AU2003200061B2 - A Receiver Beam and a Roof Assembly Containing the Receiver Beam - Google Patents

Description

A RECEIVER BEAM AND A ROOF ASSEMBLY CONTAINING THE RECEIVER BEAM FIELD OF THE INVENTION This invention is directed to a beam for use in roofing, in particular to a beam for connecting two roofing surfaces. The beam of the present invention is particularly suited for use with a veranda/patio assembly.

BACKGROUND ART Roofing assemblies comprising only metal members are becoming quite popular, as the assemblies are extremely strong, lightweight, impervious to termites, rot, twisting or warping, as is the case with roofing assemblies where the beams/rafters etc are made of wood.

However, as metal members such as extruded aluminium beams/rafters cannot be readily shaped on site it is necessary to ensure that all parts and components fit together properly.

While this is usually relatively straightforward when coupling or connecting metal members together in a straight line, there are special considerations and difficulties when connecting metal members at an angle relative to each other.

One such "angle connection" occurs when a flat roof joins to an inclined roof without an internal gutter. A flat roof is quite common over patios or verandas. The flat roof is of course not entirely level and usually has a slight fall to allow water to drain to an external gutter. More recently, these roofs have become much more aesthetically pleasing by having a combination of a flat roof portion and an inclined roof portion (also called a gable roof). This combination allows quite spectacular rooflines and roof profiles to be formed. Generally, there is no gutter between the flat roof and the inclined roof, as such gutters are quite unsightly and are susceptible to overflowing. Instead, the edge of the inclined roof overlaps the edge of the flat roof and is spaced above the flat roof such that water can flow from the inclined roof and onto the flat roof to be drained to an external guttering.

The present invention is directed to a beam which is typically formed of extruded metal and which can couple a flat roof to an inclined roof.

Previous systems for coupling a flat roof to an inclined roof have not been very successful and are either difficult and/or finicky to assemble.

Typically, flat roof panels (also called deck panels) are attached to a horizontal fascia beam using rivets or self-tapping screws. The inclined roof panels are attached to rafter beams typically formed of metal. At the junction between the inclined roof panels and the flat roof panels is a horizontal valley beam which is attached to the fascia beam and typically at right angles thereto. The valley beam sits below the flat roof panels. For this reason it is not possible to attach the rafter beams directly to the valley beam as this would result in the inclined roof panels striking the flat roof panels rather than being slightly above the flat roof panels and overlapping the edge of the flat roof panels.

Therefore, it is known to provide flashing which sits on top of the valley beam and to which the rafter beams can be attached. The flashing allows the rafter beams and/or the inclined roof panels to be attached such that the inclined roof panels sit above and over the flat roof panels.

The conventional flashing is however not very suitable and an object of the invention is to provide a receiver beam which can eliminate the need for the flashing.

Typically, flashing comprises a metal sheet which is relatively thin and which is bent at various places to provide a shape which enables the inclined rafter beams etc to be attached relative to the valley beam via the flashing. The flashing typically is bent into a somewhat inverted U-shaped configuration. The ends of the depending sidewalls are then screwed or riveted to the top of the valley beam. However, this does not provide sufficient strength to the flashing. Therefore, it is also necessary to have a longitudinal upright U-shaped channel which is screwed or riveted to the top wall of the valley beam and which is smaller than the flashing such that the flashing extends over the top of this U-shaped channel and can be attached thereto. This combination provides the minimum required strength to the flashing but it can be seen that assembly is quite cumbersome as it requires the smaller upright U-shaped channel to be initially fixed to the top of the valley beam and then the flashing needs to be bent into the required inverted U-shaped, placed over the top of the upright U-shaped channel and screwed to the U-shaped channel and to the valley beam.

One further disadvantage with this arrangement is that the flashing is quite unsightly and does not form an aesthetically pleasing attachment of the legs of the flashing over the sidewalls of the valley beam.

This is quite important as this part is visible from the bottom of the roof assembly and can easily be seen. Furthermore, the attachment of the legs of the flashing by not being neat, also introduces small gaps between the legs of the flashing and the wall of the valley beam and the gaps can quickly fill with dirt, debris, cobwebs and the like which may also become very unsightly.

In order to have the inclined roof properly attached to the top of the flashing, the top wall of the flashing needs to be inclined at exactly the same angle as the angle of the inclined roof. This requires considerable skill in bending the metal sheet into the required configuration.

The flat roof panels are attached to the sidewall of the formed flashing. It is not possible to attach the roof panels directly to the sidewall, so a C-shaped channel member must be initially screwed or riveted to the sidewall and the roof panel can then be inserted into this channel member.

Therefore, during assembly is now required to have yet to further channel initially screwed or riveted to the flashing before the flat roof panel can be attached.

To make matters somewhat more complicated, the roof panel or roof decking by being substantially horizontal must have rather high vertical sidewalls such that roof panels can be overlapped and connected to each other without water seeping between the overlapped portions. The C-shaped channel must have an internal size which is the same or slightly larger than the vertical horizontal parts of the edge of the roof decking. However, roof decking comes in at least two different sizes and therefore two different Cshaped channels must be provided depending on which roof decking is to be used.

OBJECT OF THE INVENTION We have now found a beam, typically formed of extruded metal such as aluminium, which can be readily attached to the valley beam and which allows the inclined roof to be attached relative to the flat roof without requiring attachment of separate channels etc and bending of metal sheets to form the flashing. This beam can also have the advantage of being provided with a sacrificial portion which allows the same beam to be used on flat roofing panels having profiles of different heights.

The invention provides a beam hereinafter referred to as a receiver beam which may overcome at least some of the abovementioned disadvantages or provide the public with a useful or commercial choice.

In one aspect the invention resides in an elongate receiver beam for connecting at least one inclined roof member to at least one second roof member, the receiver beam comprising an inclined first land disposed on top of said receiver beam, a sidewall having a second land extending therefrom for supporting a second roof member, and a dependent flange for engagement with a valley beam in a roofing assembly.

The receiver beam has an inclined first land disposed on the top of the receiver beam. The inclined first land may be substantially planar and inclined with the angle of the incline being the same as that of the inclined roof sheets such that the inclined roof sheets can be supported on top of the inclined first land and can be attached thereto typically using self-tapping screws or rivets. The inclined first land may have a width of between 200mm although this can vary.

The receiver beam has a second land extending from the sidewall of the receiver beam. The second land may be substantially planar and inclined with the angle of the incline being the same as that of the second roof members such that the second roof members can be supported on top of the second land and can be attached thereto typically using self-tapping screws or rivets. The second land may have a width of between 20-200mm although this can vary.

Preferably, the sidewall of the receiver beam may be a stepped sidewall. The stepped sidewall is typically substantially vertical when the beam is attached to the valley beam and has a portion that is stepped outward from the beam above the second land. The stepped portion is typically substantially horizontal and having a width of between 10-100 mm.

In a preferred form the stepped portion may suitably form a receiving channel with the second land for receiving a second roofing panel therein.

Roofing members may have different height profiles. The receiver beam of the present invention may preferably be able to engage roofing members of a variety of different height profiles, from smaller profiles having less height and to larger profiles of greater height. The spacing between the second land and the stepped portion of the sidewall is suitably such that it will accommodate the edge of a flat roof sheet of the larger size of roofing members. Thus, the spacing is typically between 50-80 mm.

In a preferred form a horizontal flange may extend from the sidewall above the second land and below the stepped portion of the sidewall.

The horizontal flange may suitably form a receiving channel with the second land for receiving a second roofing panel therein. The spacing is typically between 20-40 mm. The horizontal flange may be removable such that second roofing panels with larger profiles may be received in a receiving channel formed between the second land and a stepped portion of the stepped sidewall.

The receiving channel is typically an integrally formed C-shaped channel. The channel may be formed from the second land extending from a sidewall and a frangible horizontal flange extending from the same sidewall, with the base of the channel formed of part of the sidewall. The receiving channel functions to accept an edge of a flat roof sheet. The second land and the horizontal flange of the receiving channel are typically identical in shape and size and typically extend outwardly by a distance of between 100 mm although this can vary to suit a variety of applications.

The horizontal flange can be removed. It is preferred that the horizontal flange is frangible. Thus, the horizontal flange may be snapped off, cut away, and the like. If desired, the horizontal flange may be provided with a line of weakness or portions of weakness to facilitate removal of the horizontal flange if required. The reason for this is that it allows the larger size roof sheets to also be used with the receiver beam that is subject of the present invention, this being described in greater detail below.

There may preferably be more than one horizontal flange allowing many second roofing members having different profiles to be received.

The receiver beam includes a dependent flange for engagement with a valley beam. In a preferred form a pair of spaced apart depending flanges may be provided for receiving a valley beam therebetween in order to allow the beam to be securely attached over the top of the valley beam.

These may comprise flanges having a width of approximately 10-50 mm and which extend along each depending sidewall of the valley beam. Fasteners can be used to fasten tle beam to the valley beam. Various other methods may be used to secure the receiver beam to the valley beam including an interference fit, snap fit and ratchet teeth on each flange to engage with ridges on the valley beam.

The receiver beam may be formed in a variety of lengths for example by extrusion and is able to be cut to a desired length and be placed on top of the valley beam. The receiver beam can be attached to the valley beam by fasteners passing through the depending flanges on the receiver beam and into the sidewalls of the valley beam. The receiver beam is extremely strong and the rafter beams, inclined roof panels, and flat roof panels can be readily connected to the receiver beam.

The receiver beam is typically formed of extruded aluminium.

The receiver beam may have various lengths and indeed can be cut to length if required. The receiver beam may also have various cross-section sizes depending on the size of the roof. However, a typical approximate height of the beam will be between 100-400 mm and a typical approximate width of the beam will be between 50-300 mm. This can of course vary to suit. The receiver beam should suitably be to be strong enough to support the various loads. Thus, the receiver beam should have a wall thickness that is sufficient to do so. It is envisaged that the receiver beam will have a wall thickness of between 2-10 mm although this may also vary.

The roof members may be provided in a number of forms although it is preferred that the roof members are in the form of metal sheet such as typically provided as roof decking material.

In a second aspect, the present invention provides an elongate metal receiver beam for connecting at least one first roof member to at least 00 one second roof member, the receiver beam comprising an inclined first land 0 0 for engagement with the at least one first roof member, a bottom wall having a C pair of spaced apart depending flanges for receiving a valley beam therebetween, a first stepped sidewall and a second sidewall opposed to the 00 5 first side wall wherein said first stepped sidewall comprises a stepped portion extending between an upper portion and a lower portion, the lower portion having a second land and at least one removable horizontal flange wherein in

INO

a first condition said second land and said at least one removable horizontal Sflange form a channel for receiving the at least one second roof member therebetween and in a second condition said at least one removable Shorizontal flange is removed and said second land and said stepped portion form a channel for receiving the at least one second roof member therebetween.

The beam typically has a second sidewall against which the rafter beams can be attached. The second sidewall is typically substantially flat and in use is typically substantially vertical. The second sidewall typically extends from adjacent one edge of the incline land and the lowermost portion of the second sidewall may comprise part or all of one depending flange. The second sidewall typically has a height of between 50-400 mm although this can vary. The rafter beams are typically attached to the second sidewall via clips or other attachments.

The second sidewall is opposed to the first sidewall and typically forms a box section beam. The second sidewall is also typically arranged substantially vertical in use. The second sidewall typically has a height of between 20-100 mm although this can vary.

Definitions of the specific embodiments of the invention as claimed herein follow.

According to a first embodiment of the invention, there is provided an elongate receiver beam when used to connect an inclined roof to a flat roof, the receiver beam comprising: an inclined first land disposed on top of said receiver beam for supporting at least one inclined roof member; a sidewall having a second land extending therefrom for 00 supporting at least one flat roof member; and a dependent flange for engagement with a valley beam in a C roofing assembly.

According to a second embodiment of the invention, there is (0 c 5 provided an elongate metal receiver beam for connecting at least one first roof member to at least one second roof member, the receiver beam comprising NO an inclined first land for engagement with the at least one first roof member, a bottom wall having a pair of spaced apart depending flanges for receiving a c valley beam therebetween, a first stepped sidewall and a second sidewall opposed to the first side wall wherein said first stepped sidewall comprises a c stepped portion extending between an upper portion and a lower portion, the lower portion having a second land and at least one removable horizontal flange wherein in a first condition said second land and said at least one removable horizontal flange form a channel for receiving the at least one second roof member therebetween and in a second condiltion said at least one removable horizontal flange is removed and said second land and said stepped portion form a channel for receiving the at least one second roof member therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the invention will be described with reference to the following figures in which: Figure 1. Illustrates part of a roof assembly where a flat roof and an inclined or gable roof meet and where the receiving beam which forms part of the invention functions to attach a flat roof portion and an inclined roof portion relative to each other.

Figure 2. Illustrates an overall roof assembly and illustrating where the receiving beam is fitted.

Figure 3. Illustrates the receiver beam in section.

BEST MODE Referring to the drawings and initially to Figure 2 there is illustrated an overall roof assembly. Briefly, the roof assembly according to the embodiment illustrated in figure 2 comprises a ridge cap 10, roof panels 11, a chine beam 12, a ridge beam 13, a saddle bracket 14, a gable beam connector 15, a rafter beam 16, a barge 17, a splicing channel 18, a valley beam 19, a barge beam 20, a receiver beam (forming part of the invention) 21, a beam bracket 22, a beam end cap, a fascia beam 24, a column bracket a column 26, a gutter 27 and a gutter stop end 28. An optional king post and a king post bracket 61 is illustrated.

The invention is directed to the receiver beam 21 and this part of the roof assembly is illustrated in greater detail in figure 1. Referring to figure 1, there is illustrated briefly a flat roof panel 30, an inclined roof panel 31, an angled rafter beam 16 to which the roof panel 31 is attached, a front horizontal fascia beam 24, a gutter 27 which is attached to the fascia beam 24, a vertical post 32 which supports the structure, a horizontal valley beam 19 which sits below flat roof panel 30 and is attached to the back of fascia beam 24 at right angles thereto and via a connecting bracket 33, and the receiver beam 21.

Receiver beam 21 is fitted over the top wall of valley beam 19 as illustrated in figure 1. Receiver beam 21 is formed of extruded aluminium having a wall thickness of between 2-5 mm.

Receiver beam 21 has an inclined first land 35, a first stepped side wall 37, a second side wall 36, a receiving channel 38 formed integrally with the first side wall, an upper portion of the side wall 39, a stepped portion and a pair of spaced apart depending flanges 41, 42.

Inclined first land 35 is substantially planar but is inclined and the angle of inclination is the same as the angle of inclination of roof panel 31 which means that roof panel 31 fits over the top of inclined first land 35 and can be attached thereto by suitable fasteners 43. The width of inclined first land 35 can vary.

Second sidewall 36 depends from the edge of inclined first land and the lower edge of sidewall 36 is also one of the flanges 41. Sidewall 36 is substantially flat and substantially vertical in use. The rafter beam 16 can fit to sidewall 36 via a connecting clip 44.

The lower portion of the first stepped sidewall 37 is on the other side of the receiver beam 36. The lower portion of stepped sidewall 37 is vertical in use.

Formed integrally with the receiver beam is a channel 38.

Channel 38 receives an edge of flat roof panel 30 as illustrated in figure 1.

Channel 38 has a second land 45 and a removable horizontal flange 46. The horizontal flange 46 is designed to enable it to be snapped off or cut away.

Above the lower portion of first side wall 37 is the upper portion of the first sidewall 39. The upper potion of first sidewall 39 extends above and in front of the lower portion of the first sidewall and can be seen as a protruding portion. This upper portion is substantially flat and in use is substantially vertical, but need not be so.

If the removable horizontal flange 46 is snapped away, it can be seen that a larger channel is now formed which comprises the same second land 45, but the upper wall is now the stepped portion 40 that extends between the upper portion of the stepped sidewall 39 and lower portion of the stepped sidewall 37. The larger channel is designed to receive the roof panel having a larger profile and it can be seen that it is not now necessary to have separate C-channels which need to be separately screwed to the sidewall.

The receiver beam has internal horizontal walls 50,51 to provide strength and rigidity to the entire beam. These internal walls and the shape of the beam ensure that stepped portion 40 if used as part of the channel is a rigid part and does not flex.

The pair of spaced apart flanges 41, 42 are extruded as part of the receiver beam and can therefore be made very precisely. This allows the flanges to be fitted exactly over the outer walls of the lower valley beam such that there are no unsightly gaps, which is a problem with the previously used flashing.

If desired, a sealing member or sealing means (not illustrated) 00oo can be fitted against the lower portion of the stepped sidewall 37 to seal the 0 0flat roof panel 30 to the receiver beam against water penetration.

(N

Referring again to figure 2 there is also illustrated a barge beam 20. Barge beam 20, allows the other end of rafter beam 16 to be supported.

00 5 Barge beam 20 fits onto side beam 62 and a gutter 63 can be attached to the

(N

front substantially vertical sidewall 64 of barge beam 20. Barge beam 20 is also an extruded aluminium beam and has internal strengthening struts which can be viewed in figure 2. The rafter beam 16 is attached to the rear sidewall Sof the barge beam via a splicing channel 18. Barge beam 20 is similar to receiving beam 21 in that it also has an inclined top wall 65 to allow the Sinclined roof panel 11 to be attached to top wall 65. However, barge beam does not have the receiving channel, as it does not attached to a flat roof panel.

It should be appreciated that various other changes and modifications can be made to the embodiment described without departing from the spirit and scope of the invention.

The term "comprise" and variants of the term such as "comprises" or "comprising" are used herein to denote the inclusion of a stated integer or stated integers but not to exclude any other integer or any other integers, unless in the context or usage an exclusive interpretation of the term is required.

Claims (11)

1. An elongate receiver beam when used to connect an inclined roof to a flat roof, the receiver beam comprising: 00 5 an inclined first land disposed on top of said receiver beam for supporting at least one inclined roof member; a sidewall having a second land extending therefrom for supporting at Sleast one flat roof member; and 0 a dependent flange for engagement with a valley beam in a roofing S 10 assembly.

2. An elongate receiver beam according to claim 1 wherein the sidewall of the receiver beam is a stepped sidewall.

3. An elongate receiver beam according to claim 2 wherein the stepped sidewall has a portion that is stepped outwardly from the beam above the second land.

4. An elongate receiver beam according to claim 3 wherein the stepped portion forms a receiving channel with the second land for receiving a second roofing panel therein.

An elongate receiver beam according to any one of claims 1 to 4 wherein the receiver beam further includes a horizontal flange extending from the sidewall.

6. An elongate receiver beam according to claim 5 wherein the horizontal flange is disposed above the second land.

7. An elongate receiver beam according to either claim 5 or claim 6 wherein the horizontal flange is a frangible flange.

8. An elongate receiver beam according to any one of claims 1 to 7 wherein the receiver beam includes a pair of spaced apart depending flanges for receiving a valley beam therebetween in order to allow the beam to be securely attached over the top of the valley beam.

9. An elongate receiver beam according to any one of claims 1 to 8 wherein the elongate receiver beam is formed of extruded aluminium.

An elongate metal receiver beam for connecting at least one first roof member to at least one second roof member, the receiver beam comprising an inclined first land for engagement with the at least one first roof member, a 00 bottom wall having a pair of spaced apart depending flanges for receiving a 0 valley beam therebetween, a first stepped sidewall and a second sidewall Sopposed to the first side wall wherein said first stepped sidewall comprises a stepped portion extending between an upper portion and a lower portion, the 00oo 5 lower portion having a second land and at least one removable horizontal flange wherein in a first condition said second land and said at least one removable horizontal flange form a channel for receiving the at least one INO second roof member therebetween and in a second condition said at least Sone removable horizontal flange is removed and said second land and said stepped portion form a channel for receiving the at least one second roof Smember therebetween.

11. A receiver beam as claimed in claim 1 and substantially as described herein with reference to the accompanying drawings. Date: 28 February 2008