AU2014213575B2

AU2014213575B2 - Spacer

Info

Publication number: AU2014213575B2
Application number: AU2014213575A
Authority: AU
Inventors: Kevin Frederick Carey
Original assignee: J Clip Holdings Pty Ltd
Current assignee: J Clip Holdings Pty Ltd
Priority date: 2013-08-19
Filing date: 2014-08-18
Publication date: 2018-07-19
Anticipated expiration: 2034-08-18
Also published as: NZ628936A; GB201414588D0; GB2518518B; AU2014213575A1; GB2518518A

Abstract

The present invention provides a roofing spacer comprising a crossbar, wherein the crossbar comprises two side walls and is adapted to be spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members, wherein each of the leg members: (i) is adapted to be fixable to the purlin, and (ii) passes through one or both side walls of the crossbar, whereby uplift of the crossbar is substantially prevented. A 116 100 110 124 122 115 113 112 111 124

Description

SPACER

Field of the Invention [0001] The present invention relates to roofing and in particular to an improved device for attaching a metal roof to a purlin lying therebeneath.

Background to the Invention [0002] Metal roofing sheets are used in many applications and most commonly in factory roofs. Since metal is a good conductor of heat, it is desirable to include some type of insulating material beneath the metal roofing sheets. To this end, a wire mesh is typically positioned on the purlin to which the roofing sheets are attached and a layer of insulating material is positioned on top of the mesh, with the roof sheets being laid on top of the insulating material. A problem with insulating a roof in this manner is that areas of the insulating material, which directly overlie the purlins, are compressed between the purlins and the roof sheets. Such an arrangement dramatically reduces the thermal effectiveness of the insulating material in those compressed areas.

[0003] In the past, several attempts have been made to overcome this problem, for example, by increasing the thickness of the insulating material. However, this can result in the roofing sheets being difficult to properly secure because the bulk of the insulating material must be compressed before the roofing sheets can be secured to the purlin.

[0004] A further previous option has been to place a spacer between the purlin and the roofing sheets. In particular, by placing blocks of polystyrene on top of the insulating material where the roofing sheets are to be secured. Although these blocks also compress the insulating material by virtue of being located between the roofing sheets and the purlin, the thermal efficiency of the polystyrene to some degree compensates for the reduced thermal efficiency in the insulating material due to its compression. While this is quite an effective solution, polystyrene is relatively lightweight and the blocks are readily blown out of position on top of the insulating material prior to being secured in place. This also results in an increase in the installation time of roofing sheets and therefore results in increased costs associated with preparing a roof in this manner. In yet a further variant, a crossbar including legs has been used. The legs are used to space the crossbar above the insulating material and the roofing sheets are attached to the crossbar. This type of arrangement is effective, but the currently available versions have certain shortcomings; the present invention seeks to overcome at least some of these shortcomings.

Summary of the Invention [0005] The present invention provides a roofing spacer comprising: a crossbar, wherein the crossbar comprises two side walls and is adapted to be spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members, wherein each of the leg members: (i) is adapted to be fixable to the purlin, and (ii) passes through one or both side walls of the crossbar, whereby uplift of the crossbar is substantially prevented.

[0006] In one embodiment, each of the plurality of leg members passes through an opening and/or a respective opening comprised in one and/or both of the side walls of the crossbar. The opening or respective opening may be adapted to receive the respective leg member. The adapted opening may comprise a profile complementary to the respective leg member. The complementary profile may comprise one or more grooves, each to substantially match a strengthening ridge in the leg member.

[0007] The leg members preferably comprise a substantially “C-shape”. The leg members may be bent from a single piece of metal comprising a planar structure into the substantially C-shape.

[0008] The leg members may comprise three structural sections: a lower portion; an upright portion; and an upper portion. The upper portion may comprise a tab portion wherein when the leg member is bent into a substantially “C-shape” the tab portion comprises a lip. The lip may be a turned lip.

[0009] One or more of the plurality of leg members may, optionally, further comprise one or more strengthening ridges that may be pressed into the leg member prior to the leg members being bent or folded into the substantially C-shape or modified “C-shape”.

[0010] One or more of the plurality of leg members may, optionally, further comprise one or more strengthening pieces that connect the lower portion and the upright portion.

The one or more strengthening piece may comprise supplemental bracing such as a cross-brace.

[0011] The upper portion of the leg member may be adapted to pass through the opening or respective opening.

[0012] The crossbar may comprise holes which align with corresponding holes in one of the plurality of leg members to allow a user to pass a fastener and/or a tool through the hole in order to fix the spacer to a purlin. The holes may be comprised in the upper portion.

[0013] The crossbar may further comprise a first connector end and a second connector end, wherein the first connector end is adapted to receive the second connector end of an adjacent spacer, whereby a plurality of roofing spacers may be joined end-to-end.

[0014] The present invention also provides a roof comprising a roofing spacer as described herein. Preferably the roof further comprises metal roofing sheets secured, directly or indirectly, to the crossbar of the spacer. Preferably the roof further comprises insulting material located between the roofing sheets and the purlin, wherein the insulating material is substantially non-compressed.

[0015] The present invention also provides a roofing spacer kit comprising: one or more crossbars adapted to be spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members fixed to or adapted to be fixable to the crossbar, each of the plurality of leg members adapted to be secured to the purlin and pass through the crossbar, whereby in use, uplift of the crossbar is substantially prevented.

[0016] The present invention also provides a roofing spacer substantially as herein defined with or without respect to the figures.

[0017] Accordingly, the spacer of the present invention allows attachment of roofing sheets to a purlin of a roof structure whilst at the same time minimising the regions of insulation material which are compressed between the purlin of the roof structure. Furthermore, the roof sheets can be rapidly and efficiently installed, thereby reducing labour costs. In addition, the insulating material is advantageously able to maintain an overall higher thermal efficiency (R-value) than insulation material installed in accordance with the prior art.

Brief Description of the Figures [0018] Figure 1 shows a view of an embodiment of a crossbar of a spacer according to the present invention. Panel A shows a view from above; panel B, from a side; panel C, from an end; and panel D shows a close up view of an opening which includes grooves for accommodating strengthening ridges.

[0019] Figure 2 shows a leg member according to an embodiment of the present invention. Panel A shows a cross-section through the leg member; and panel B shows a plan view of a leg member prior to bending and installation.

[0020] Figure 3 shows views of an embodiment of a spacer according to the present invention, which may be of any length, as indicated by the break in the drawing. Panel A shows a view from a side; panel B, from above; and panel C shows a cross section through a leg member when fixed to the crossbar.

[0021] Figure 4 shows a perspective view of the embodiment of the spacer illustrated in Figure 3.

[0022] Figure 5 shows a perspective view of the receiving end of the embodiment of the spacer illustrated in Figure 4.

[0023] Figure 6 shows a leg member according to an embodiment of the present invention. Panel A shows the leg member engaged with the crossbar; and panel B shows an exploded view of the leg member showing the nature of an embodiment of the strengthening piece.

[0024] Figure 7 shows a leg member according to an embodiment of the present invention, and illustrates another embodiment of the strengthening piece.

Detailed Description of the Invention [0025] Referring to all the Figures wherein like reference numerals designate like or corresponding parts throughout the several views. The Figures show exemplary embodiments of the present invention. It is to be understood that these embodiments are not intended to limit the scope of the present invention. The skilled addressee will readily recognise alternative embodiments that may be used to put the present invention into practice, such embodiments are equally understood to be encompassed by the present invention. Accordingly, the following description refers to a specific embodiment of the present invention and is in no way intended to limit the scope of the present invention to that specific embodiment.

[0026] The present invention provides a roofing spacer 100 including a crossbar 110 and a plurality of leg members 120 fixed thereto, wherein the crossbar 110 is adapted to be spaced apart from, and substantially parallel to, a purlin. The crossbar 110 preferably comprises an upper mounting surface 111, a first side wall 112 and a second side wall 113, wherein the side walls 112,113 extend substantially perpendicular to the mounting surface 111. Each of the leg members 120 is adapted to be secured to the purlin and passes through an opening 114 in the first and second side walls 112,113 of the crossbar 110. Advantageously, the present invention substantially prevents uplift of the crossbar 110. Preferably, the openings 114 in the first and second side walls 112,113 of the crossbar 110 are adapted to receive a leg member 120.

[0027] In use, the roofing spacer 100 is intended to raise the fixing point of roofing sheets above the underlying purlin so that insulating material placed between the purlin and the roofing sheets is substantially non-compressed, thereby retaining its effective insulating properties. Accordingly, in use, roof securing means (not shown) may be attached to an upper mounting surface 111 of the crossbar 110. Roof securing means typically include roof clips, to which roofing sheets are attached without the need for screws or bolts. Roofing sheets are typically metal roofing sheets. Such sheets are available in many different profiles and each profile requires its own specific roof clip. Accordingly, provision of a spacer 100 having roof clips pre-installed is an impractical option. Attachment of the roof clips to the crossbar 110 may be done directly, or more conveniently, by using a rail of clips. A rail of clips is commonly purchased off-the-shelf and includes roof clips mounted to a metal rail at the correct spacing to suit the profile of particular roof sheets being used. The rail of clips may then be fastened to the upper surface 112 of the crossbar 110, preferably with screws, prior to securing the roof sheets thereon. Accordingly, the roofing sheets may be secured, directly or indirectly, to the crossbar 110.

[0028] Attachment of the leg members 120 to the crossbar 110 is of importance to the present invention. In particular embodiments, the leg members 120 are substantially “C-shape” (Figure 2A) and bent into shape from a single piece of metal (Figure 2B). As shown in Figure 2B the single piece of metal may be bent from a planar structure into the substantially “C-shape”.

[0029] Each leg member 120 comprises three structural sections: a lower portion 121; an upright portion 122; and an upper portion 123. The upper portion 123 optionally further includes a tab portion 124. In embodiments that include tab portion 124, the leg members 120 may be bent into a modified “C-shape” which has a lip comprising tab portion 124. In the embodiment shown in FIGS. 3 and 5, the lip is a turned lip, wherein tab portion 124 is turned at an angle to upper portion 123.

[0030] In preferred embodiments, each leg member 120 further includes strengthening ridges 125 that may be pressed into the leg member 120 prior to being bent or folded into its substantially C-shape or modified “C-shape”.

[0031] The upper portion 123 is adapted to pass through openings 114 located in the side walls 112,113 of the crossbar 110. Such an arrangement provides the spacer with resistance to being lifted and/or being forced downwards. Holes 117 in the crossbar 110 align with holes 127 in the upper portion 123. This alignment allows a user to pass a fastener and/or tool through the hole in order to fix the spacer to a purlin.

[0032] In a preferable embodiment upper portion 123 includes the optional tab portion 124. When the upper portion 123 is in position and passing through the side walls 112,113 of the crossbar 110, the tab portion 124 protrudes and may be bent (see Figures 3C and 5), whereby it is used to fix the upper portion 123, and thereby the entire leg member 120 to the crossbar 110.

[0033] As noted above, in the embodiment shown in FIGS. 1-5, the openings 114 in the first and second side walls 112,113 of the crossbar 110 are adapted to receive a leg member 120. In particular, openings 114 may be arranged in pairs being positioned directly opposite in opposing side walls 112,113. Further, the openings 114 in the side walls 112,113 may be different and may be adapted to match the cross-section of the leg member 120. For example, in an embodiment of the invention wherein the leg member 120 includes strengthening ridges 125, at least one of the openings 114a in a pair may include grooves 116 that closely match and accommodate the strengthening ridges 125. Accordingly, in such an embodiment, the tab portion 124 of the leg member 120 is first passed through the groove-containing opening 114a and then through the non-groove-containing opening. Since the tab portion 124 does not contain strengthening ridges 125, it may pass through both openings 114 unhindered. However, the strengthening ridges 125 may only pass through the groove-containing opening 114a. Once the tab portion 124 has passed through the two side walls 112,113, it may be bent over to prevent withdrawal of the leg member 120 and substantially fix the leg member 120 to the crossbar 110.

[0034] The upright portion 122 of the leg member 120 is used to position the crossbar 110 above the purlin. The length of the upright portion 122 defines the height of the crossbar 110 and thus, the thickness of insulating material that may be positioned between the purlin and the crossbar 110. As such, upright portion 122 may comprise a variable length. From the teaching herein a skilled person is readily able to select a suitable length for upright portion 122.

[0035] The lower portion 121 of the leg member 120 includes an opening 126 through which a fastener, such as a screw, is passed to fasten the roofing spacer 100 to the purlin. In certain embodiments of the present invention, the lower portion 121 may incorporate a captured, or pre-installed, fastener, whereby the user simply has to screw the fastener into the underlying purlin.

[0036] The spacer 100 of the present invention has leg members 120 that have a single upright portion 122, or “leg”. In order to remain evenly balanced when in use, it is preferable have some “legs” situated on each side of the crossbar 110. In the illustrated embodiments, the legs are on alternating sides of the crossbar 110. This preferred arrangement provides a more stable spacer 100.

[0037] As noted above, the leg members 120 pass through the crossbar 110 and are secured thereto by the tab portion 124. By fitting the leg members 120 to the crossbar 110 in this manner, considerable resistance to uplift is achieved. Accordingly, any roofing material secured to the spacer 110 will be well secured to the underlying purlin. In particular, such an arrangement may allow a roof, which incorporates a spacer 110 of the present invention to achieve a rating to resist strong winds, preferably gale force winds and most preferably cyclones. It is envisaged that further embodiments of the present invention may include leg members 120 with supplementary bracing 130 between the lower portion 121 and the upright portion 122 whereby additional strength is imparted upon the leg member.

[0038] For example, the bend between the upright portion 122 and the lower portion 121 may be strengthened by supplemental bracing which is fixed to the two portions. As illustrated in Figure 6, the supplemental bracing may be in the form of a cross-brace 130 and may include flanges 132 that facilitate joining the cross-brace to both the upright portion 122 and the lower portion 121 by, for example, spot welding.

[0039] In an alternative embodiment, the cross-brace 130 may be ARC-welded to both the upright portion 122 and the lower portion 121, as illustrated in Figure 7.

[0040] In order to provide some flexibility in use, the roofing spacers of the present invention may be used in a modular manner whereby several spacers can be linked together to provide various effective lengths of roofing spacer. Thus, in use, a large number of spacers 100 may be required. Specifically, the spacers are preferably linkable whereby several spacers 100 may be joined end-to-end. Preferably, the crossbar 110 includes a first connector end 115 and a second connector end 116, whereby the first connector end 115 is adapted to receive the second connector end 116 of an adjacent spacer 100. This arrangement allows the spacing of the leg members 120 to remain constant along the length of the end-to-end-joined spacers 100.

[0041] The spacers according to the present invention may have dimensions that are suitable for mounting the spacer on a purlin, supporting roof sheeting above the spacer and resisting uplift during strong winds. The number and spacing of the leg members may be adapted to suit different applications, as may the length of the roof spacer. Preferably, the length of the roof spacer is between about 750mm and about 2000mm. The number and spacing of leg members will be determined by the length of the roof spacer and by the amount of strength required. The spacing is preferably regular, but may be irregular if a particular application requires such an arrangement. In the illustrated embodiments of the present invention, there are six leg members, spaced at approximately 200mm intervals, such that the spacer has an overall length of approximately 1200mm.

[0042] The height of the upright portion of the leg members determines the height of the crossbar above the purlin, and thus the thickness of material that may be positioned therebetween. Preferably, the top of the crossbar is raised between about 70mm and about 150mm above the underlying purlin. For example, preferred heights include approximately 75mm, approximately 100mm and approximately 120mm.

[0043] The width of the crossbar must be sufficient to support roof clips or a rail of roof clips. Preferably the crossbar is between about 75mm and 40mm. In the illustrated embodiments of the present invention, the crossbar is approximately 52mm wide.

[0044] The height of the side walls of the crossbar must be sufficient to accommodate the leg members passing therethrough and provide sufficient strength and resistance to tearing or breakage such that the roof spacer remains fixed to the purlin during strong winds. Preferably, the side walls are between about 8mm and about 25mm high. In the illustrated embodiments of the present invention, the side walls are approximately 11mm high.

[0045] Accordingly, a roof incorporating a spacer of the present invention will include roofing sheets secured, directly or indirectly, to the crossbar; and insulating material between the roofing sheets and the purlin, wherein the insulating material is substantially non-compressed. Uplift of the roofing sheets in strong winds is substantially prevented by the leg members. In particular, by passing the leg members through the crossbar, the crossbar may be more securely fastened to the purlin than if the legs were simply spot welded to the underside of the crossbar.

[0046] Exemplary roofing spacers according to the present invention may be made of a metal such as, but not limited to, aluminium.

[0047] The present invention is not to be limited in scope by the specific embodiments and Figures described herein, which are intended as single illustrations of individual aspects of the invention, and functionally equivalent methods and components are within the scope of the invention. Indeed, various modifications of the invention, in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and accompanying Figures. Such modifications are intended to fall within the scope of the present invention.

[0048] Where the terms “comprise”, comprises”, “comprising”, “include”, “includes”, “included” or “including” are used in this specification, they are to be interpreted as specifying the presence of the stated features, integers, steps or components referred to, but not to preclude the presence or addition of one or more other feature, integer, step, component or group thereof.

[0049] Further, any prior art reference or statement provided in the specification is not to be taken as an admission that such art constitutes, or is to be understood as constituting, part of the common general knowledge.

[0050] One of ordinary skill in the art will appreciate that materials and methods, other than those specifically exemplified can be employed in the practice of the invention without resort to undue experimentation. All art-known functional equivalents, of any such materials and methods are intended to be included in this invention. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by examples, preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended Example Claims.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A roofing spacer comprising: a crossbar, wherein the crossbar comprises an upper mounting surface and two side walls and is adapted to be spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members, wherein each of the leg members: (i) is adapted to be fixable to the purlin; (ii) passes through one or both side walls of the crossbar, whereby uplift of the crossbar is substantially prevented; and (iii) is substantially C-shape, and optionally further comprises one or more strengthening ridge that may be pressed into each leg member prior to each leg member being bent or folded into the substantially C-shape.
2. The roofing spacer of claim 1, wherein each of the plurality of leg members passes through or is adapted to pass through an opening or a respective opening comprised in one or both of the side walls of the crossbar.
3. The roofing spacer of claim 1 or claim 2, wherein the crossbar comprises holes which align with corresponding holes in each of the leg members which allows a user to pass a fastener and/or a tool through the hole in order to fix the spacer to the purlin.
4. The roofing spacer of any one of the preceding claims, wherein one or more of the plurality of leg members optionally includes supplementary bracing between the upright portion of the leg member and the lower portion of the leg member.
5. The roofing spacer of claim 4, wherein the supplementary bracing is a cross-brace.
6. A roof comprising a roofing spacer according to any one of the preceding claims, optionally further comprising any one or more of: roofing sheets secured, directly or indirectly, to the crossbar; and insulating material between the roofing sheets and the purlin, wherein the insulating material is substantially non-compressed.