein, which embodiments can
be used in the roofing system according to the present disclosure.
Additionally, U.S. Provisional Patent Application No. 61/494,266,
filed Jun. 7, 2011, entitled, "SYSTEM AND METHOD FOR MANAGEMENT OF
A ROOF" is incorporated by reference herein in its entirety,
including, for example, the description of a roofing system,
components, and method for managing airflow by or within the
roofing system, the environmental thermal loads of the roofing
system, the temperature of conditioned and/or unconditioned spaces
in a building, and the ventilation of the conditioned and/or
unconditioned spaces in a building Also, it should be understood
that this disclosure is not to be unduly limited to the
illustrative embodiments set forth hereinabove. In particular, as
used herein, the recitation of numerical ranges by endpoints is
intended to include all numbers subsumed within that range (e.g. 1
to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). In addition, all
numbers used herein are assumed to be modified by the term `about`.
Various exemplary embodiments have been described. These and other
embodiments are within the scope of the following claims.
* * * * *