Vent cap for an opening in a roof, wall, or other structure

Abstract

A vent cap that is configured for use in guarding an opening in a structure, such as an opening in a roof or wall. The invention is particularly well suited for use on panels that have flats separated by one or more upstanding ribs. The inventive vent cap includes a rib receiver designed to fit closely over a panel rib. Two lateral shoulders are preferably provided to increase the footprint and internal volume of the hollow vent cap. These lateral shoulders allow the vent pipe to be laterally displaced from the panel rib while the vent cap remains centered on the rib.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This non-provisional patent application is a continuation-in-part of U.S. patent application Ser. No. 18 / 642,034. The parent application was filed on Apr. 22, 2024. It named the same inventor.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicableMicrofiche Appendix

[0003] Not ApplicableBACKGROUND OF THE INVENTION1. Field of the Invention

[0004] The present invention pertains to the field of construction. More specifically, the invention comprises a cap for shielding a plumbing vent pipe or similar device that penetrates a roof, wall, or other structure.2. Description of the Related Art

[0005] FIG. 1 depicts an exemplary type of prior art panel—in this case a metal roof panel. Metal roof panel 10 includes flats 18, 20 and a series of evenly spaced ribs 12, 14, 16. Such panels are usually much longer-10 to 20 feet long—but the cross section is uniform for the entire length. FIG. 1 shows only a portion of such a panel, but it serves to illustrate the challenges present in the prior art and the advantages offered by the present invention.

[0006] Plumbing drain pipes are generally equipped with a vertically extending vent pipe. Such vent pipes equalize pressure in the drain system and carry sewage odors outside the structure. Most such vent pipes extend vertically through the roof structure. FIG. 2 shows such an installation. Once the location of the vent pipe is determined, opening 22 is cut through the metal roof panel. A tool such as a reciprocating saw is often used—with the result that the opening is somewhat irregular. Vent pipe 24 is then installed, with a portion of the vent pipe sticking up through the roof panel.

[0007] It is necessary to create a seal between the vent pipe and the roof structure. For a shingle roof, a metal or plastic flashing piece is usually tucked under the shingles on the slope above the vent pipe and sealed over the top of the shingles in the area below the vent pipe. This is a fairly simple and effective process. The example of FIG. 2, however, illustrates a problem that is often encountered for metal roofs. The roof panels are typically installed before the vent pipes are added. Thus, the location needed for a vent pipe may well intersect one of the ribs. As shown in FIG. 2, opening 22 passes through portions of flat 18, rib 14, and flat 20. The complex nature of the gap creates a sealing challenge.

[0008] FIG. 3 shows a known prior art solution for this problem. Tapered boot 26 has a pliable rubber side wall that can be cut to stretch and slip over vent pipe 24. The lower edge of the boot is bonded to metal flange 28. The metal flange is thin and bendable. It can usually be bent by hand to conform to the complex shape of the flats 18, 20 and rib 14. A large number of fasteners (usually sheet metal screws) are then passed through flange 28 and into the metal roof panel to hold it secure. Caulk or other sealant is then liberally applied to the joint between the flange and the roof panel and the joint between the tapered boot and the vent pipe.

[0009] The system depicted does work, but it is cumbersome and labor intensive. It is also somewhat unsightly when finished. The present invention provides a solution for this problem that is easier to install and more pleasing in its finished appearance.BRIEF SUMMARY OF THE INVENTION

[0010] The present invention comprises a vent cap that is configured for use in guarding an opening in a structure, such as an opening in a roof or a wall. The invention is particularly well suited for use on panels that have flats separated by one or more upstanding ribs. The inventive vent cap includes a rib receiver designed to fit closely over a panel rib. Two lateral shoulders are preferably provided to increase the footprint and internal volume of the hollow vent cap. These lateral shoulders allow the vent pipe to be laterally displaced from the panel rib while the vent cap remains centered on the rib.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0011] FIG. 1 is a perspective view, showing a prior art metal roof panel.

[0012] FIG. 2 is a perspective view, showing the prior art roof panel of FIG. 1 with a vent pipe installed.

[0013] FIG. 3 is a perspective view, showing a prior art sealing device placed around the vent pipe of FIG. 2.

[0014] FIG. 4 is a perspective view, showing an exemplary embodiment of the present invention installed on a roof panel.

[0015] FIG. 5 is a perspective view with a cutaway, showing interior details of the installation of FIG. 4.

[0016] FIG. 6 is an elevation view, showing interior details of the installation of FIG. 4.

[0017] FIG. 7 is an elevation view, showing interior details of the installation of FIG. 4.

[0018] FIG. 8 is an elevation view, showing interior details of the installation of FIG. 4.

[0019] FIG. 9 is a plan view, showing how the inventive vent cap sits on the roof panel.

[0020] FIG. 10 is a perspective view, showing an alternate embodiment of the inventive vent cap.

[0021] FIG. 11 is an elevation view, showing the embodiment of FIG. 10 with the addition of some explanatory dimensions.

[0022] FIG. 12 is a perspective view, showing an embodiment incorporating a flow directing feature on the up-slope side.

[0023] FIG. 13 is a sectional elevation view, showing a variation for the rib receiver.

[0024] FIG. 14 is a sectional elevation view, showing another variation for the rib receiver.

[0025] FIG. 15 is a sectional elevation view, showing an alternate location for the vent opening.

[0026] FIG. 16 is a perspective view, showing how an embodiment of the present invention that is configured to be stacked for more efficient shipping and storage.

[0027] FIG. 17 is a perspective view, showing an embodiment of the invention that includes a larger rib receiver.

[0028] FIG. 18 is a perspective view, showing an embodiment of the invention installed on a wall.

[0029] FIG. 19 is a perspective view, showing an alternate embodiment of the present invention.

[0030] FIG. 20 is a perspective view, showing the interior of the embodiment of FIG. 19.

[0031] FIG. 21 is a side elevation view with a partial section, showing the embodiment of FIG. 19.

[0032] FIG. 22 is a front elevation view, showing the embodiment of FIG. 19.REFERENCE NUMERALS IN THE DRAWINGS10 metal roof panel

[0034] 12 rib

[0035] 14 rib

[0036] 16 rib

[0037] 18 flat

[0038] 20 flat

[0039] 22 opening

[0040] 24 vent pipe

[0041] 26 tapered boot

[0042] 28 metal flange

[0043] 29 vent cap

[0044] 30 fastener

[0045] 32 flange

[0046] 34 rib receiver

[0047] 36 opening

[0048] 38 overhang

[0049] 40 central portion

[0050] 42 shoulder

[0051] 44 shoulder

[0052] 46 shoulder

[0053] 48 shoulder

[0054] 50 centerline

[0055] 52 cricket

[0056] 54 convoluted rib

[0057] 56 rib receiver

[0058] 58 butyl tape

[0059] 60 standing seam rib

[0060] 62 rib receiver

[0061] 64 setback

[0062] 66 drip rail

[0063] 68 opening

[0064] 70 enlarged rib receiver

[0065] 72 wall panel

[0066] 74 drip rail

[0067] 76 vent cap

[0068] 78 opening

[0069] 80 grate wall

[0070] 82 dividing wallDETAILED DESCRIPTION OF THE INVENTION

[0071] FIG. 2 depicts the problem to be addressed-a vent pipe 24 protruding through an opening 22 in a metal roof panel. FIG. 4 depicts an embodiment of the present invention installed over the vent pipe and opening. Vent cap 29 is a hollow structure configured to secure to the metal roof panel-including lying over one of the upstanding ribs.

[0072] The roof panel has a slope, though the slope is not great for the example shown. “Downslope” is the direction water travels under the influence of gravity as it travels off the roof panel. “Upslope” is the opposite direction. First and second lateral directions are orthogonal to the upslope / downslope directions.

[0073] Central portion 40 in this example is a hollow “box” structure with an open bottom that fits over the roof panel. Opening 36 is provided—in this case on the downslope side of the vent. Overhang 38 is preferably provided to shield the opening and prevent the ingress of rain. Shoulder 42 extends laterally from a first side of central portion 40 and shoulder 44 extends from the opposite side. The two shoulders expand the interior volume of the hollow structure and provide additional room for possible misalignment of the vent pipe—as will be explained.

[0074] Flange 32 extends outward from the lower portion of the hollow structure. Most of the flange is flat so that it can lay against the flats of the roof panel. However, rib receiver 34 is provided in the flange and adjacent structures in order to accommodate rib 14 of the roofing panel. The ribs on the roofing panel have standard dimensions. Rib receiver 34 is sized to fit snugly over the ribs of the roofing panel. The rib receiver runs all the way from the downslope to the upslope side of the vent cap-though not of course in the hollow central portion where no relief for the upstanding rib is needed. Only the downslope portion of the rib receiver is visible in FIG. 4.

[0075] FIG. 5 shows the same assembly with half of the vent cap cut away to reveal internal features. The reader will note how the rib receiver fits snugly over the upstanding rib. The reader will also note how central portion 40 easily accommodates the protruding vent pipe 24. The vent cap is preferably a thin-walled hollow structure so that the internal volume is maximized. Its internal dimensions are made large enough in the upslope / downslope directions to provide good clearance for the pipe and accommodate any installation errors. The internal dimensions are made even larger in the lateral directions.

[0076] FIG. 6 illustrates the advantage of providing more lateral internal volume. FIG. 6 is looking along the plane of the roof panel in the upslope direction. Vent pipe 24 is installed vertically, which causes it to appear tilted away from the viewer when looking along the plane of the sloping roof panel. The portion of the vent pipe protruding into the inventive vent cap is shown as a hidden line. Shoulder 42 extends away from central portion 40 in a first lateral direction and shoulder 44 extends away in a second lateral direction.

[0077] The vent cap functions well with the vent pipe located anywhere within the interior volume. No matter the location of the vent pipe, gasses escaping from the vent pipe will exit opening 36. However, extending the coverage of shoulders 42, 44 allows a vent pipe that is farther and farther from the rib on which the inventive vent cap is mounted to be accommodated. In the example shown, rib receiver 34 is provided on the centerline of the inventive vent cap. The reader will appreciate that the vent cap can slide easily along the rib in the upslope / downslope direction, but it cannot move laterally because of the interface between rib receiver 34 and the rib on which the vent cap is mounted.

[0078] FIG. 7 shows a vent pipe 24 that is offset a greater distance from rib 14 than was the case in the example of FIG. 6. The presence of shoulder 42 accommodates this greater offset. FIG. 8 shows a lateral view of the same assembly—with the plane of the roof vent panel again being oriented horizontally (though it is of course sloped in the actual installation). Vent pipe 24 is again installed vertically—but appears at an angle because of the view being referenced to the roof panel. The portion of the vent pipe extending into vent cap 29 is again shown in hidden lines. The reader will note how adequate clearance is provided in the upslope / downslope directions. This clearance allows for installation errors.

[0079] FIG. 9 shows a plan view of the same installation-looking down on the plane of the roof panel. The reader will note how flange 32 runs entirely around the lower portion of the hollow structure. Centerline 50 is an axis running through the middle of this example. Rib receiver 34 in this example is provided along centerline 50.

[0080] Looking back at FIG. 7, the reader will note that-even with the presence of shoulders 42, 44—there is a limit to how much lateral displacement of vent pipe 24 from rib 14 can be accommodated. The inventive vent cap can only be placed upon a rib for lateral positioning. Thus, while one can lift it and move it over to the next rib—this will not always accommodate a large vent pipe such as shown in FIG. 7 that is laterally displaced too far from the rib on which the vent cap is mounted. Thus, it is desirable to provide an embodiment with additional lateral capacity.

[0081] FIG. 10 depicts such an embodiment. Shoulders 46, 48 include a vertical portion extending up from flange 32 and a sloping portion that joins central portion 40. This version increases the lateral displacement of the vent pipe that can be accommodated within the interior volume. FIG. 11 illustrates this principle.

[0082] In the example of FIG. 11, vent pipe 24 has a diameter w. It is offset from rib 14 a distance x. The ribs on the roofing panel have a standard fixed pitch y (the distance from the center of one rib to the center of the next rib). The maximum displacement of the center of the vent pipe from any rib is therefore given by the expression:xmax=y / 2

[0083] Shoulders 46, 48 are offset from the centerline of the vent cap a distance z. In order to accommodate every possible lateral offset of the vent pipe, it is preferable to make z according to the following equation:z=y2+w2+t,where t is the thickness of the wall of the vent cap in the vicinity of the vent pipe. Using this expression as a guide for the vent cap dimensions ensures that you can fit the vent pipe within the vent cap at the current rib installation location (or move the vent cap over to the next rib and install it there).Some additional explanation as to the installation of the vent cap is helpful. In the view of FIG. 4, the reader will note how flange 32 conforms to the shape of the flats and ribs of the roof panel. Fasteners 30 are installed through flange 32 and the roof panel. Holes can be provided in the flange to receive the fasteners. Alternatively, the flange can be made of a material that allows self-tapping or other fasteners to be driven through without the provision of pre-existing holes through the flange.

[0085] A seal between the flange and the roof panel is important, particularly on the upslope side. An adhesive or sealant can be applied to the underside of the flange before the vent cap it pressed down into position. The adhesive / sealant can even be applied as part of the manufacturing process and covered by a removable strip. The strip would be removed just prior to installation.

[0086] Compressible butyl tape is a particularly effective sealant. This substance has been used in the roofing industry for many years and its performance and endurance is well established. Double-sided butyl tape is preferably adhered to the downward-facing surfaces of the flange. The downward-facing surface of the butyl tape is then covered by a removable strip. The strip is left in place while the vent pipe cap is test fitted. When it is time to permanently install the cap, the strip is removed, and the tape is pressed against the roofing panel. Securing screws can then be driven through the flange, the butyl tape, and the roofing panel. The screws are tightened to compress the tape and secure a good seal.

[0087] Alternatively, the vent cap can be screwed in place and the adhesive / sealant can be added after the mechanical installation is complete. The invention is not limited to any particular method of installation. Many other methods will occur to those skilled in the art.

[0088] The invention can assume many other forms incorporating desirable features in different combinations. FIG. 12 provides an alternate embodiment of the inventive vent cap. The vantage point is from the up-slope side of the installation. In this embodiment, a flow-directing feature is provided to the up-slope side of the vent cap. Cricket 52 divides the water flow coming down the roof and helps it split and flow around the vent cap without pooling against the uphill side of the vent cap. The “vee” shape is commonly called a cricket in the field of roofing. Many other shapes can be employed for the cricket, so long as they direct the water around the vent cap. The reader will note how flange 32 and rib receiver 24 conform to the shape of the cricket used.

[0089] The rib receiver provided in a particular embodiment is preferably shaped to fit closely over a particular type of rib. As those skilled in the art will know, many different rib types are used in roofing panels. FIGS. 13 and 14 provide sectional elevation views through two very different types of ribs. FIG. 13 shows convoluted rib 54. A corresponding rib receiver 56 is provided to approximate the shape of the convoluted rib. Butyl tape 58 is compressed between the rib receiver and the convoluted rib. The butyl tape is quite compressible-allowing it to accommodate some mismatch between the shape of the rib receiver and the shape of the convoluted rib.

[0090] FIG. 14 shows a rib created by a junction in a standing seam metal roof-designated as standing seam rib 60. Rib receiver 62 is provided to conform to the shape of the standing seam rib. Butyl tape is again provided. The reader will note how a very different shape of the rib receiver is provided in FIG. 14 as compared to the example of FIG. 13. Many different shapes for the rib receiver can be provided and the invention is not limited to any particular shape.

[0091] FIG. 15 shows a section view through another embodiment of the inventive vent cap. This embodiment features a more horizontally oriented opening 68 (covered by screen or mesh), contained within setback 64. Drip rail 66 is provided so that even a hard rain will not tend to drip into the opening. Many other shapes and locations for these features are possible.

[0092] Most embodiments of the inventive vent cap will include thin walls surrounding a hollow interior. This results in the vent cap having a low overall density. Such bulky but light items are inefficient for shipping and storage. It is beneficial to provide an alternate design that can be nested and stacked-thereby increasing storage and shipping efficiency. FIG. 16 shows such an embodiment. The inventive vent caps 29 shown include thin walls surrounding a hollow interior. All of the side walls are given a suitable draft angle so that they tilt inward when proceeding from bottom to top. Suitable fillet radii are preferably also provided on the corners. These features allow multiple instances of the vent cap 29 to be stacked as shown. The instances can be urged together until central portion 40 of the lower instance bears against setback 64 of the upper instance. Even deeper nesting can be provided by eliminating the use of setback 64.

[0093] Many other variations are possible for the inventive embodiments. As an example, the inventive vent pipe cap can be made with tapering sidewalls so that multiple instances of the invention can be stacked for storage and shipping. Metal versions can be provided using galvanized steel. Injection-molded plastic versions can be provided. Still other versions can be pressed from sheet molding compound.

[0094] FIG. 17 shows an additional embodiment of the inventive vent cap 29. Enlarged rib receiver 70 is provided in this example. The enlarged rib receiver accommodates ribs that are larger than a typical “5V” rib and formed in a different profile. The embodiment of FIG. 17 is designed to accommodate a rib that is wider and that also includes a flat portion at the top of the rib. The reader will observe how enlarged rib receiver 70 fits closely overs such an alternate profile.

[0095] The embodiment of FIG. 17 includes sloping shoulders 42, 44. It also includes sloping walls on the upslope and downslope sides of the vent cap. Opening 36 extends parallel to central portion 40. Its upper extreme is guarded by overhang 38, which prevents most moisture from dripping into the opening.

[0096] Most of the inventive embodiments can be used to cover openings in structures other than a roof. As an example, the inventive vent cap can be mounted to cover an opening in a vertical wall. FIG. 18 illustrates an embodiment of vent cap 29 mounted on a vertical wall panel 72. The wall panel in this example has flats 18 separated by ribs 12, 14, 16. Rib receiver 34 fits over rib 14. The vent cap is positioned over the opening through the wall and secured in placed by any suitable means-such as driving fasteners 30 through flange 32.

[0097] Cricket 52 is positioned on the upslope side of the vent cap (in this case the top side in the vertical orientation). A cutaway is provided so that the reader can visualize some of the hidden portions of this embodiment. Opening 36 faces downward. It is covered in this example by a suitable wire mesh. Drip rail 74 is provided proximate the outward side of the opening. Any water flowing down the wall will pass over cricket 52 and central portion 40. The water will then drip off of drip rail 74 rather than entering the vent cap through opening 36.

[0098] FIGS. 19-22 show still another embodiment of the inventive vent cap. This version includes a more hidden opening that presents a cleaner exterior appearance when the vent cap is installed. It is configured for installation on a roof, a wall, or other suitable surface.

[0099] Looking at FIG. 19, vent cap 76 includes a broadened central portion 40. Cricket 52 transitions into both the central portion and the two shoulders 42, 44. A suitable rib receiver is provided as for the prior examples. In this case, enlarged rib receiver 70 is provided. Opening 78 is provided on the side opposite cricket 52. The opening 78 is thus provided on the downslope side of the expected water flow. The opening leads to the hollow interior of the vent cap.

[0100] FIG. 20 shows the same vent cap 76 from the opposite side-allowing the viewer to perceive the nature of hollow interior 78. The reader will note how flange 32 runs around the base of the structure-including enlarged rib receiver 70. FIG. 21 provides a side elevation view of vent cap 76, with a partial cutaway revealing a sectional view in the vicinity of opening 78. In this example, opening 78 does not lead directly into the hollow interior. Instead, it leads to a smaller chamber bounded by dividing wall 82 and grate wall 88. The grate wall includes multiple openings leading into the hollow interior.

[0101] FIG. 22 shows a front elevation view. The reader will note how grate wall 80 is visible through opening 78. The grate wall includes numerous opening 84 leading into the hollow interior of the vent cap. Gasses emitted from a vent pass freely through these openings. However, the openings are preferably made small enough to prevent the passage of birds, bats, mice, and larger insects.

[0102] Returning to FIG. 19, the reader will note how vent cap 76 can be installed on a sloping roof surface (with the cricket 52 being upslope) or a vertical wall surface (with the cricket 52 facing upward). This embodiment provides a clean appearance in any desired orientation. Further, the grate wall is not readily visible to an outside observer. This also contributes to the clean appearance.

[0103] The inventive vent cap is useful for guarding an opening through a roof and through a side wall. It is also useful for guarding openings through other types of structures-such as a dormer wall, a negatively sloping wall, and an underground shelter. While it is suitable for use on surfaces having flats and ribs, it can also be used where no ribs are present. In that case, the user will add a sealant to seal the open portion of the rib receiver.

[0104] The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the claims ultimately drafted, rather than by the examples given.

Claims

1. A vent cap for covering an opening in a panel having a first flat, a second flat, and an upstanding rib therebetween, comprising:(a) a hollow central portion including an opening;(b) a hollow first shoulder extending laterally from a first side of said central portion;(c) a hollow second shoulder extending laterally from a second side of said central portion;(d) a flange running around said central portion, said first shoulder, and said second shoulder; and(e) said flange including a rib receiver sized to fit over said upstanding rib of said metal roof panel.

2. The vent cap as recited in claim 1, further comprising an overhang proximate said opening.

3. The vent cap as recited in claim 1, wherein said rib receiver runs along a centerline of said vent cap.

4. The vent cap as recited in claim 1, further comprising:(a) a cricket; and(b) wherein said flange runs around said cricket as well as said central portion, said first shoulder and said second shoulder.

5. The vent cap as recited in claim 1, wherein said central portion, said first shoulder, said second shoulder, said flange, and said rib receiver are made as an integral piece.

6. The vent cap as recited in claim 1, wherein said central portion, said first shoulder, said second shoulder, said flange, and said rib receiver are made as an assembly of multiple pieces.

7. The vent cap as recited in claim 1, wherein:(a) said panel has multiple ribs and a standard distance between each of said ribs;(b) said vent cap has a centerline; and(c) said first shoulder extends a lateral distance from said rib receiver that is at least one-half said standard distance between each of said ribs.

8. A vent cap for covering an opening in a panel having a plurality of upstanding ribs with a standard distance therebetween, comprising:(a) a hollow central portion including an opening;(b) a hollow first shoulder extending laterally from a first side of said central portion;(c) a hollow second shoulder extending laterally from a second side of said central portion;(d) a flange running around said central portion, said first shoulder, and said second shoulder; and(e) said flange including a rib receiver sized to fit over one of said upstanding ribs of said panel.

9. The vent cap as recited in claim 8, further comprising an overhang proximate said opening.

10. The vent cap as recited in claim 8, wherein said rib receiver runs along a centerline of said vent cap.

11. The vent cap as recited in claim 8, wherein each of said first and second shoulders include a vertical portion and an angled portion.

12. The vent cap as recited in claim 8, wherein said central portion, said first shoulder, said second shoulder, said flange, and said rib receiver are made as an integral piece.

13. The vent cap as recited in claim 8, wherein said central portion, said first shoulder, said second shoulder, said flange, and said rib receiver are made as an assembly of multiple pieces.

14. The vent cap as recited in claim 1, wherein said first shoulder extends a lateral distance from said rib receiver that is at least one-half said standard distance between each of said ribs.

15. A vent cap for covering an opening in a vertically-oriented wall panel having a plurality of upstanding ribs with a standard distance therebetween, comprising:(a) a hollow body including a first lateral extreme, a second lateral extreme, and an opening;(b) a flange running around said hollow body; and(c) said flange including a rib receiver sized to fit over one of said upstanding ribs of said wall panel.

16. The vent cap as recited in claim 15, further comprising a drip rail proximate said opening.

17. The vent cap as recited in claim 15, wherein said rib receiver runs along a centerline of said vent cap.

18. The vent cap as recited in claim 15, wherein:(a) said hollow body includes a cricket; and(b) said flange runs around said cricket as well as said hollow body.

19. The vent cap as recited in claim 15, wherein said hollow body, said flange, and said rib receiver are made as an integral piece.

20. The vent cap as recited in claim 15, wherein said hollow body, said flange, and said rib receiver are made as an assembly of multiple pieces.

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