AU2009202566A1 - Spacer - Google Patents

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s): BLUESCOPE STEEL LIMITED Invention Title: SPACER The following statement is a full description of this invention, including the best method for performing it known to me/us: P77997AU.2 Pat_Set_Fuing Appication 2009-25.doc (M) 2 SPACER The present invention relates to a spacer for a roof. 5 The present invention relates particularly, although by no means exclusively, to a spacer for allowing a required thickness of insulation to be positioned in a roof cavity between a roof and an underlying structure 10 that define the roof cavity. Many modern buildings are constructed with roof panels, typically profiled decking sheets made from steel strip having a corrosion resistant metallic coating and an 15 outer paint coating. The size of the roof panels enables large roof areas to be covered by installing fewer roof panels and covered in less construction time. Typically, the roof panels are profiled by being 20 roll-formed from strip and cut into sheets and include one or more parallel ribs, pan sections, and side edge formations that enable the sheets to be positioned side by side in overlapping relationship. 25 It is known to secure roof panels to an underlying roof support structure, such as roof purlins, by fastening the sheets directly to the underlying structure using fasteners, such as roofing nails or screws, that pierce the sheets and penetrate the 30 underlying structure. It is also known to secure roof panels to an underlying structure by using concealed clip assemblies that include clips that are secured to the structure by 35 fasteners and are formed to extend into the ribs and engage re-entrant portions of the ribs and thereby retain the sheets to the clips. These clip assemblies are often N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\SpeciS\Spacer System ge.doc 25/06/09 3 preferred over nails because they enable concealed fixing of roof panels to an underlying structure. In warm climates there is considerable cost in 5 keeping the inside of buildings cool compared to the outside. Many modern buildings are air-conditioned and the cost of air-conditioning is an important cost 10 consideration. In cool climates there is considerable cost in keeping the inside of buildings warm compared to the outside. Many modern buildings are heated and the cost of 15 heating is an important cost consideration. A large amount of heat transfer from and to an interior of a building is through the roofing system of the building. Thus, a roofing system that reduces heat 20 transfer is one option for reducing air conditioning and heating costs. The present invention is concerned with providing a spacer for use in constructing an insulated roof that 25 reduces heat transfer via the roofing from and to the interior of the building. The present invention provides a spacer to position a roof of a building above an underlying roof 30 support structure comprises an elongate platform for supporting roof panels of the roof directly on the platform or indirectly via at least one concealed clip mounted to the platform. The spacer also comprises first and second end element at opposite ends of the platform to 35 mount the spacer to the underlying roof support structure. Each end element comprises, in an operative position of the spacer, a leg to space the platform above the Nr\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Speci\Spacer System gs.doc 25/06/09 4 underlying structure and a mounting component to mount that end of the spacer to the underlying structure. According to the present invention there is 5 provided a spacer to position a roof of a building above an underlying roof support structure of the building that comprises: (a) an elongate platform for supporting roof 10 panels of the roof directly on the platform or indirectly via at least one concealed clip mounted to the platform, (b) a first end element at one end of the platform to mount the spacer to the underlying roof 15 support structure, a second end element at the other end of the platform to mount the spacer to the underlying roof support structure, each end element comprising in an operative position of the spacer a leg to space the platform above the underlying structure and a mounting 20 component to mount that end of the spacer to the underlying structure. The mounting component of the first end element may be positioned directly on the underlying structure or 25 on the second end element of another spacer that has previously been located on the underlying structure. The mounting component of the second end element may be formed to enable the mounting component of the 30 first end element of another spacer to be positioned to overlap that end element so that the other spacer is a longitudinal extension of the spacer. The overlapped mounting components may be secured 35 to the underlying structure by one single fastener. This feature enables a roofer to fasten a first mounting component of one spacer to an underlying structure, then N:\Melbourne\Caseo\Patent\77000-77999\P77997.AU.2\Specio\Spacer System gs.doc 25/06/09 5 position a first mounting component of another spacer over the second mounting component of the other end of the spacer and align both spacers in end to end array (i.e. longitudinally), then use a single fastener to fasten the 5 overlapped mounting components to the underlying structure. The mounting components may have complementary shapes in order to facilitate overlapping of the mounting 10 components. Each mounting component may comprise a fastening aperture that is positioned so that the apertures of overlapping mounting components can be brought into 15 alignment prior to passing a fastener through the apertures into the underlying structure. The features described in the two preceding paragraphs enable a roofer to quickly and easily install 20 the spacers in an end to end arrangement thereby limiting the amount of time the roofer needs to spend on a roof. This is an important safety advantage of the invention. The first end element may be an extension of the 25 platform in the length direction of the platform, with a fold line separating the platform and the leg, and the mounting component extending at an angle to the leg, and with the arrangement being such that, in use, the first end element can be secured to the underlying structure by 30 hammering or screwing a fastener through the mounting component into the underlying structure with the platform and the leg extending from the mounting component at an angle so that the platform and the leg do not interfere with the required hammering or screwing action and then 35 folding the platform downwardly about the fold line relative to the leg to position the platform in the operative position with the platform overlying the N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Speci\Spacer System go.doc 25/06/09 6 underlying structure. The "fold line" may be any suitable formation that allows the platform to be folded relative to the leg 5 of the first end element. The leg and the mounting component of each end element are at an angle relative to each other. 10 The angle may be an included angle of 75-90*. The length of the legs of the mounting components of the end elements and the angles between the legs and the mounting components may be selected so that in the 15 operative position the legs space the platform a required distance above the underlying structure to suit the type of insulation required for a roof cavity between the roof and the underlying structure that define the roof cavity. 20 The spacer may be a one-piece unit. The spacer may be formed from sheet steel. The platform may be sufficiently long to mount at 25 least two concealed clips on the platform, with the spacing between the concealed clips being selected to correspond to the spacing between ribs of roof panels that are adapted to be engaged by the clips. 30 The platform may include means to facilitate mounting of concealed clips to the platform in required locations, for example that ensure correct spacing of the clips along the length of the platform. For example, the platform may have markings, for example printed indicia, 35 that visually identify the required location of the clips. The visual identification may be formed in the platform and may for example be in the form of recessed sections or NW\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\SpeciS\Spacer System go.doc 25/06/09 7 projections that physically define mounting locations for the clips. The concealed clips may be mounted to an elongate 5 strap and the platform may be adapted to mount the strap to the platform. The platform may comprise a top wall and opposed side walls. 10 The platform may comprise a flange extending outwardly from each side wall. This configuration can be described as a "top hat" configuration. 15 The roof panels may be in the form of profiled decking sheets, such as profiled decking sheets made from steel strip having a corrosion resistant metallic coating and an outer paint coating. 20 The profiled decking sheets may have at least one rib separated by pans. The rib may be formed with a re-entrant section to engage a conceal clip. 25 The roof panels may have complementary side edge formations that facilitate locating adjacent panels in side by side overlapping relationship. 30 The underlying roof support structure may be a roof purlin. According to the present invention there is provided a roof panel retaining system that comprises the 35 above-described spacer and a plurality of concealed clips mounted to the platform of the spacer for engaging a roof panel. N:\Melbourne\Cases\Patent\77000-77999\P72997.AU.2\Specis\Spacer System gs.doc 25/06/09 8 According to the present invention there is provided a roof that comprises: 5 (a) a plurality of the above-described spacers mounted to an underlying structure; (b) a layer of insulation positioned on the underlying structure and between the spacers; and 10 (c) a plurality of roof panels mounted directly to the platforms of the spacers or indirectly via concealed clips. 15 According to the present invention there is provided a method of locating the above-described spacer to an underlying structure that comprises: (a) positioning the mounting component of the 20 first end element of the spacer on the underlying structure, with the platform and the leg of the first end element extending from the mounting component at an angle that positions the platform and the leg so that they do not interfere with subsequent hammering or screwing action 25 to secure the mounting component to the underlying structure; (b) hammering or screwing a fastener through the mounting component and thereby securing the mounting 30 component and that end of the spacer to the underlying structure; and (b) folding the platform about the fold line that separates the first end element and that end of the 35 platform downwardly into the operative position in which the platform overlies the underlying structure. N.\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Spcci\Spacer System gs.doc 25/06/09 9 Successive spacers may be located on the underlying structure by positioning the mounting component of the first end element of the next spacer on the mounting component of the second spacer of the last spacer 5 to be located on the underlying structure so that the mounting components are in overlapping relationship, and repeating the steps described in the preceding paragraph. According to the present invention there is 10 provided a method of constructing a roof that comprises: (a) constructing underlying roof support structure; 15 (b) locating a plurality of the above-described spacer to the underlying structure; (c) laying insulation on the underlying structure; 20 (d) securing roof panels directly on the platforms of the spacers or indirectly on the panels via concealed clips mounted to the platforms. 25 According to the present invention there is provided a method of manufacturing the above-described spacer that comprises: (a) forming a fold line towards one end of a 30 sheet of steel to form a first end element and a platform on opposite sides of the fold line; and (b) folding the first end element to form a leg extending from the platform and a mounting component 35 extending from the leg at an angle to the leg. Step (b) may comprise folding the first end N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specia\Spacer SyStem ga.doc 25/06/09 10 element so that the angle between the leg and the mounting component is an included angle of 75-90*. The method may comprise folding the sheet steel 5 so that the platform comprises a top wall and opposed side walls and a flange extending outwardly from each side wall. The present invention is described further by way 10 of example with reference to the accompanying drawings, of which: Figure 1 is a perspective view of one embodiment of a spacer in accordance with the present invention in an 15 operative position mounted to an underlying roof support structure; Figure 2 is an enlargement of the left hand end of the spacer shown in Figure 1; 20 Figure 3 is a perspective view of the right hand end of the spacer shown in Figure 1 in an as-manufactured form of the spacer prior to folding the spacer into the operative position shown in Figure 1; and 25 Figure 4 is a perspective view of an as manufactured spacer positioned on the already-positioned spacer shown in Figure 1, illustrating a first step in a method of positioning the spacer in the operative position 30 on the underlying structure. Figure 1 illustrates one embodiment of a spacer 3 in accordance with the present invention in an operative position mounted to an underlying roof support structure 35 5, such as a roof purlin. The Figure shows one spacer 3 in solid lines and two spacers 3 in outline. It is evident from the Figure that the spacers 3 can be N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System ga.doc 25/06/09 11 positioned end to end along the length of the support structure 5. As will be evident from the following description, the structure of the spacer 3 makes it possible to quickly and efficiently install the line of 5 spacers 5 shown in Figure 1 on the underlying structure 5. In order to put the description into context, the spacers 3 are typically at least 800 mm, more typically of the order of 1200 mm, long. It is noted that the present 10 invention is not limited to any particular length of spacer 5, and the spacers 5 may be any suitable length. The spacer 3 shown in the Figures is formed as a one-piece unit from sheet steel. The spacer 3 comprises 15 an elongate platform 7 (which can also be described as a "span" member) for supporting roof panels (not shown) of the roof (a) directly on the platform 7 or (b) indirectly on the platform via at least one concealed clip (one of which is identified by the numeral 41 in Figure 1) mounted 20 to the platform. The spacer 3 also comprises a first end element 9 at one end of the platform 7 to mount that end of the spacer 3 to the underlying structure 5 and a second end element 11 at the other end of the platform 7 to mount that end of the spacer 3 to the underlying structure 5. 25 The combination of the spacer 3 and the concealed clip or clips 41 form one embodiment of a roof panel retaining system in accordance with the present invention. In situations where there is a plurality of such clips 41, 30 the spacing of the clips is selected to coincide with the spacing of ribs in roof panels that are engaged by the clips 41 when the roof is constructed. The platform 7 is a generally "top hat" 35 configuration and comprises a top wall 13, opposed side walls 15, and a flange 17 extending outwardly from each side wall. This configuration provides mechanical N:\Melbourne\Casea\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09 12 strength to the spacer 3 and makes it possible to form the spacer from thin gauge sheet steel. The profile of the top-hat platform 7 is advantageous because it provides sufficient strength and stability to support the weight of 5 a roof panel and the weight of a worker on the panel. Accordingly, the spacer 3 will support workers during construction and maintenance. Alternatively, C-shaped or Z-shaped profiles may be used to form the platform 7 in applications where strength and stability requirements for 10 the spacer 3 are less demanding. Each end element 9, 11 comprises a leg 21 to space the platform 7 above the underlying structure 5 and a mounting component 23 to mount that end of the spacer 3 15 to the underlying structure 5. Each mounting component 23 comprises an aperture 25 to facilitate securing the mounting component 23 to the underlying structure with a fastener (not shown), such as 20 a screw or roofing nail. The spacer 3 is formed by folding and slitting a sheet of steel into the form shown in the Figures. 25 As can best be seen in Figure 2, in the as manufactured form of the spacer 3, the second end element 11 is formed as an extension of the platform 7, more particularly the top wall 13 of the platform 7. The leg 21 extends at 900 to that end of the top wall 13, and the 30 mounting component 23 extends at 900 to the leg 21. A fold line 59 between leg 21 and the top wall 13 comprises diamond -shaped indents 61 to reduce bending along the join, thereby contributing to lateral stability of the spacer 3. 35 As can best be seen in Figure 3, in the as manufactured form of the spacer 3, the first end element 9 N:\Melbourne\Casea\Patent\77000-77999\P77997.AU.2\Specis\Spacer System ge.doc 25/06/09 13 is formed as an extension of the platform 7. More particularly, a fold line 29 separates the top wall 13 of the platform 7 and the leg 21 of the first end element 9. The fold line 29 is formed by a transverse slot 31 and 5 slits 33. In this as-manufactured form of the spacer 3 shown in Figure 3, the leg 21 of the first end element 9 is in the same plane as the top wall 13 of the platform 7. 10 In addition, the mounting component 23 of the first end element 9 extends at an angle of 900 to the leg 21. This arrangement is such that, in use, the first end element 9 can be secured to the underlying structure 5 by hammering or screwing a fastener (not shown) through the aperture 35 15 in the mounting component 23 into the underlying structure 5 with the platform 7 and the leg 21 extending from the mounting component 23 at the angle of 900 - this is shown in Figure 4 in the context of securing a successive spacer 3 to a spacer that has already been secured to the 20 underlying structure 5. In this position, the platform 7 and the leg 21 of the first end element 9 do not overlie the mounting component 23 and therefore do not interfere with the required hammering or screwing action to secure the mounting platform 23 to the underlying structure 5. 25 After the fastener has been hammered or screwed into the underlying structure 5, the roofer folds the platform 7 downwardly about the fold line 29 relative to the leg 21 and positions the platform 7 in the operative position with the platform 7 overlying the underlying structure 5, 30 as shown in Figure 1. With reference to Figure 4, a similar procedure to that described in the preceding paragraph is used to secure each successive spacer 3 to the underlying 35 structure 5. The procedure includes positioning the mounting component 23 of the first end element 9 of the successive spacer 3 on the mounting plate 23 of the N,\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09 14 already located spacer 3, with the apertures 35 of the mounting components 23 aligned. As is evident from Figure 4, the structure of the spacer 3 is such that the platform 7 and the leg 21 of this successive spacer 3 extend 5 upwardly from the mounting component 23 of the spacer 3 and do not overlie the mounting component 23 and therefore do not interfere with the required hammering or screwing action to secure the mounting components 23 of (a) the successive spacer 3 and (b) the already located spacer 3 10 to the underlying structure 5. After the fastener has been driven into the underlying structure 5, the roofer folds the platform 7 of the successive spacer 3 downwardly about the fold line 29 relative to the leg 21 and positions the platform 7 in the operative position with 15 the platform 7 overlying the underlying structure 5, as shown in Figure 1. This procedure can be repeated as required to secure a required number of spacers 5. 20 The advantages of the above-described spacer include the following advantages. * One piece construction. 25 " Low screw count required for installation. e Fast and straightforward installation - hence productivity and safety advantages. 30 Many modifications may be made to the present invention described above without departing from the spirit and scope of the invention. 35 By way of example, whilst the spacer 3 is described as being made form sheet steel as a one piece unit, the present invention is not so limited and the N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09 15 spacer may be made from any suitable material and as an assembly of two or more components. In addition, whilst the fold line 29 that 5 separates the first end element 9 and the platform 7 at that end of the spacer is formed by a transverse slot 31 and slits 33, the present invention is not so limited and the fold line may be formed in any suitable way. N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System ga.doc 25/06/09

Claims (16)

1. A spacer to position a roof of a building above an underlying roof support structure of the building that 5 comprises: (a) an elongate platform for supporting roof panels of the roof directly on the platform or indirectly via at least one concealed clip mounted to the platform, 10 (b) a first end element at one end of the platform to mount the spacer to the underlying roof support structure, a second end element at the other end of the platform to mount the spacer to the underlying roof 15 support structure, each end element comprising in an operative position of the spacer a leg to space the platform above the underlying structure and a mounting component to mount that end of the spacer to the underlying structure. 20

2. The spacer defined in claim 1 wherein the mounting components have complementary shapes in order to facilitate overlapping of the mounting components. 25

3. The spacer defined in claim 2 wherein each mounting component comprises a fastening aperture that is positioned so that the apertures of overlapping mounting components can be brought into alignment prior to passing a fastener through the apertures into the underlying 30 structure.

4. The spacer defined in any one of the preceding claims wherein the first end element is an extension of the platform in the length direction of the platform, with 35 a fold line separating the platform and the leg, and the mounting component extending at an angle to the leg, and with the arrangement being such that, in use, the first N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09 17 end element can be secured to the underlying structure by hammering or screwing a fastener through the mounting component into the underlying structure with the platform and the leg extending from the mounting component at an 5 angle so that the platform and the leg do not interfere with the required hammering or screwing action and then folding the platform downwardly about the fold line relative to the leg to position the platform in the operative position with the platform overlying the 10 underlying structure.

5. The spacer defined in any one of the preceding claims wherein the length of the legs of the mounting components of the end elements is selected so that in the 15 operative position the legs space the platform a required distance above the underlying structure to suit a type of insulation required for a roof cavity between the roof and the underlying structure that define the roof cavity. 20

6 The spacer defined in any one of the preceding claims wherein the platform is sufficiently long to mount at least two concealed clips on the platform, with the spacing between the concealed clips being selected to correspond to the spacing between ribs of roof panels that 25 are adapted to be engaged by the clips.

7. The spacer defined in any one of the preceding claims wherein the platform comprises a top wall and opposed side walls. 30

8. The spacer defined in claim 7 wherein the platform comprises a flange extending outwardly from each side wall, whereby the configuration can be described as a "top hat" configuration. 35

9. A roof panel retaining system that comprises the spacer defined in any one of the preceding claims and a N:\Melbourne\Casea\Patent\77000-77999\P77997.AU.2\Specio\Spacer Sytem go.doc 25/06/09 18 plurality of concealed clips mounted to the platform of the spacer for engaging a roof panel.

10. A roof that comprises: 5 (a) a plurality of the spacers defined in any one of claims 1 to 8 mounted to an underlying structure; (b) a layer of insulation positioned on the 10 underlying structure and between the spacers; and (c) a plurality of roof panels mounted directly to the platforms of the spacers or indirectly via concealed clips. 15

11. A method of locating the spacer defined in any one of claims 1 to 8 to an underlying structure that comprises: 20 (a) positioning the mounting component of the first end element of the spacer on the underlying structure, with the platform and the leg of the first end element extending from the mounting component at an angle that positions the platform and the leg so that they do 25 not interfere with subsequent hammering or screwing action to secure the mounting component to the underlying structure; (b) hammering or screwing a fastener through 30 the mounting component and thereby securing the mounting component and that end of the spacer to the underlying structure; and (b) folding the platform about the fold line 35 that separates the first end element and that end of the platform downwardly into the operative position in which the platform overlies the underlying structure. N-\Melbourne\Casea\Patent\77000-77999\P77997.AU.2\Speci\Spacer System ga.doc 25/06/09 19

12. The method defined in claim 11 comprises locating successive spacers on the underlying structure by positioning the mounting component of the first end 5 element of the next spacer on the mounting component of the second spacer of the last spacer to be located on the underlying structure so that the mounting components are in overlapping relationship, and repeating the steps defined in claim 11. 10

13. A method of constructing a roof that comprises: (a) constructing underlying roof support structure; 15 (b) locating a plurality of the spacer defined in any one of claims 1 to 8 to the underlying structure; (c) laying insulation on the underlying 20 structure; (d) securing roof panels directly on the platforms of the spacers or indirectly on the panels via concealed clips mounted to the platforms. 25

14. A method of manufacturing the spacer defined in any one of claims 1 to 8 that comprises: (a) forming a fold line towards one end of a 30 sheet of steel to form a first end element and a platform on opposite sides of the fold line; and (b) folding the first end element to form a leg extending from the platform and a mounting component 35 extending from the leg at an angle to the leg.

15. The method defined in claim 14 wherein step (b) N:\Melbourne\Cases\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09 20 comprises folding the first end element so that the angle between the leg and the mounting component is an included angle of 75-90". 5

16. The method defined in claim 14 or claim 15 comprises folding the sheet steel so that the platform comprises a top wall and opposed side walls and a flange extending outwardly from each side wall. N3\Melbourne\Case\Patent\77000-77999\P77997.AU.2\Specis\Spacer System gs.doc 25/06/09