Roof batten

Information

  • Patent Grant
  • 6357193
  • Patent Number
    6,357,193
  • Date Filed
    Thursday, December 16, 1999
    25 years ago
  • Date Issued
    Tuesday, March 19, 2002
    23 years ago
Abstract
A roof batten for use in spacing tiles or similar exterior roofing members from a roof overlayment is provided. In one embodiment, the batten includes at least one layer of a corrugated plastic material with a pair of generally planar plies and a convoluted ply cooperating with the planar plies to define a multiplicity of passages. The passages allow drainage of water infiltrating the tiles and further promote drying.
Description




FIELD OF THE INVENTION




This invention relates to roof coverings and, in particular, this invention relates to building materials or devices which extend the lives of tile roofs by preventing water infiltration.




BACKGROUND OF THE INVENTION




Most tile roofs include an exterior decking or sheathing, which overlays a structural framework of either trusses or rafters. Typically, decking includes plywood sheets or other planking members. One or more layers of overlayment, such as felt (tar) paper, is usually attached to the decking. Battens are normally placed over the felt paper before tiles are installed. The battens are usually fixed to the roof by fasteners, such as nails or staples, driven through the battens and felt paper and into the roof decking. Battens are typically wood strips and serve to separate the tiles from the overlayment. Separation between tiles and overlayment is necessary to ensure that water infiltrating the tiles onto the felt paper evaporates quickly. If water is otherwise allowed to stand or pool, the water may infiltrate through the felt paper and penetrate the roof decking, thereby potentially causing deterioration of the roof decking and the underlying framework. When horizontal batting is installed, water which has infiltrated the roof tiles tends to pool on the upper-slope sides of the battens, thereby potentially causing roof deterioration.




Means previously used to avert or diminish the likelihood of deterioration to tile roofs due to water pooling and infiltration include leaving gaps between adjacent battens and cutting drainage channels on the undersides of the battens. These means have been largely ineffective and have often added to the expense and time necessary for tile roof installation as well.




As depicted in

FIG. 1

, roof


20


has installed thereon counter batten system


22


of the prior art. Counter batten system


22


includes vertical battens


24


overlaid with horizontal riser strips


26


. Typically, vertical battens


24


are ⅜ by 1½ inch wooden boards, often four feet in length. Vertical battens


24


are typically installed every 16 inches, on center. Horizontal riser strips


26


are typically wooden lathes and are installed atop vertical battens


24


at spacings determined by the dimensions of the tiles to be installed. While counter batten system


22


is somewhat effective in eliminating pooled water, the expense and time required to install counter batten system


22


is often prohibitive.




There is then a need for a device or roofing material which spaces tiles from underlaying roofing and structural members, which greatly reduces or eliminates water pooling when water infiltrates the roof tile system, and which may be installed quickly and efficiently.




SUMMARY OF THE INVENTION




This invention substantially meets the aforementioned needs. There is provided a spacer operatively disposable between a roof decking and an exterior roofing material. The spacer may include at least one layer of a material, the material defining a multiplicity of passages therethrough. The passages defined may extend generally transversely to a longitudinal axis of the spacer and may allow infiltrated liquids to drain therethrough, thereby preventing accumulation of the infiltrated liquids. The spacer may further include a generally planar first ply and a convoluted second ply cooperating to define the multiplicity of passages. A plurality of first plies and a generally convoluted second ply may be present. The second ply may include a multiplicity of cross-plies extending between the first plies. The spacer may include a plurality of layers. Each adjacent layer of the spacer may be hingably connected. The layers, when assembled in a stacked relationship, may be fastened together by stitching, staples, glue, hot air welding, ultrasonic welding, infrared bonding, other methods known to the art, or any combination thereof.




There is also provided a tile roof system, the tile roof system including an overlayment, a tile, and a batten. The batten may be disposable between the tile and the overlayment and may include at least one layer of a material defining a multiplicity of passages therethrough, the passages extending generally transversely to a longitudinal axis of the batten and allowing infiltrated liquids to drain therethrough.




There is further provided a method of installing a tile on a roof with a slope. The method may include the step of providing first and second battens, each batten comprising at least one layer of a material defining a multiplicity of air passages therethrough. The defined passages may extend generally transversely to a longitudinal axes of the batten and may allow infiltrated liquids to drain therethrough. The method may further include the step of fixing the first and second battens on the roof such that longitudinal axis of the first and second battens are generally parallel and extend generally horizontally to the roof's slope. The method may further include the step of fixing the tile atop the first and second battens.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of a roof of the prior art with a counter-batten system installed thereon;





FIG. 2

is a perspective view of one embodiment of the batten of this invention;





FIG. 3

is an end view of the batten of

FIG. 2

;





FIG. 4

is a fragmentary, cross-sectional view of a first embodiment of two layers of the batten of

FIG. 2

;





FIG. 5

is a fragmentary, cross-sectional view of a second embodiment of one layer of the batten of

FIG. 2

;





FIG. 6

is a fragmentary, cross-sectional view of a third embodiment of four layers of the batten of

FIG. 2

;





FIG. 7

is a plan view of a sheet of convoluted material suitable for forming the batten of

FIG. 2

;





FIG. 8

is a side plan view of the sheet of

FIG. 7

being foldably assembled into the batten of

FIG. 2

after layers have been defined therein;





FIG. 9

is a perspective view of an exemplary roof upon which battens of

FIG. 2

has been installed; and





FIG. 10

is a plan view of tiles installed atop the batten of

FIG. 2

on the roof of FIG.


9


.











DETAILED DESCRIPTION OF THE DRAWINGS




Referring to

FIGS. 2 and 3

, exemplary batten (spacer)


30


is depicted. Batten


30


generally includes one or more layers


34


and may be characterized by longitudinal axis


36


. Layers


34


are described below and generally serve two functions. The first function is to allow water to drain therethrough. The second is to enable air exchange. These complimentary functions prevent water pooling and promote drying on roofs on which batten


30


is installed. While one or more layers


34


are contemplated to be within the scope of this invention, if a plurality of layers


34


are present, these layers may be stacked and fixed to each other by such means as stitching


38


. However, other fastening means which may be used include hot air welding (or other fastening means using thermal energy), ultrasonic welding, infrared bonding, staples, glue, or other methods known to the art.




One embodiment of two layers of layer


34


is depicted in

FIG. 4

generally as layers


50


. Each layer


50


includes planar plies


52


and


54


and convoluted ply


56


. Convoluted ply


56


is disposed between and bonded to (or otherwise cooperates with) planar plies


52


and


54


to define a multiplicity of air channels


58


therebetween.




Another embodiment of layer


34


is depicted in

FIG. 5

generally as layer


60


. Layer


60


includes planar plies


52


and


54


and second ply


62


. Second ply


62


includes a multiplicity of cross-plies


64


. Cross-plies


64


extend generally perpendicular (or otherwise transversely) between planar plies


52


and


54


. Thus, planar plies


52


and


54


and second ply


62


cooperate to define a multiplicity of channels


58


therebetween.




Referring to

FIG. 6

, yet another embodiment of layers


34


is depicted generally as four layers


70


. Each layer


70


includes planar ply


52


and convoluted ply


56


. Planar and convoluted plies


52


and


56


are bonded to (or otherwise cooperate with) each other to define a multiplicity of channels


58


therebetween. Layers


70


may be stacked such that convoluted plies


56


abut, thereby defining another multiplicity of channels


58


therebetween.




These embodiments of layers


34


include a corrugated plastic (resin) material with a nominal weight appropriate for the structure, and often between a range of about 140 and 160 pounds per thousand square feet. One nominal weight may be about 150 pounds per thousand square feet. The plastic resin may have a 4.0 to 4.5-millimeter profile. The plastic resin may further include an about 4.0 (±0.2) millimeter profile. The plastic material may still further be black and include ultraviolet (UV) inhibitors to enable the plastic resin to withstand extended exposure to direct UV light. The plastic resin may include a high-density, polyethylene, corrugated, plastic resin with a brittleness temperature of about −103.0 degrees F., a deflection temperature of about +162.0 degrees F. at 66 pounds per square inch, a bum rate of about 2.5 inches per minute, a self-ignition temperature of about 734.0 degrees F., and may also merit a label of “excellence” for smoke density of a 9.3 percent average.




Referring to

FIGS. 7 and 8

, exemplary sheet


80


may be formed of the materials discussed with respect to FIG.


4


and further described above. Thus, sheet


80


includes a multiplicity of channels


58


defined by a cooperation of members such as planar plies


52


and


54


and convoluted ply


56


. Sheet


80


displays first and second surfaces


82


and


84


. Exemplary layers


34


may be formed from sheet


80


by the slit-scoring technique or by the nick-scoring technique, each technique being more fully described below. Alternatively, layers


34


may be formed by completely severing sheet


80


generally along lines


86


. Separate layers


34


are then stacked and fixed as described above.




The slit-scoring technique is described in U.S. Pat. No. 4,803,813, issued to Fitterman on Feb. 14, 1989, the entire contents of which are hereby incorporated by reference. In the slit-scoring technique, hingelines


88


alternate with hingelines


90


. Hingelines


88


are defined by extending a slit generally along a line


86


and parallel (or generally transversely) to channels


58


. The slit extends through planar ply


54


and convoluted ply


56


, thereby leaving planar ply


52


intact. Hingelines


90


are defined by extending a slit generally along a line


86


and generally parallel to hingelines


88


. The slit extends through planar ply


52


and convoluted ply


56


, thereby leaving planar ply


54


intact. Intact planar plies


52


and


54


are thus used as hinges and batten


30


is assembled by Z-folding layers


34


along hingelines


88


and


90


in the manner depicted in FIG.


8


.




The nick-scoring technique is an alternative hinge-forming technique described in U.S. Pat. No. 5,094,041, issued to Kasner et al., on Mar. 10, 1992, the entire contents of which are hereby incorporated by reference. In the nick-scoring technique, lines


86


include a series of generally linear perforations. Each perforation substantially extends through planar plies


52


and


54


and convoluted ply


56


. Substantially intact portions of planar plies


52


and


54


and convoluted ply


56


remain between perforations. Lines


86


are thusly formed into hinges and thereby define layers


34


. Layers


34


may be Z-folded along lines


86


in a manner substantially resembling

FIG. 8

to assemble batten


30


.




Still another hinge-forming technique includes forming completely separated layers


34


and hingably connecting adjacent layers


34


with a pliable adhesive member such as tape.




Channels


58


extend generally perpendicularly, or otherwise transversely, to longitudinal axis


36


of batten


30


. As more fully described below, batten


30


is installed in generally horizontal rows on a roof. Channels


58


therefore allow water to drain therethrough, preventing water pooling and enabling air exchange once tiles, or other similar materials, are installed.




As depicted in

FIG. 9

, roof


100


includes overlayment


102


installed over a decking member as described above. Battens


30


are fixed to roof


100


in generally parallel rows


104


. Rows


104


extend substantially horizontally with respect to the slope of roof


100


. The distance between rows


104


is determined by the dimensions of the tiles or other materials to be installed. As depicted in

FIG. 10

, exterior roofing members such as tiles


110


, are installed atop battens


30


. Thusly installed on a roof, battens


30


function to space tile


110


from the remainder of roof


100


and to drain water which has infiltrated between installed tiles


110


, thereby preventing the infiltrated water from pooling atop overlayment


102


and preventing the water from penetrating into the decking and structural members of roof


100


. Also as installed on roof


100


, channels


58


of battens


30


serve as conduits for air exchange beneath tiles


110


, thereby further promoting evaporation of infiltrating water.




Exemplary roof batten


30


may be about ⅝ inches in thickness, 1½ inches in width, and include two hinged segments 48 inches in length. However, many other dimensions are contemplated to be within the scope of this invention. Exemplary roof batten


30


may be utilized with clay or cement tiles, including flat tiles, S-tiles, and barrel tiles. Moreover, while exemplary roof batten


30


is depicted as being used in conjunction with roof tiles, other exterior roof materials including slate, clay, metal, and cedar may also be installed using exemplary roof batten


30


.




Batten


30


of this invention thereby promotes ventilation and prevents water accumulation beneath tiles or similar exterior roofing members. The result of installing the batten of this invention is thusly a roof, which remains drier and is more protected from decomposition and damage than if battens of the prior art were used. The roof batten of this invention will not rot, warp, or absorb water as do many of the wooden roof battens of the prior art. Exemplary batten


30


further eliminates excessive nail protrusion through roof coverings, which can also promote water penetration and roof damage. Roof batten


30


of this invention may also enable a substantial decrease in time and expense necessary to install a tile roof as compared to lathe-batten systems of the prior art. Because one embodiment of roof batten


30


includes a pliable, yet resilient resin, tile breakage during installation is reduced when workers step on installed tiles. Other benefits of utilizing batten


30


include elimination of waste and wood splinters during installation. Exemplary battens


30


also weigh less than wooden battens. In contrast to wood battens, battens


30


are easily cut to desired lengths with utility knives.




Because numerous modifications may be made of this invention without departing from the spirit thereof, the scope of the invention is not to be limited to the embodiments illustrated and described. Rather, the scope of the invention is to be determined by appended claims and their equivalence.



Claims
  • 1. A tile roof system, comprising:an overlayment; a tile; and a batten disposable between the tile and the overlayment, the batten comprising: at least one layer comprising a generally planar first ply and a second ply, the first and second plies cooperating to define a multiplicity of passages extending generally transversely to a longitudinal axis of the batten.
  • 2. The batten of claim 1, in which the second ply includes a multiplicity of cross plies extending between the first plies.
  • 3. The batten of claim 1, in which the second ply is generally convoluted.
  • 4. The batten of claim 3, in which a pair of first plies is present.
  • 5. The batten of claim 4, in which a plurality of layers are present.
  • 6. The batten of claim 5, in which adjacent layers are hingably connected by a hingeline extending generally parallel to a batten longitudinal axis.
  • 7. The batten of claim 6, in which the hingeline is defined by a slice extending through the second ply and one of the first plies.
  • 8. The batten of claim 6, in which first and second hingelines are present, the first hingeline defined by a first slice extending through one of the first plies and the second ply, and the second hingeline defined by a second slice extending though the other of the first plies and the second ply.
  • 9. The batten of claim 6, in which the hingeline is defined by alternate severed and intact portions, the severed portions comprising substantially severed first and second plies, the intact portions comprising substantially intact first and second plies.
  • 10. The batten of claim 5, in which the layers are stacked and fastened together.
  • 11. The batten of claim 10, further comprising means for fastening the layers together.
  • 12. The batten of claim 10, in which the layers are fastened together by stitching.
  • 13. The batten of claim 10, in which the layers are fastened together by fasteners selected from the group consisting of staples, glue, hot air welding, stitching, ultrasonic welding, infrared bonding, and any combination thereof.
  • 14. A method of installing a tile on a roof with a slope, comprising the steps of:providing first and second battens, each batten comprising at least one layer of a material comprising first and second plies defining a multiplicity of air passages therethrough, the passages extending generally transversely to a longitudinal axis of the batten; fixing the first and second battens on the roof such that longitudinal axes of the first and second battens are generally parallel and extend generally horizontally to the roof slope; and fixing the tile atop the first and second battens.
  • 15. The method of claim 14, in which the layer comprises a first and second generally planar ply and a generally convoluted ply disposed between the first and second plies.
  • 16. The method of claim 15, in which the provided battens comprise a plurality of layers.
  • 17. The method of claim 16, in which the layers further comprise means for fixing said layers in a stacked relationship.
  • 18. The method of claim 17, in which the fixing means includes stitching.
  • 19. The method of claim 17, in which the fixing means is selected from the group consisting of staples, glue, hot air welding, stitching, ultrasonic welding, infrared bonding, and any combination thereof.
  • 20. The method of claim 15, in which the provided battens comprise a plurality of hingably-connected layers.
  • 21. A spacer operatively disposable between a roof decking and an exterior roof material and comprising a plurality of stacked layers, each layer comprising a generally planar first ply and a second ply cooperating with the first ply to define a multiplicity of passages, the passages extending generally transversely to a longitudinal axis of the spacer, the layers fastened together by stitching, adjacent layers connected by a hingeline extending generally parallel to the spacer longitudinal axis.
  • 22. A spacer operatively disposable between a roof decking and an exterior roof material and comprising a plurality of stacked, completely separated layers fastened together by stitching, each layer comprising a generally planar first ply and a second ply cooperating with the first ply to define a multiplicity of passages, the passages extending generally transversely to a longitudinal axis of the spacer.
CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to, and hereby incorporates by reference, U.S. Provisional Application No. 60/112,597, filed Dec. 17, 1998.

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Provisional Applications (1)
Number Date Country
60/112597 Dec 1998 US