Illuminated 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 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 an internal light source that projects light in a desired direction—such as along a wall panel.

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 / 804,258, which is itself a continuation-in-part of U.S. patent application Ser. No. 18 / 642,034. The parent applications both name 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, panel opening 22 is cut through the metal roof panel. A tool such as a reciprocating saw is often used-with the result that the panel 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, panel 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 an internal light source that projects light in a desired direction-such as along a wall panel.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. I 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 exterior 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.

[0033] FIG. 23 is a side elevation with a partial section, showing the installation of a light within the inventive vent cap.

[0034] FIG. 24 is a perspective view, showing an illuminated vent cap installed on a vertical wall panel.

[0035] FIG. 25 is a side elevation view with a partial section, showing an illuminated vent cap that includes a solar panel and a battery.

[0036] FIG. 26 is an elevation view, showing the operation of an illuminated vent cap.

[0037] FIG. 27 is an exploded perspective view, showing a universal vent cap aligned with a panel-specific base of a first type.

[0038] FIG. 28 is an exploded perspective view, showing a universal vent cap aligned with a panel-specific base of a second type.REFERENCE NUMERALS IN THE DRAWINGS10 metal roof panel

[0040] 12 rib

[0041] 14 rib

[0042] 16 rib

[0043] 18 fat

[0044] 20 flat

[0045] 22 panel opening

[0046] 24 vent pipe

[0047] 26 tapered boot

[0048] 28 metal flange

[0049] 29 vent cap

[0050] 30 fastener

[0051] 32 flange

[0052] 34 rib receiver

[0053] 36 exit opening

[0054] 38 overhang

[0055] 40 central portion

[0056] 42 shoulder

[0057] 44 shoulder

[0058] 46 shoulder

[0059] 48 shoulder

[0060] 50 centerline

[0061] 52 cricket

[0062] 54 convoluted rib

[0063] 56 rib receiver

[0064] 58 butyl tape

[0065] 60 standing seam rib

[0066] 62 rib receiver

[0067] 64 setback

[0068] 66 drip rail

[0069] 68 exit opening

[0070] 70 enlarged rib receiver

[0071] 72 wall panel

[0072] 74 drip rail

[0073] 76 vent cap

[0074] 78 exit opening

[0075] 79 hollow interior

[0076] 80 grate wall

[0077] 81 interior opening

[0078] 82 dividing wall

[0079] 84 grate opening

[0080] 86 light

[0081] 88 reflector

[0082] 90 mount

[0083] 92 power lead

[0084] 94 battery

[0085] 96 solar panel

[0086] 98 light pattern

[0087] 100 universal vent cap

[0088] 102 panel-specific base

[0089] 104 hole

[0090] 106 hole

[0091] 108 panel-specific base

[0092] 110 standing seam receiverDETAILED DESCRIPTION OF THE INVENTION

[0093] FIG. 2 depicts the problem to be addressed—a vent pipe 24 protruding through a panel opening 22 in a metal roof panel. FIG. 4 depicts an embodiment of the present invention installed over the vent pipe and panel opening. Vent cap 29 is a hollow structure configured to secure to the metal roof panel—including lying over one of the upstanding ribs.

[0094] Several embodiments of the vent cap will be described in detail, so it is helpful to establish some uniform terminology. The term “panel opening” means an opening through the structure on which the inventive vent cap is being installed. The panel opening may be provided through a roof, a wall, or some other portion of the structure. Usually, the panel opening will be provided through a flat roof or wall panel. However, the use of the word “panel” in the term “panel opening” should not be viewed as restricting the term to flat panels. In some cases, the “panel opening” will be provided through a piece of board siding or through a section of roofing shingles.

[0095] The inventive vent cap is a hollow structure with two or more openings. All the embodiments include an “entrance opening,” where the vented gases enter the cap's hollow interior (usually through a vent pipe) and an “exit opening” where vent gases within the hollow interior escape to the surrounding atmosphere. The entrance opening will generally face toward the panel or other structure on which the inventive vent cap is mounted. An example of an exit opening is exit opening 36 in the embodiment of FIG. 4.

[0096] The roof panel has a slope, though the slope is not great for the example shown in FIG. 4. “Downslope” is the direction water travels under the influence of gravity as it travels off the roof or wall panel. “Upslope” is the opposite direction. First and second lateral directions are orthogonal to the upslope / downslope directions.

[0097] Central portion 40 in this example is a hollow “box” structure with an open bottom (constituting the entrance opening) that fits over the roof panel. Exit opening 36 is provided—in this case on the downslope side of the vent. Overhang 38 is preferably provided to shield the exit 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 an installed vent pipe—as will be explained.

[0098] Flange 32 extends outward from the lower portion of the hollow structure, surrounding the entrance opening. 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.

[0099] 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.

[0100] 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.

[0101] The vent cap functions well with the vent pipe located anywhere within the interior volume. No matter the location of the vent pipe, gases escaping from the vent pipe will escape through 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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

[0107] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] FIG. 15 shows a section view through another embodiment of the inventive vent cap. This embodiment features a more horizontally oriented exit 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 exterior opening. Many other shapes and locations for these features are possible.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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. Exit opening 36 extends parallel to central portion 40. Its upper extreme is guarded by overhang 38, which prevents most moisture from dripping into the exterior opening.

[0120] Most of the inventive embodiments can be used to cover panel openings in structures other than a roof. As an example, the inventive vent cap can be mounted to cover a panel 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 panel opening through the wall and secured in placed by any suitable means—such as driving fasteners 30 through flange 32.

[0121] 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. Exit opening 36 faces downward in this mounting scheme. It is covered in this example by a suitable wire mesh. Drip rail 74 is provided proximate the outward side of the exterior 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 exit opening 36.

[0122] FIGS. 19-22 show still another embodiment of the inventive vent cap. This version includes a more hidden exit 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.

[0123] Looking at FIG. 19, vent cap 76 includes a broadened central potion 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. Exit opening 78 is provided on the side opposite cricket 52. The exit opening 78 is thus provided on the downslope side of the expected water flow. The exit opening leads to the hollow interior of the vent cap.

[0124] FIG. 20 shows the same vent cap 76 from the opposite side-allowing the viewer to perceive the nature of hollow interior 79. The reader will note how flange 32 runs around the perimeter of entrance opening 81. The flange includes 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 exit opening 78. In this example, exit 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 grate openings leading into the hollow interior.

[0125] FIG. 22 shows a front elevation view. The reader will note how grate wall 80 is visible through exit opening 78. The grate wall includes numerous grate openings 84 leading into the hollow interior 79 of the vent cap. Gases emitted from a vent pass freely through these grate openings. However, the grate openings are preferably made small enough to prevent the passage of birds, bats, mice, and larger insects.

[0126] 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.

[0127] The inventive vent cap is useful for guarding a panel opening through a roof and through a side wall. It is also useful for guarding panel 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.ILLUMINATED EXAMPLES

[0128] Other useful features can be added to the vent cap. Returning to FIG. 18, the reader will recall that the inventive vent cap can be installed over a panel opening through a vertical or steeply sloped wall. In this configuration, adding a light to the vent cap transforms the vent cap to act as both a vent and a sconce light. This provides both functional and aesthetic value.

[0129] FIG. 23 provides a side elevation view of a vent cap 76 modified with the addition of an internal light source. Light 86 is added by passing mount 90 through a hole provided in dividing wall 82. The mount can be secured in any convenient manner, such as tightening a nut on a threaded section. Power leads 92 provide electrical power. In this example, a parabolic reflector 88 is provided. Exemplary light 86 is a small and bright source—such as one or more chip LEDs. Light is projected and focused by reflector 88 so that it passes out exit opening 78 as an expanding beam.

[0130] FIG. 24 shows this embodiment of vent cap 76 installed on vertical wall panel 72. The reader will note how light 86—and its associated reflector—are positioned to throw a beam of light downward through exit opening 78. The light itself is shielded from direct view. FIG. 26 shows a vertical elevation view of this installation. The reflector is preferably oriented to throw the light beam downward and thereby create a pleasing light pattern 98 on vertical wall panel 72. Differing combinations of light sources and reflectors can be selected to create a wide variety of desired light patterns.

[0131] FIG. 25 shows another illuminated embodiment. This example includes an external solar panel 96 feeding storage battery 94. The battery includes an integrated charge controller that regulates the storage and use of energy from solar panel 96. Light 86 is preferably a low-consumption LED so that it can remain on for several hours at a time—using the energy stored in battery 94.

[0132] An external light sensor can be used to automatically switch on light 86 for any of the illuminated versions. As an example, the external light sensor can be used to switch on light 86 when the sun goes down. This can provide safety illumination around out-buildings. The light sensor can be a dedicated photoelectric cell. Alternatively, the charge controller can monitor the output of solar panel 96 and switch to battery power once the solar panel's output drops below a defined threshold.

[0133] The reader will appreciate that many other configurations are possible for an illuminated vent cap. Looking still at FIG. 25, an opaque coating can be provided on the interior surfaces of the vent cap around light 86. This will prevent any light leakage through the vent cap (which can occur when materials such as molded plastic are used). Alternatively, it is possible to provide an illuminated vent cap molded from a translucent polymer. In this case the entire vent cap would be illuminated in addition to the beam of light thrown through the exterior opening. One can also add other visual effects-such as printed graphics-that would be internally illuminated.Universal Vent Cap Examples

[0134] The prior examples of the inventive vent cap have included a rib receiver configured to fit closely over a corresponding feature on the roof or wall. For example, the vent cap of FIG. 12 includes a rib receiver 34 configured to fit closely over the “vee” of a metal roof panel. FIGS. 13 and 14 show some of the differing shapes needed for rib receivers 56 and 62. Rib receiver 56 is designed to fit over convoluted rib 54 whereas rib receiver 62 is provided with a very different shape—designed to fit over standing seam rib 60.

[0135] For an integral molded or stamped metal vent cap, a separate set of tooling is needed for the incorporation of each different rib receiver. The embodiment of FIG. 17 provides a good example of this issue. The mold used to make vent cap 29 must be shaped to form a specific rib receiver. If a different rib receiver is desired, a new mold for the entire integral part must generally be made.

[0136] In order to avoid this problem, a different approach is advantageously employed. FIGS. 27 and 28 show an alternate embodiment of the inventive vent cap in which a universal vent cap is mated to a variety of specifically configured bases. FIG. 27 shows universal vent cap 100. This is a molded plastic part having internal features that are the same as the previously disclosed vent caps—including exit opening 78. Flange 32 is provided around the lower perimeter of the vent cap. This flange does not include a rib receiver. Instead, a separate panel-specific base 102 is provided. Panel-specific base 102 includes enlarged rib receiver 70, which is shaped to fit over a convoluted rib 54 such as shown in FIG. 13.

[0137] Alignment or engagement features can be provided on the universal vent cap and the panel-specific base in order to aid installation. In the example of FIG. 27, holes 104 are provided in flange 32. Aligned holes 106 are provided in panel-specific base 102. Mounting screws (or other fasteners) can be passed through these holes 104,106 and into the roof or wall panel on which the vent cap is installed.

[0138] FIG. 28 shows a second exemplary panel-specific base. The same universal vent cap 100 is provided. However, a different panel-specific base 108 is combined with the universal vent cap. Panel-specific base 108 bas a standing seam receiver 110 shape to fit over the joints in a standing-seam roof.

[0139] The general term for standing seam receiver 110, enlarged rib receiver 70, and similar features is a “feature receiver.” The term “feature receiver” means a passage through the panel-specific base configured to receive and lie closely around any upstanding feature on the panel to which the vent cap assembly is attached.

[0140] The system of combining a universal vent cap with a variety of panel-specific bases allows one set of tooling for the complex features of the universal vent cap. Much simpler tooling can be used to create the panel-specific bases. The two components are then united to create a vent cap assembly.

[0141] As an example of the simpler tooling that can be used to make the panel-specific bases, the bases can be injection-molded using simple two-piece molds with no transverse slides needed. The bases can even be made using other manufacturing processes-such as 3D printing. The use of an additive process like 3D printing allows custom or low-volume production where a customer can order a custom base that is made in very small quantities.

[0142] Of course, high-volume processes can still be used for those panel-specific bases that will be used in greater quantities. Thus, injection molding might be used for some bases and 3D printing used for others.

[0143] 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.

Examples

Embodiment Construction

[0093]FIG. 2 depicts the problem to be addressed—a vent pipe 24 protruding through a panel opening 22 in a metal roof panel. FIG. 4 depicts an embodiment of the present invention installed over the vent pipe and panel opening. Vent cap 29 is a hollow structure configured to secure to the metal roof panel—including lying over one of the upstanding ribs.

[0094]Several embodiments of the vent cap will be described in detail, so it is helpful to establish some uniform terminology. The term “panel opening” means an opening through the structure on which the inventive vent cap is being installed. The panel opening may be provided through a roof, a wall, or some other portion of the structure. Usually, the panel opening will be provided through a flat roof or wall panel. However, the use of the word “panel” in the term “panel opening” should not be viewed as restricting the term to flat panels. In some cases, the “panel opening” will be provided through a piece of board siding or through a ...

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This non-provisional patent application is a continuation-in-part of U.S. patent application Ser. No. 18 / 804,258, which is itself a continuation-in-part of U.S. patent application Ser. No. 18 / 642,034. The parent applications both name 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, panel opening 22 is cut through the metal roof panel. A tool such as a reciprocating saw is often used-with the result that the panel 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, panel 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 an internal light source that projects light in a desired direction-such as along a wall panel.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. I 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 exterior 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.

[0033] FIG. 23 is a side elevation with a partial section, showing the installation of a light within the inventive vent cap.

[0034] FIG. 24 is a perspective view, showing an illuminated vent cap installed on a vertical wall panel.

[0035] FIG. 25 is a side elevation view with a partial section, showing an illuminated vent cap that includes a solar panel and a battery.

[0036] FIG. 26 is an elevation view, showing the operation of an illuminated vent cap.

[0037] FIG. 27 is an exploded perspective view, showing a universal vent cap aligned with a panel-specific base of a first type.

[0038] FIG. 28 is an exploded perspective view, showing a universal vent cap aligned with a panel-specific base of a second type.REFERENCE NUMERALS IN THE DRAWINGS10 metal roof panel

[0040] 12 rib

[0041] 14 rib

[0042] 16 rib

[0043] 18 fat

[0044] 20 flat

[0045] 22 panel opening

[0046] 24 vent pipe

[0047] 26 tapered boot

[0048] 28 metal flange

[0049] 29 vent cap

[0050] 30 fastener

[0051] 32 flange

[0052] 34 rib receiver

[0053] 36 exit opening

[0054] 38 overhang

[0055] 40 central portion

[0056] 42 shoulder

[0057] 44 shoulder

[0058] 46 shoulder

[0059] 48 shoulder

[0060] 50 centerline

[0061] 52 cricket

[0062] 54 convoluted rib

[0063] 56 rib receiver

[0064] 58 butyl tape

[0065] 60 standing seam rib

[0066] 62 rib receiver

[0067] 64 setback

[0068] 66 drip rail

[0069] 68 exit opening

[0070] 70 enlarged rib receiver

[0071] 72 wall panel

[0072] 74 drip rail

[0073] 76 vent cap

[0074] 78 exit opening

[0075] 79 hollow interior

[0076] 80 grate wall

[0077] 81 interior opening

[0078] 82 dividing wall

[0079] 84 grate opening

[0080] 86 light

[0081] 88 reflector

[0082] 90 mount

[0083] 92 power lead

[0084] 94 battery

[0085] 96 solar panel

[0086] 98 light pattern

[0087] 100 universal vent cap

[0088] 102 panel-specific base

[0089] 104 hole

[0090] 106 hole

[0091] 108 panel-specific base

[0092] 110 standing seam receiverDETAILED DESCRIPTION OF THE INVENTION

[0093] FIG. 2 depicts the problem to be addressed—a vent pipe 24 protruding through a panel opening 22 in a metal roof panel. FIG. 4 depicts an embodiment of the present invention installed over the vent pipe and panel opening. Vent cap 29 is a hollow structure configured to secure to the metal roof panel—including lying over one of the upstanding ribs.

[0094] Several embodiments of the vent cap will be described in detail, so it is helpful to establish some uniform terminology. The term “panel opening” means an opening through the structure on which the inventive vent cap is being installed. The panel opening may be provided through a roof, a wall, or some other portion of the structure. Usually, the panel opening will be provided through a flat roof or wall panel. However, the use of the word “panel” in the term “panel opening” should not be viewed as restricting the term to flat panels. In some cases, the “panel opening” will be provided through a piece of board siding or through a section of roofing shingles.

[0095] The inventive vent cap is a hollow structure with two or more openings. All the embodiments include an “entrance opening,” where the vented gases enter the cap's hollow interior (usually through a vent pipe) and an “exit opening” where vent gases within the hollow interior escape to the surrounding atmosphere. The entrance opening will generally face toward the panel or other structure on which the inventive vent cap is mounted. An example of an exit opening is exit opening 36 in the embodiment of FIG. 4.

[0096] The roof panel has a slope, though the slope is not great for the example shown in FIG. 4. “Downslope” is the direction water travels under the influence of gravity as it travels off the roof or wall panel. “Upslope” is the opposite direction. First and second lateral directions are orthogonal to the upslope / downslope directions.

[0097] Central portion 40 in this example is a hollow “box” structure with an open bottom (constituting the entrance opening) that fits over the roof panel. Exit opening 36 is provided—in this case on the downslope side of the vent. Overhang 38 is preferably provided to shield the exit 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 an installed vent pipe—as will be explained.

[0098] Flange 32 extends outward from the lower portion of the hollow structure, surrounding the entrance opening. 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.

[0099] 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.

[0100] 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.

[0101] The vent cap functions well with the vent pipe located anywhere within the interior volume. No matter the location of the vent pipe, gases escaping from the vent pipe will escape through 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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

[0107] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] FIG. 15 shows a section view through another embodiment of the inventive vent cap. This embodiment features a more horizontally oriented exit 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 exterior opening. Many other shapes and locations for these features are possible.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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. Exit opening 36 extends parallel to central portion 40. Its upper extreme is guarded by overhang 38, which prevents most moisture from dripping into the exterior opening.

[0120] Most of the inventive embodiments can be used to cover panel openings in structures other than a roof. As an example, the inventive vent cap can be mounted to cover a panel 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 panel opening through the wall and secured in placed by any suitable means—such as driving fasteners 30 through flange 32.

[0121] 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. Exit opening 36 faces downward in this mounting scheme. It is covered in this example by a suitable wire mesh. Drip rail 74 is provided proximate the outward side of the exterior 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 exit opening 36.

[0122] FIGS. 19-22 show still another embodiment of the inventive vent cap. This version includes a more hidden exit 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.

[0123] Looking at FIG. 19, vent cap 76 includes a broadened central potion 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. Exit opening 78 is provided on the side opposite cricket 52. The exit opening 78 is thus provided on the downslope side of the expected water flow. The exit opening leads to the hollow interior of the vent cap.

[0124] FIG. 20 shows the same vent cap 76 from the opposite side-allowing the viewer to perceive the nature of hollow interior 79. The reader will note how flange 32 runs around the perimeter of entrance opening 81. The flange includes 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 exit opening 78. In this example, exit 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 grate openings leading into the hollow interior.

[0125] FIG. 22 shows a front elevation view. The reader will note how grate wall 80 is visible through exit opening 78. The grate wall includes numerous grate openings 84 leading into the hollow interior 79 of the vent cap. Gases emitted from a vent pass freely through these grate openings. However, the grate openings are preferably made small enough to prevent the passage of birds, bats, mice, and larger insects.

[0126] 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.

[0127] The inventive vent cap is useful for guarding a panel opening through a roof and through a side wall. It is also useful for guarding panel 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.ILLUMINATED EXAMPLES

[0128] Other useful features can be added to the vent cap. Returning to FIG. 18, the reader will recall that the inventive vent cap can be installed over a panel opening through a vertical or steeply sloped wall. In this configuration, adding a light to the vent cap transforms the vent cap to act as both a vent and a sconce light. This provides both functional and aesthetic value.

[0129] FIG. 23 provides a side elevation view of a vent cap 76 modified with the addition of an internal light source. Light 86 is added by passing mount 90 through a hole provided in dividing wall 82. The mount can be secured in any convenient manner, such as tightening a nut on a threaded section. Power leads 92 provide electrical power. In this example, a parabolic reflector 88 is provided. Exemplary light 86 is a small and bright source—such as one or more chip LEDs. Light is projected and focused by reflector 88 so that it passes out exit opening 78 as an expanding beam.

[0130] FIG. 24 shows this embodiment of vent cap 76 installed on vertical wall panel 72. The reader will note how light 86—and its associated reflector—are positioned to throw a beam of light downward through exit opening 78. The light itself is shielded from direct view. FIG. 26 shows a vertical elevation view of this installation. The reflector is preferably oriented to throw the light beam downward and thereby create a pleasing light pattern 98 on vertical wall panel 72. Differing combinations of light sources and reflectors can be selected to create a wide variety of desired light patterns.

[0131] FIG. 25 shows another illuminated embodiment. This example includes an external solar panel 96 feeding storage battery 94. The battery includes an integrated charge controller that regulates the storage and use of energy from solar panel 96. Light 86 is preferably a low-consumption LED so that it can remain on for several hours at a time—using the energy stored in battery 94.

[0132] An external light sensor can be used to automatically switch on light 86 for any of the illuminated versions. As an example, the external light sensor can be used to switch on light 86 when the sun goes down. This can provide safety illumination around out-buildings. The light sensor can be a dedicated photoelectric cell. Alternatively, the charge controller can monitor the output of solar panel 96 and switch to battery power once the solar panel's output drops below a defined threshold.

[0133] The reader will appreciate that many other configurations are possible for an illuminated vent cap. Looking still at FIG. 25, an opaque coating can be provided on the interior surfaces of the vent cap around light 86. This will prevent any light leakage through the vent cap (which can occur when materials such as molded plastic are used). Alternatively, it is possible to provide an illuminated vent cap molded from a translucent polymer. In this case the entire vent cap would be illuminated in addition to the beam of light thrown through the exterior opening. One can also add other visual effects-such as printed graphics-that would be internally illuminated.Universal Vent Cap Examples

[0134] The prior examples of the inventive vent cap have included a rib receiver configured to fit closely over a corresponding feature on the roof or wall. For example, the vent cap of FIG. 12 includes a rib receiver 34 configured to fit closely over the “vee” of a metal roof panel. FIGS. 13 and 14 show some of the differing shapes needed for rib receivers 56 and 62. Rib receiver 56 is designed to fit over convoluted rib 54 whereas rib receiver 62 is provided with a very different shape—designed to fit over standing seam rib 60.

[0135] For an integral molded or stamped metal vent cap, a separate set of tooling is needed for the incorporation of each different rib receiver. The embodiment of FIG. 17 provides a good example of this issue. The mold used to make vent cap 29 must be shaped to form a specific rib receiver. If a different rib receiver is desired, a new mold for the entire integral part must generally be made.

[0136] In order to avoid this problem, a different approach is advantageously employed. FIGS. 27 and 28 show an alternate embodiment of the inventive vent cap in which a universal vent cap is mated to a variety of specifically configured bases. FIG. 27 shows universal vent cap 100. This is a molded plastic part having internal features that are the same as the previously disclosed vent caps—including exit opening 78. Flange 32 is provided around the lower perimeter of the vent cap. This flange does not include a rib receiver. Instead, a separate panel-specific base 102 is provided. Panel-specific base 102 includes enlarged rib receiver 70, which is shaped to fit over a convoluted rib 54 such as shown in FIG. 13.

[0137] Alignment or engagement features can be provided on the universal vent cap and the panel-specific base in order to aid installation. In the example of FIG. 27, holes 104 are provided in flange 32. Aligned holes 106 are provided in panel-specific base 102. Mounting screws (or other fasteners) can be passed through these holes 104,106 and into the roof or wall panel on which the vent cap is installed.

[0138] FIG. 28 shows a second exemplary panel-specific base. The same universal vent cap 100 is provided. However, a different panel-specific base 108 is combined with the universal vent cap. Panel-specific base 108 bas a standing seam receiver 110 shape to fit over the joints in a standing-seam roof.

[0139] The general term for standing seam receiver 110, enlarged rib receiver 70, and similar features is a “feature receiver.” The term “feature receiver” means a passage through the panel-specific base configured to receive and lie closely around any upstanding feature on the panel to which the vent cap assembly is attached.

[0140] The system of combining a universal vent cap with a variety of panel-specific bases allows one set of tooling for the complex features of the universal vent cap. Much simpler tooling can be used to create the panel-specific bases. The two components are then united to create a vent cap assembly.

[0141] As an example of the simpler tooling that can be used to make the panel-specific bases, the bases can be injection-molded using simple two-piece molds with no transverse slides needed. The bases can even be made using other manufacturing processes-such as 3D printing. The use of an additive process like 3D printing allows custom or low-volume production where a customer can order a custom base that is made in very small quantities.

[0142] Of course, high-volume processes can still be used for those panel-specific bases that will be used in greater quantities. Thus, injection molding might be used for some bases and 3D printing used for others.

[0143] 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.

Examples

Embodiment Construction

[0093]FIG. 2 depicts the problem to be addressed—a vent pipe 24 protruding through a panel opening 22 in a metal roof panel. FIG. 4 depicts an embodiment of the present invention installed over the vent pipe and panel opening. Vent cap 29 is a hollow structure configured to secure to the metal roof panel—including lying over one of the upstanding ribs.

[0094]Several embodiments of the vent cap will be described in detail, so it is helpful to establish some uniform terminology. The term “panel opening” means an opening through the structure on which the inventive vent cap is being installed. The panel opening may be provided through a roof, a wall, or some other portion of the structure. Usually, the panel opening will be provided through a flat roof or wall panel. However, the use of the word “panel” in the term “panel opening” should not be viewed as restricting the term to flat panels. In some cases, the “panel opening” will be provided through a piece of board siding or through a ...

Claims

1. An illuminated vent cap assembly for covering an opening in a panel having a first flat, a second flat, and an upstanding feature therebetween, comprising:(a) a hollow central portion;(b) an entrance opening leading into said hollow central portion;(c) an exit opening leading from said hollow central portion to a surrounding environment;(d) a feature receiver configured to receive said upstanding feature lying between said first and second flats;(e) a light source contained within said hollow central portion; and(f) wherein said light source is positioned to project light out of said exit opening.

2. The vent cap assembly as recited in claim 1, further comprising a reflector positioned to focus light from said light source into a beam.

3. The vent cap assembly as recited in claim 1, further comprising:(a) wherein said vent cap is installed on a vertical panel with said exit opening facing downward; and(b) wherein said light source is positioned to project light downward through said exit opening.

4. The vent cap assembly as recited in claim 1, wherein said feature receiver is a rib receiver.

5. The vent cap assembly as recited in claim 1, wherein said feature receiver is a standing seam receiver.

6. The vent cap assembly as recited in claim 1, further comprising:(a) wherein said entrance opening includes a flange;(b) a panel-specific base mated to said flange; and(c) wherein said panel-specific base includes a feature receiver.

7. The vent cap assembly as recited in claim 1, further comprising a battery providing electrical power to said light source.

8. The vent cap assembly as recited in claim 7, further comprising a solar panel providing electrical power to said battery.

9. The vent cap assembly as recited in claim 6, wherein said feature receiver is a rib receiver.

10. The vent cap assembly as recited in claim 6, wherein said feature receiver is a standing seam receiver.

11. An illuminated vent cap assembly for covering an opening in a panel having an upstanding feature, comprising:(a) a hollow central portion;(b) an entrance opening leading into said hollow central portion;(c) an exit opening leading from said hollow central portion to a surrounding environment;(d) a feature receiver configured to receive said upstanding feature lying on said panel;(e) a light source mounted in said hollow central portion; and(f) said light source projecting light out of said exit opening.

12. The vent cap assembly as recited in claim 11, further comprising a reflector positioned to focus light from said light source into a beam.

13. The vent cap assembly as recited in claim 11, further comprising:(a) wherein said vent cap is installed on a vertical panel with said exit opening facing downward; and(b) wherein said light source is positioned to project light downward through said exit opening.

14. The vent cap assembly as recited in claim 11, wherein said feature receiver is a rib receiver.

15. The vent cap assembly as recited in claim 11, wherein said feature receiver is a standing seam receiver.

16. The vent cap assembly as recited in claim 11, further comprising:(a) wherein said entrance opening includes a flange;(b) a panel-specific base mated to said flange; and(c) wherein said panel-specific base includes a feature receiver.

17. The vent cap assembly as recited in claim 11, further comprising a battery providing electrical power to said light source.

18. The vent cap assembly as recited in claim 17, further comprising a solar panel providing electrical power to said battery.

19. The vent cap assembly as recited in claim 16, wherein said feature receiver is a rib receiver.

20. The vent cap assembly as recited in claim 16, wherein said feature receiver is a standing seam receiver.

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