AU2009202443B2 - Spacer - Google Patents

Abstract

A spacer for spacing cladding from a support structure, the spacer comprising a spacer body having a mounting surface arranged in use to support cladding, and a plurality of supports extending from the body in a direction opposite the direction of the mounting surface faces, the supports being spaced from one another such that, when the supports are located at the support structure a space is defined between the spacer body and the support structure. (14 CY)j

Description

SPACER Technical Field 5 The present invention relates generally to a cladding technique where cladding sheets are mounted to a support structure and to components for use in said cladding. The invention has particular application to roof cladding and the invention is herein described in that context. However, it is to be appreciated that the invention may be used in other application such as wall cladding and the like. 10 Background In the construction of metal deck roofs, it is known in prior art to first erect the underlying support structure with an overlying of rafters and purlins. The metal deck roof sheet is then fastened onto the underlying support structure. 15 It is a known method to fasten the metal deck roof using specialised roof clips, which comprise of a metal strip with a series of clips at predetermined intervals. The roof clips are typically screwed to the purlins in longitudinal alignment, and the metal deck roof is subsequently attached to the roof clip to provide a concealed fix system. 20 To increase energy efficiency, insulation blankets are often used. In a typical construction, a safety mesh is first laid flat across the underlying support structure. The insulation blankets are then placed over the safety mesh, including the area directly above the purlins. The roof clips are then positioned over the insulation 25 blanket directly above the purlin, and the roof clips screwed downwards into place. This causes the insulation between the clips and the purlin to be compressed. When the metal deck roof is attached to the roof clips, this further compresses the insulation in the vicinity of the purlin. A disadvantage of this prior art is the diminished insulation properties of compressed insulation blankets. 30 This prior art also relies on the roof safety mesh to sag and dish between the purlins in order for the insulation to expand to the desired thickness. This poses a problem, as increased insulation requirements would require greater sag to allow the insulation to expand and recover to its design insulation blanket thickness. In addition, the 35 insulation blankets by its tendency to expand from a compressed state would exert 1 7460288_1 force on the roof safety mesh. This force on the roof safety mesh is a safety concern, as the tension on the mesh wires will reduce the capacity to perform its primary safety function. 5 It is known in prior art to use spacers to elevate the metal deck roof from the purlins to provide additional space for the insulation to expand and recover. One solution is to mount a solid spacer, such as a length of wood or foam block between the roof clips and the insulation blanket. Although this will allow more room for the insulation to expand and recover, the insulation is still significantly compressed along the length of 10 the purlins by the solid spacer. Summary According to a first aspect of the present invention there is provided a spacer for spacing cladding from a support structure, the spacer comprising, a spacer body 15 having a mounting surface arranged in use to support cladding; and a plurality of supports integrally formed with and extending from the body in a direction opposite the direction of the mounting surface faces, the supports being spaced from one another such that, when the supports are located at the support structure a space is defined between the spacer body and the support structure; the mounting surface being 20 arranged to receive one or more clips that are adapted to engage the cladding, wherein in use the one or more clips are secured to the spacer body by one or more mechanical fasteners so as to facilitate fixing of the cladding with respect to the spacer body; the spacer body and the supports being configured so that the one or more mechanical fasteners are able to extend through the one or more clips, the spacer 25 body support and into the support structure. In one embodiment, the mounting surface is arranged to receive one or more clips that are adapted to engage the cladding, wherein in use the clips are secured to the spacer body so as to facilitate fixing of the cladding with respect to the spacer body. In a 30 further embodiment, the mounting surface is arranged to receive clip devices, each device including a plurality of clips mounted on a support element. In one form, the mounting surface is arranged to receive mechanical fasteners so as to allow the cladding, or clip, or clip device to be secured to the spacer body via the one 35 or more mechanical fasteners. The mechanical fasteners may be able to extend from 2 7460288_1 the cladding, or clip, or clip device through the spacer body and into the support structure. The fastener may be in the form of a long screw passing through the clip and the spacer body, thereby providing a rigid and robust attachment to the support. 5 The spacer may be provided with one or more apertures along the mounting surface of the spacer body, wherein the apertures extend into the spacer body and are configured to receive respective ones of the mechanical fasteners. In one embodiment, the apertures are located in alignment with the supports, to allow 10 the mechanical fastener to extend through each respective support. In another embodiment, the apertures are located intermediate of two supports. In one embodiment of the spacer, at least one of the supports comprise two spaced support legs. In one form, a mechanical fastener is arranged to be received on said 15 mounting surface so as to extend between the two spaced support legs of a said support. The spacer can be configured to provide sufficient clearance between adjacent supports, allowing an insulation blanket to be located between the cladding and the 20 support structure. This has the advantage of providing space for the insulation to expand between the clip and the support structure. Furthermore, by allowing additional clearance for insulation to expand, there is reduced force and sag on the roof safety mesh. In one form, the spacer body is formed as a strip. 25 In another aspect, the present invention provides a spacer for spacing cladding from a support structure, the spacer comprising a plurality of interconnecting supports, the supports being spaced apart from one another to form one or more spaces between said supports and arranged to receive insulation. 30 The spacer may further comprise an elongated member interconnecting the plurality of supports, the elongated member having a first mounting surface, and the plurality of supports extending from the elongated member in a direction opposite the direction of the first mounting surface face to a second mounting surface. 3 7460288_1 The first or second mounting surface may be arranged to locate on the support structure, so that the other mounting surface receives one or more clips that are adapted to engage the cladding, wherein in use the one or more clips are secured to the spacer so as to facilitate fixing of the cladding with respect to the spacer. In a 5 further embodiment, the first or second mounting surface is arranged to receive one or more clip devices, each device including a plurality of the clips mounted on a support element. In a further embodiment, the first or second mounting surface is arranged to receive one or more mechanical fasteners that are able to extend from the cladding, or clip, or clip device though the spacer and into the support structure. 10 The spacer may be interfaced with the clip before installation. This has the advantage of facilitating installation, as the operator is merely required to focus on positioning and fastening one assembly on the support structure, instead of positioning the separate components of spacer and clip to the support structure before fastening. 15 The spacer may be constructed of a polymeric material, such as ABS injected moulded plastic. In an alternative embodiment, the spacer may be configured to support the cladding 20 without the use of clips. In one embodiment, the cladding may be secured to the structure by a fastener extending between the cladding and the structure, such that the fastener extends through the elongated body of the spacer. This advantageously allows fixing of the roof cladding without roof clips. 25 According to another aspect of the present invention, there is provided a clip assembly for fixing cladding comprising; an elongated member; a plurality of support legs arranged to locate on an underlying structure, the support legs being integrally formed with and extending from the elongated member in 30 a first direction; a plurality of clips for engaging the cladding, the clips extending in a direction opposite to the first direction and being secured to the elongated member; and one or more fasteners to secure the clip assembly to the underlying structure; wherein in use, the support legs provide a clearance between the clips and the 35 underlying structure, and wherein the elongated member, the support legs and the 4 7460288_1 clips are configured to receive the one or more mechanical fasteners that are able to extend through the clips, the support legs and into the underlying structure. In an embodiment of the invention, the clip assembly comprising of a plurality of clips, 5 an elongated member, and a plurality of support legs are integrated into a single unit before use. In an alternative embodiment of the clip assembly, the elongated member is formed from first and second elongated bodies which are in overlaying relation, and wherein 10 said plurality of clips and the first elongated body form a clip device and the said plurality of support legs are attached to the second elongated body to form a spacer described above, wherein the clip device and the spacer are matched to each other to form the clip assembly before use. 15 In one embodiment of the clip assembly, at least one of the clips is arranged in alignment with at least one support. In a further embodiment, the clip assembly is arranged to receive one or more fasteners to secure the clip assembly to the structure. Advantageously, the clip assembly can be handled, positioned and installed as one 20 assembly by a single operator. The clip assembly avoids the disadvantage of the prior art requiring the positioning and alignment of separate components before fastening. According to another aspect of the present invention, there is provided a method for attaching cladding to a structure, the method comprising the steps of, positioning an 25 elongate member having integrally formed support legs extending therefrom on the structure; supporting a plurality of clips in a spaced relationship from each other and from the structure so as to form a space between said clips and said structure; securing the clips to the structure by locating one or more fasteners such that they extend through the clips the support legs and into the structure; and attaching the 30 cladding to the clips. The method may comprise the step of installing insulation in the space formed between the clips and the structure. In another embodiment of the method, wherein the plurality of clips are mounted on a spacer to enable the clips to be in spaced 35 relationship from the structure. 5 7460288_1 Brief description of drawings It will hereinafter be convenient to describe an embodiment of the invention with reference to the accompanying drawings. It is to be understood that the particularity of 5 these drawings and the related description does not supersede the preceding broad description of the invention. Figure 1 is a side elevation of an embodiment of the spacer. Figure 2 is the end elevation of the spacer in Figure 1. 10 Figure 3 is a perspective view of the spacer in Figure 1. Figure 4 is a side elevation of a clip assembly comprising of the spacer in Figure 1 matched with a prior art roof clip. Figure 5 is an end elevation of the clip assembly in Figure 4. Figure 6 is a perspective view of the clip assembly in Figure 4. 15 Figure 7 is a cross-sectional view of a roof assembly incorporating an embodiment of the spacer. Figure 8 is a cross-sectional view of the roof assembly along line A-A of Figure 7. Figure 9 is a cross-sectional view of the roof assembly with one section installed. Figure 10 is a cross-sectional view of the roof assembly of Figure 9 with a second clip 20 assembly in the process of installation. Figure 11 is a cross-sectional view of the roof assembly of Figure 9 with two sections installed. Figure 12 an alternative rebated edge design for an embodiment of the spacer. Figure 13 is an end elevation of an alternative embodiment of the spacer. 25 Figure 14 is a side elevation of the spacer in Figure 13. Figure 15 is a bottom elevation of the spacer in Figure 13. Figure 16 is an end elevation of another embodiment of the spacer. Figure 17 is a side elevation of the spacer in Figure 16. Figure 18 is a bottom elevation of the spacer in Figure 16. 30 Figure 19 is an end elevation of another embodiment of the spacer. Figure 20 is a side elevation of the spacer in Figure 19. Figure 21 is a bottom elevation of the spacer in Figure 19. Figure 22 is an end elevation of another embodiment of the spacer. Figure 23 is a side elevation of the spacer in Figure 22. 35 Figure 24 is a side elevation of the spacer in Figure 22. 6 7460288_1 Figure 25 is a perspective view of the spacer in Figure 13. Figure 26 is a perspective view of an alternative embodiment of the spacer. Figure 27 is a perspective view of yet another embodiment of the spacer. Figure 28 is a cross-sectional view of a roof assembly in accordance with another 5 embodiment of the invention. Detailed Description Firstly reference should be made to figures 1-3 which illustrate a spacer 10 according to an embodiment of the present invention. The spacer 10 has an elongated thin body 10 12, a plurality of legs 14, and a plurality of apertures 16. The legs 14 extrude transversely from the elongated thin body 12, in pairs around apertures 16. Apertures 16 are located at intervals along the elongated thin body 12. A void 18 is located between each set of leg 14 pairs. 15 At a first end of the elongated thin body 12 is an upper rebated edge 20, located above a first pair of legs 22. On the other end of the elongated thin body 12 is a spacer overhang 24 extending past a last pair of legs 26. At the end of the spacer overhang 24 is a lower rebated edge 28. The upper rebated edge 20 and the lower rebated edge 28 have an overlapping relationship when multiple spacers 10 are used, and this 20 relationship will be described later. Figures 4-6 show the spacer 10, matched with a prior art roof clip 30 to form a clip assembly 31. The roof clip 30 comprises of a metal strap 32, a plurality of pairs of clips 34 extending transversely from the metal strap 32, and a plurality of fastener apertures 25 36. The fastener apertures 36 are located on the metal straps, in between each pair of clips 34. A first pair of clips 37 is located on one end of the metal strap 32. At the other end, the metal strap 32 extends beyond the last pair of clips 40 to form a trailing strap 38. At the end of the trailing strap is a tail 42. Located on the tail 42 is a tail aperture 43. 30 As illustrated in figure 4-6, the clip assembly 31 comprising of the spacer 10 and roof clip 30 that are matched so the elongated thin body 12 abuts the metal strap 32, where the clips 34 extend in a first direction away from the abutting surface, and the legs 14 extend in a second direction opposite to the first direction. The apertures 16 are 35 aligned to be coincident with the fastener apertures 36. As illustrated in Fig 4-6, each 7 7460288_1 clip 34 is supported by a corresponding leg 14. The first pair of clips 37 partially overhangs the upper rebated edge 20. The tail 42 partially overhangs the spacer overhang 24 and lower rebated edge 28. 5 The abutting surfaces of the spacer 10 and roof clip 30, may be profiled to expedite alignment of the two components. The elongated thin body 12 and the metal strap 32 when matched as the clip assembly 31 are of sufficient narrowness to enable an operator to clasp the two components together with one hand and maintain the alignment. 10 Figure 7-8 illustrates the overall general arrangement of the roof assembly. The clip assembly 31 is located longitudinally with the purlin 44. The clip assembly 31 is positioned so the roof clip 30 is elevated from the purlins 44 by the spacer 10. The clip assembly 31 is fastened to the purlin 44 with roof screws 46 that passes through the 15 fastener apertures 36, apertures 16, in between the corresponding pair of legs 14 and into the purlin 44. A metal roof sheet 48 is secured to the roof clip 30. The roof safety mesh 48 and insulation 50 are located between the spacer 10 and purlin 44. As illustrated in figure 8, the void 30 in the spacer 10 enables insulation 50 to occupy 20 the space between the elongated thin body 12 and the purlin 44. A detailed description of the interface between multiple adjacent clip assemblies 31 will now be given. In this description of multiple clip assemblies, the components will be described as a preceding or subsequent part. 25 As illustrated in Figure 4 and 11, the lower rebated edge 28 of the preceding spacer overhang 24 is designed to overlap the upper rebated edge 20 of a subsequent spacer. The tail 42 of the preceding roof clip 30 slots between metal strap 32 and thin body 12 of a subsequent clip assembly 31. The preceding tail 42, is also located 30 underneath the first pair of clips 37 of the subsequent roof clip 30. The tail aperture 43 of the preceding roof clip 30, is positioned to be coincident with the fastening aperture 36 and aperture 16 of the subsequent clip assembly 31. Therefore the roof screw 46 fastening the first end of a subsequent clip assembly 31 to the purlin 44, also passes through the tail aperture 43 of the preceding roof clip 30. This ensures alignment 35 between two adjacent clip assemblies 31. 8 7460288_1 Figures 9-11 illustrate the sequence of installing a roof assembly when multiple clip assemblies 31 are required. The method of installing the roof assembly will now be described. 5 Figure 9 conveniently shows the step of fastening the first clip assembly 60 to purlin 44, using roof screw 46. A first metal roof sheet 62 is secured to the first clip assembly 60 as shown in figure 10. 10 Figure 10 shows the step of the second clip assembly 64 been positioned, where the upper rebated edge 20 and metal strap 32 is aligned with and receives the corresponding lower rebated edge 28 and tail of the first clip assembly 60. Figure 11 illustrates the first clip assembly 60 installed to the adjacent second clip 15 assembly 64. Roof screw 66, fastens second clip assembly 64 to the purlin 44, and maintains relative alignment between the first clip assembly 60 and the second clip assembly 64. With the exception of the apertures located with the first pair of clips 37, the roof 20 screws 46 may be pre-positioned in the apertures of the clip assembly 31 before installation, as conveniently shown in figure 10. This assists in maintaining alignment of the spacer 10 and roof clip 30 of the clip assembly 31. Figure 12 illustrates an alternative rebated edge for the spacer 10. In this embodiment, 25 the spacer overhang 24 partially overlaps the upper rebated edge 20, without a corresponding lower rebated edge 28. Figures 13 to 15, and 25 illustrates an alternative embodiment of the spacer 110, with an alternative arrangement of the rebated edges and legs. As disclosed in the prior 30 embodiments the spacer 110 has an elongated body 12 and a plurality of apertures 16. A plurality of legs 114 are provided along the elongated body 12. The apertures 16 are arranged to collocate through the legs 114. At one end of the elongated body 12 is a minor overhang 120 adjacent to the first leg 122. On the other end of the elongated body 12 is a spacer overhang 24 extending past the last legs 126. At the end of the 35 spacer overhang 24 is a rebated edge 128. In use the rebated edge 128 is arranged to 9 7460288_1 locate under the minor overhang 120. The spacer 110 may have an approximate height of 45mm, width of 30mm and length of 700mm. The elongated body may have an approximate thickness of 4mm, and a further embodiment may have a thickness of 10mm. This embodiment of the spacer 110 may be used with wall cladding. 5 Figures 16 to 18 illustrate yet another embodiment of the spacer 210 as described in the first embodiment. Spacer 210 has an elongated body 12, a plurality of legs 14, a plurality of apertures 16, a spacer overhang 24 and an upper rebated edge 20. In addition this embodiment has the features of intermediate legs 270 with additional 10 apertures 272 passing therein. The intermediate legs 270 and additional apertures 272 provide additional means for supporting and securing the spacer 210 to the underlying structure. The additional apertures 272 may also provide alternative means for fixing pierced roof cladding without clips to the structure. The spacer 210 may have an approximate height of 45mm, width of 30mm and length of 700mm. The elongated 15 body may have an approximate thickness of 4mm and a further embodiment may have a thickness of 10mm. Figures 19 to 21 illustrate a further embodiment of the spacer 310. In contrast with the embodiment of Figures 16 to 18, the legs 14 and intermediate legs 270 are longer than 20 those in the embodiment of Figures 16 to 18 thereby providing a larger void 18. A larger void 18 allows use of thicker insulation. The spacer 310 may have an approximate height of 75mm, width of 30mm and length of 700mm. The elongated body may have an approximate thickness of 4mm and a further embodiment may have a thickness of 10mm. 25 Figures 22 to 24 illustrate yet another embodiment of the spacer 410. In contrast with the preceding embodiments illustrated by Figures 16 to 21, the spacer has a plurality of enlarged legs 414, where the width of a pair of enlarged legs 414 is wider than the width of the elongated body 12. The enlarged legs 414 provide an increased surface 30 area of contact to the support structure, thereby providing increased stability. It also provides increased resistance to the spacer rolling around the longitudinal axis, especially if the spacer is mounted on a sloping surface. The spacer 410 may have an approximate height of 75mm, and length of 700mm. The elongated body 12 may have an approximate width of 30mm and a thickness of 4mm. A further embodiment may 35 have a thickness of 10mm. In one embodiment, the overall width of the spacer 410, 10 7460288_1 including the width of the enlarged legs 414 may be twice the width of the elongated body 12. Figure 26 illustrates another embodiment of the spacer 510. In contrast with the 5 embodiment of Figures 19 to 21, the legs 514 are unitary as opposed to extending in pairs. Figure 27 illustrates another embodiment of the spacer 610. In contrast with the embodiment of Figures 22 to 24, the legs 614 are unitary as opposed to extending in 10 pairs. Figure 28 illustrates a general arrangement of a roof assembly 700 according to another embodiment of the invention. The roof assembly 700 comprises roof sheet 748, elevated from the purlin 44 by spacer 710. The roof sheet 748 is fastened to the 15 purlin 48 with roof screws 46 that passes through the spacer 710. The roof screws 46 may pass through preformed apertures in the spacer 710. Alternatively, the operator may form an aperture in the spacer 710 by screwing through the spacer 710 when installing the roof assembly. Optionally, spacer screws 747 may be used to position and fasten the spacer 710 to the purlin 44. 20 Figure 28 illustrates that the spacer 710 may be used without roof clips securing the roof sheet. Furthermore, the fasteners in the form of roof screws 46, may pass through the elongated body 12 at regions intermediate to supports 714. 25 In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the 30 invention. It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country. 35 11 7460288_1

Claims (21)

1. A spacer for spacing cladding from a support structure, the spacer 5 comprising: a spacer body having a mounting surface arranged in use to support cladding; and a plurality of supports integrally formed with and extending from the body in a direction opposite the direction of the mounting surface faces, the 10 supports being spaced from one another such that, when the supports are located at the support structure a space is defined between the spacer body and the support structure; the mounting surface being arranged to receive one or more clips that are adapted to engage the cladding, wherein in use the one or more 15 clips are secured to the spacer body by one or more mechanical fasteners so as to facilitate fixing of the cladding with respect to the spacer body; the spacer body and the supports being configured so that the one or more mechanical fasteners are able to extend through the one or more clips, the support and into the support structure. 20

2. A spacer according to claim 1 wherein at least one of the supports comprise two spaced support legs.

3. A spacer according to claim 2, wherein a said mechanical fastener is 25 arranged to be received on said mounting surface so as to extend between the two spaced support legs of a said support.

4. A spacer according to any preceding claim wherein the mounting surface is arranged to receive one or more clips that are adapted to engage the 30 cladding, wherein in use the one or more clips are secured to the spacer body so as to facilitate fixing of the cladding with respect to the spacer body.

5. A spacer according to any preceding claim wherein the mounting surface is 35 arranged to receive one or more mechanical fasteners so as to allow the 12 7460288_1 cladding, or clip, or clip device to be secured to the spacer body via the one or more mechanical fasteners.

6. A spacer according to any preceding claim, wherein one or more apertures 5 are provided along the mounting surface of the spacer body, wherein the apertures extend into the spacer body and are configured to receive respective ones of the mechanical fasteners.

7. A spacer according to claim 6 wherein at least one of the apertures is 10 located in alignment with a said support, to allow the mechanical fastener to extend through that support.

8. A spacer according to claim 6 or 7 wherein at least one of the apertures is located intermediate two of the plurality of supports. 15

9. A spacer according to any one of the preceding claims, wherein sufficient clearance is provided between adjacent supports to allow an insulation blanket to be located between the cladding and the support structure. 20

10. A spacer according to any one of the preceding claims, where the spacer body is formed as a strip.

11. A spacer according to any one of the preceding claims, wherein the spacer is constructed of a polymeric material. 25

12. A clip assembly for fixing cladding comprising; an elongated member; a plurality of support legs arranged to locate on an underlying structure, the support legs being integrally formed with and extending from 30 the elongated member in a first direction; a plurality of clips for engaging the cladding, the clips extending in a direction opposite to the first direction and being secured to the elongated member; and one or more fasteners to secure the clip assembly to the underlying 35 structure; 13 7460288_1 wherein in use, the support legs provide a clearance between the clips and the underlying structure, and wherein the elongated member, the support legs and the clips are configured to receive the one or more mechanical fasteners that are able to extend through the clips, the support 5 legs and into the underlying structure.

13. A clip assembly according to claim 12 wherein the said plurality of clips, the elongated member, and the said plurality of support legs are integrated into a single unit before use. 10

14. A clip assembly according to claim 13 wherein the elongated member is formed from first and second elongated bodies which are in overlaying relation, and wherein said plurality of clips and the first elongated body form a clip device and the said plurality of support legs are attached to the 15 second elongated body to form a spacer according to any one of claims 1 11, wherein the clip device and the spacer are matched to each other to form the clip assembly before use.

15. A clip assembly according to any one of claims 12 to 14, wherein at least 20 one of the clips is arranged in alignment with at least one support.

16. A clip assembly according to any one of claims 12 to 15, wherein the clip assembly is arrange to receive one or more fasteners to secure the clip assembly to the structure. 25

17. A method for attaching cladding to a structure, the method comprising the steps of: positioning an elongate member having integrally formed support legs extending therefrom on the structure; 30 supporting a plurality of clips in a spaced relationship from each other and from the structure so as to form a space between said clips and said structure; securing the clips to the structure by locating one or more fasteners such that they extend through the clips the support legs and into the 35 structure; and 14 7460288_1 attaching the cladding to the clips.

18. A method according to claim 17 further comprising the step of installing insulation in the space formed between the clips and the structure. 5

19. A method according to either claim 17 or 18 wherein the plurality of clips are mounted on a spacer to enable the clips to be in spaced relationship from the structure. 10

20. A spacer substantially as herein described with reference to the accompanying drawings.

21. A method of constructing a roof with reference to the accompanying drawings. 15 7460288_1