AU2015213247B2 - A roof - Google Patents
A roof Download PDFInfo
- Publication number
- AU2015213247B2 AU2015213247B2 AU2015213247A AU2015213247A AU2015213247B2 AU 2015213247 B2 AU2015213247 B2 AU 2015213247B2 AU 2015213247 A AU2015213247 A AU 2015213247A AU 2015213247 A AU2015213247 A AU 2015213247A AU 2015213247 B2 AU2015213247 B2 AU 2015213247B2
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- AU
- Australia
- Prior art keywords
- roof
- battens
- sheets
- roof cladding
- sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B7/00—Roofs; Roof construction with regard to insulation
- E04B7/02—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
- E04B7/022—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of a plurality of parallel similar trusses or portal frames
- E04B7/024—Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of a plurality of parallel similar trusses or portal frames the trusses or frames supporting load-bearing purlins, e.g. braced purlins
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
- E04D12/004—Battens
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/36—Connecting; Fastening
- E04D3/365—Connecting; Fastening by simple overlapping of the marginal portions with use of separate connecting elements, e.g. hooks or bolts for corrugated sheets
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S20/00—Solar heat collectors specially adapted for particular uses or environments
- F24S20/60—Solar heat collectors integrated in fixed constructions, e.g. in buildings
- F24S20/67—Solar heat collectors integrated in fixed constructions, e.g. in buildings in the form of roof constructions
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/40—Arrangement of stationary mountings or supports for solar heat collector modules using plate-like mounting elements, e.g. profiled or corrugated plates; Plate-like module frames
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
- E04D3/30—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of metal
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S20/00—Solar heat collectors specially adapted for particular uses or environments
- F24S2020/10—Solar modules layout; Modular arrangements
- F24S2020/13—Overlaying arrangements similar to roof tiles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/20—Solar thermal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
Abstract
A roof includes a roof frame and a plurality of roof cladding sheets (9) mounted to the roof frame. The roof frame includes a plurality of trusses (17) extending between a gutter and a ridge of the roof and a plurality of horizontally-extending battens (19) (with double top hat profile) mounted to the trusses. The roof cladding sheets extend horizontally across the roof and are mounted to the trusses and supported by the battens. Also claimed is the roof cladding sheet (9) of minimum dimensions, a solar panel mounting section, a reinforcing rib, a downturned lip and intermediate pan section. Also claimed is a batten spacer member (43).
Description
A ROOF
TECHNICAL FIELD
The present invention relates to a roof for a building that includes a roof cladding sheet and a roof frame that supports the roof cladding sheet.
The present invention also relates to a roof cladding sheet for a building.
In particular, the present invention relates to a roof that can provide useful functions in addition to the basic function as a weatherproof covering for a building. The additional useful functions may include any one or more of the following functions: converting solar energy into other forms of energy (such as electrical and/or thermal); acoustics; and fire resistance.
The present invention relates particularly although by no means exclusively to a solar roof panel assembly that includes a roof cladding sheet and a solar roof panel, which may be a solar (PV) roof panel, for converting solar energy into another form of energy, such as electrical energy, mounted on the roof cladding sheet.
The term “solar roof panel” is understood herein to mean a panel that can convert solar energy into another form of energy, such as electrical or thermal energy, and can be mounted to a roof of a building. By way of example, one type of solar roof panel of interest to the applicant includes a photovoltaic cell module for converting solar energy into electrical energy.
The present invention also relates particularly although by no means exclusively to a system for generating electrical energy from solar energy using the solar roof panel mounted on the roof cladding sheet.
BACKGROUND ART
The roof of a residential or a commercial building is a convenient surface for mounting a solar energy conversion unit for converting solar energy into electrical energy and/or thermal energy that can be used in the building and/or a local electricity network.
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The following description of the background art and of the invention focuses on but is not confined to this function of a roof. More specifically, the invention is not confined to providing a surface for mounting a solar energy conversion unit.
Traditionally, roof cladding sheets for a residential building are custom-cut to a length required to cover a distance from an eave to a ridge of a roof. This eliminates a number of joins in the roof sheets, particularly along the sheet length. However, custom-cutting sheets to length can have an impact on cost.
The roll forming industry in Australia tends towards very short lead times (sometimes as low as 24 hours) from placement of an order to delivery. This makes the production of Building Integrated (BIPV) roof panels difficult. A BIPV roof panel is manufactured by adhering a photovoltaic (PV) panel to a roof cladding sheet. This extra step in the manufacturing process can significantly increase the lead time and hence delay the delivery of BIPV roof panels to site.
There are limited references in the prior art patent literature to mounting roof cladding sheets for a residential building extending horizontally across the roof. The roof cladding sheets known to the applicant from the patent literature are complicated profiles from manufacturing and installation perspectives and are not suited for mounting solar energy conversion units.
The above description should not be taken to be an admission of the common general knowledge in Australia or elsewhere.
SUMMARY OF THE DISCLOSURE
The present invention provides a roof that includes a roof frame and a plurality of roof cladding sheets secured to the roof frame, with the roof frame including a plurality of trusses extending between a gutter and a ridge of the roof and a plurality of horizontally-extending battens secured to the trusses, with the roof cladding sheets extending horizontally across the roof and secured to the trusses and supported by the battens.
The battens make it possible for the roof cladding sheet to be formed with a wide flat pan as a non-structural member in the sense that it is not necessary for the roof cladding sheet to be formed to be the sole support for the weight of a person standing in
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PCT/AU2015/000048 the centre of the wide pan on the sheet when the sheet is secured to the trusses of the roof frame, for example when the trusses are spaced apart in accordance with building industry standards. The battens provide the additional support required so that the assembly of the trusses, the battens and the roof cladding sheets can support the weight of a person standing on the sheets without significant deformation of the sheets. More specifically, the combination of the trusses and the battens provides effective support for the roof cladding sheets (in combination with the structural capacity of the cladding sheets, bearing in mind the above comment that the sheets can be a non-structural member) and provides an opportunity for a roof to be constructed that can carry a trafficable load on the roof cladding sheets. This is an advantage in terms of installation of the roof cladding sheets on the roof frame.
In particular, the battens are advantageous in relation to the end lap or join between successive roof cladding sheets across a roof. The end lap or join is a potential weak spot of the roof in that it may not be able to support the same load as the roof cladding sheets. In order to overcome this, without the battens, the roof cladding sheets would need to be of larger cross sectional stiffness or the end lap or join would need to coincide with a truss (which may be described as a rafter). The battens enable the end lap or join to be placed between truss frames, with the end lap or join being supported directly by the battens.
The battens and the roof cladding sheets may be positioned so that the battens are mid-way between the sides of the roof cladding sheets.
The battens may be secured to the trusses of the roof frame by any suitable fastener systems.
The battens may be formed from any suitable material.
The battens may be any suitable length and any suitable width and any suitable profile.
Typically, the battens do not cover a significant part of the surface area of the roof. Battens covering a significant part of the surface area of a roof is a feature of one reference in the patent literature. In this reference, the battens are provided in large part for the safety of roof installers working on a roof during the installation of the roof. The prior art battens cover a substantial part of the surface area of the roof and form a barrier to installers falling through the roof. This is not a primary driver for the battens
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PCT/AU2015/000048 of the invention. In the invention, the primary function of the battens is to act as structural members to support roof cladding sheets. Typically, the battens cover no more than 30%, typically no more than 25%, of the surface area of the roof.
The battens may be formed from steel strip.
Each batten may include at least one rib extending along the length of the batten to contribute to the rigidity of the batten.
Each batten may include a pair of parallel ribs separated by a central pan.
The rib or ribs may include a flat mounting surface for the roof cladding sheets.
Each batten may be formed so that when the batten is secured to the trusses, the flat mounting surface of the rib or ribs forms a plane that is at a required angle to the trusses for securing the roof cladding sheets to the roof frame.
The roof may include a spacer member setting the spacing of the battens with respect to each other.
The time required for installing the battens can be reduced by means of the spacer members. The spacer members can be left in place to provide additional support for the roof cladding sheets, particularly at the end laps. Alternatively, the spacer members can be removed after the battens are installed on an underlying roof frame structure.
The spacer member may extend between and be secured to adjacent battens and thereby set the spacing of the battens with respect to each other.
The spacer member may be detachably secured to the battens.
Each spacer member may have ends that are shaped to conform to a least a section of the profile of the battens so that the ends overlie the sections of the battens.
The battens may be formed to facilitate locating the spacer members in relation to the battens.
For example, each batten may include cut-out sections that define locations for the spacer members at spaced intervals along the length of the batten.
The spacer member may be secured to the battens by any suitable fastener systems.
The spacer member may be made from any suitable material.
The sides of adjacent roof cladding sheets may be in overlapping or abutting relationship.
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The roof cladding sheets may be any suitable profile and dimensions.
Typically the roof cladding sheets are quadrilateral.
Typically, the roof cladding sheets may have the following dimensions - at least m in length and at least 250 mm, typically at least 300 mm, more typically at least 350 mm, and more typically less than 500 mm in width.
Each roof cladding sheet may be profiled to include a pan section, typically a wide [an, and optionally includes side edge formations that enable a plurality of the sheets to be positioned side by side in abutting or overlapping relationship.
The side edge formations may be a reinforcing rib extending along one side and a downturned lip extending along the other side of the roof cladding sheet.
The reinforcing rib may be in the form of an elongate channel.
With this arrangement, the sides of adjacent roof cladding sheets may be in overlapping relationship with the downturned lip along the side of one roof cladding sheet overlapping the reinforcing rib along the side of an adjacent roof cladding sheet.
The pan section of each roof cladding sheet may be a mounting section for a solar roof panel on the sheet between the side edge formations.
The pan section of the roof cladding sheet may be a wide pan in that the pan section is at least 85%, typically at least 90%, of the total upper surface of the roof cladding sheet.
The reinforcing ribs and the downturned lips are advantageous in terms of facilitating mounting adjacent roof cladding sheets in overlapping relationship on the roof frame.
Typically, the first roof cladding sheets that are installed on a roof frame are the sheets at a gutter line of the roof, with the downturned lip of each roof cladding sheet in a first line of sheets being positioned adjacent the gutter line and the reinforcing rib of each sheet being positioned on the roof frame away from the gutter line. Alternatively the first sheet may be a narrower profiled sheet, whereby the reinforcing rib is located close to the gutter line. The reinforcing ribs of the sheets in this first line provide effective reference points for locating the next line of roof cladding sheets on the roof frame. Specifically, the downturned lip of each roof cladding sheet in the next line of sheets is positioned to overlie the reinforcing ribs of the roof cladding sheets in the first line of sheets and thereby provide continuous coverage at the overlap. Hence, the
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PCT/AU2015/000048 reinforcing ribs of the roof cladding sheets in the first line of sheets cooperate with the downtumed lips of the roof cladding sheets in the next line of sheets to locate the next line of sheets on the roof frame.
Another method of installation is to provide a gap between the reinforcing ribs of the roof cladding sheets in one line of sheets and the downturned lips of roof cladding sheets in the next line of sheets. By providing this gap, the cover of the sheets can be adjusted within limits of 1 to 20 mm to take into account roof runs which are not a integer multiple of the roof sheet cover width. Ideally, marks are printed or embossed on roof cladding sheets to facilitate aligning the sheets to give an even space between o the adjacent reinforcing ribs and the downturned overlap rib.
The reinforcing ribs and the downtumed lips are also advantageous because installing roof cladding sheets on the roof frame with the downturned lips of the sheets on the gutter line provides an opportunity, optionally in conjunction with suitable flashing, to close the roof at the gutter line and minimise the risk of ember entry into a 15 roof space at the gutter line.
The roof may include a flashing sheet between a gutter line of the roof and a first line of roof cladding sheets adjacent the gutter line.
The flashing sheet may include a reinforcing rib extending along one side of the sheet. With this arrangement, the downturned lip of each roof cladding sheet in the first
0 line of roof cladding sheets overlies the reinforcing rib of the flashing sheet.
The roof cladding sheets may be mounted to the roof frame, more particularly the trusses, by any suitable fastener systems.
Secret fix fastening may be used, subject to the shape of the reinforcing rib being adapted to be retained by a secret fix fastener, such as a screw or a concealed clip.
5 The roof may include a plurality of solar roof panels mounted to at least some of the roof cladding sheets.
Each solar roof panel may include (a) a photovoltaic cell module for converting solar energy into electrical energy and (b) electrical components, such as a wiring junction box and electrical cables and other devices, for transferring electrical energy
0 from the solar roof panel for use in an electrical system of the building or a local electrical network.
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The roof may also include other functionality in addition to or instead of solar functionality, including but not limited to functionality in relation to thermal, acoustics and fire resistance.
The roof may be a pitched roof.
The present invention also provides a roof cladding sheet that has a pair of parallel sides and is profiled to include a pan section and side edge formations that enable a plurality of the sheets to be positioned side by side in abutting or overlapping relationship, with the side edge formations including a reinforcing rib extending along one side and a downtumed lip extending along the other side.
o The roof cladding sheet may be a quadrilateral sheet.
The roof cladding sheet may be any suitable dimensions.
Typically, the roof cladding sheet may have the following dimensions - at least 2 m in length and at least 250 mm, typically at least 300 mm, more typically at least 350 mm, and more typically less than 500 mm in width.
The mounting section may be a flat surface.
The mounting section may include stiffening ribs. The stiffening ribs may be formed to hide any defects such as oil-canning.
The roof cladding sheet may be formed to maximise the area of the mounting section as a proportion of the total surface area of the sheet and therefore, by way of o example, maximise the proportion of the surface area of the roof cladding sheet that is covered by the solar roof panel. The mounting section of the roof cladding sheet may be at least 85%, typically at least 90%, of the total upper surface of the roof cladding sheet.
The roof cladding sheet may include the solar roof panel mounted to the
5 mounting section of the sheet.
In other words, the invention extends to a roof cladding sheet per se and to a BIPV panel in the form of a solar roof panel assembly that includes (a) a roof cladding sheet and (b) a solar roof panel mounted to the roof cladding sheet.
The reinforcing rib may be any suitable profile.
o The reinforcing rib may be a channel shape and include a top wall and two opposed side walls.
The solar roof panel may be any suitable panel.
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The solar roof panel may include (a) a photovoltaic cell module for converting solar energy into electrical energy and (b) electrical components, such as a wiring junction box and electrical cables and other devices for transferring electrical energy from the solar roof panel for use in an electrical system of the building or a local electrical network.
The solar roof panel may be in the form of a flexible film.
The photovoltaic cell module may include a semi-conductor material electrodeposited or otherwise deposited on an electrically-conductive, such as stainless steel or plastic, flexible substrate and encapsulated in a moisture barrier laminate material.
The photovoltaic cell module may include organic photovoltaic material encapsulated in a moisture barrier laminate material.
The photovoltaic cell module may include organic or semi-conductor material directly applied/deposited on the profiled sheet and encapsulated in a moisture barrier laminate material.
The roof cladding sheet may be made from any suitable material. Steel is one suitable material.
The roof cladding sheet may be formed from strip steel, for example by pressforming or roll-forming painted or unpainted steel strip into a required profile.
The roof cladding sheet may be formed from extruded aluminium.
The roof cladding sheet may be formed from injection-moulded plastics material.
The roof cladding sheet may be formed from metallic strip, for example by press-forming or roll-forming painted or unpainted aluminium or copper strip into a required profile.
The present invention also provides a method of installation of roof cladding sheets that includes laying successive roof cladding sheets horizontally on a roof frame starting at a gutter edge of the roof frame and working up the roof frame to a ridge of the frame, with the roof cladding sheets being laid in side by side overlapping relationship and being supported on roof trusses of the roof frame that extend between the gutter edge and the ridge and battens of the roof frame that extend horizontally and are secured to the trusses.
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The present invention also provides BIPV panel in the form of a solar roof panel assembly that includes (a) the above-described roof cladding sheet and (b) a solar roof panel mounted to the roof cladding sheet.
The present invention also provides a system for generating electrical energy from solar energy that includes converting solar energy that is incident on solar panels on the above-described roof into electrical energy.
The system may include an inverter system for transferring electrical energy to an electrical system of the building or a local electrical network.
The present invention also provides a spacer member for setting the spacing of the battens of the above-described roof with respect to each other, the spacer being an elongate member having ends that are shaped to conform to a least a section of the profile of the battens so that the ends overlie the sections of the battens
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described further, by way of example only, with reference to the accompanying drawings of which:
Figure 1 is a perspective view of a section of a roof of a building in accordance with one embodiment of the invention having a plurality of roof cladding sheets in accordance with one embodiment of the invention mounted to the roof frame and solar roof panels mounted on the roof cladding sheets;
Figure 2 is a side view of the section of the partially-constructed roof shown in Figure 1;
Figure 3 is an enlarged side elevation of the section of the partially-constructed roof shown in Figure 1;
Figure 4 is a perspective view of three roof cladding sheets used in the construction of the section of the partially-constructed roof shown in Figure 1;
Figure 5 is a perspective view of one of the roof cladding sheets;
Figure 6 is a side view of one of the roof cladding sheets;
Figure 7 is a perspective view of a section of a roof of a building in accordance with another, although not the only other, embodiment of the invention having a
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PCT/AU2015/000048 plurality of roof cladding sheets in accordance with another, although not the only other, embodiment of the invention mounted to the roof frame;
Figure 8 is a perspective view showing in more detail one part of the section of the partially-constructed roof shown in Figure 7;
Figure 9 is a perspective view of a batten that is part of the section of the partially-constructed roof shown in Figure 7;
Figure 10 is an end view of the batten shown in Figure 9;
Figure 11 is a top plan view of the batten shown in Figure 9;
Figure 12 is a perspective view of three battens and two batten spacer members that are part of the section of the partially-constructed roof shown in Figure 7;
Figure 13 is a perspective view of one of the batten spacer members shown in Figure 12;
Figure 14 is a side view of the batten spacer member shown in Figure 13; and
Figure 15 is a top plan view of the batten spacer member shown in Figure 13.
DESCRIPTION OF AN EMBODIMENT
The partially-constructed hip roof, including the separate components of the roof, in accordance with one embodiment of the invention shown in Figures 1 to 6 includes:
(a) a roof frame, (b) a plurality of roof cladding sheets 9 in accordance with one embodiment of the invention mounted to the roof frame, (c) a plurality of solar roof panels 15 mounted to the roof cladding sheets 9, (d) a gutter 7, and (e) a roof flashing sheet 11 that extends between the gutter 7 and a first roof cladding sheet 9 adjacent the gutter 7.
The roof frame includes a plurality of parallel spaced-apart upright A-frame assemblies that are connected together. Each A-frame assembly includes a pair of trusses 17 that extend downwardly and outwardly from an apex of the A-frame assembly. The trusses 17 extend between a gutter line and a ridge of the roof frame.
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The roof frame also includes a plurality of horizontal battens 19 mounted to the trusses 17 at spaced intervals from the gutter line to the ridge of the roof frame. The roof cladding sheets 9 are mounted directly to the trusses 17 and the battens 19 by any suitable fastening means, such as fasteners, adhesives and concealed clips. Alternatively, the roof cladding sheets 9 may be mounted directly to the trusses 17 and positioned to be supported by and not fastened to the battens 19. The positions of the battens 19 are selected so that the roof cladding sheets 9 are positioned on the battens 19 mid-way between the sides of the roof cladding sheets 9 in the assembled roof.
With reference to Figure 3, the battens 19 are formed from steel strip and include a pair of parallel ribs 61 separated by a central pan 65. The ribs 61 are formed to define a flat mounting surface for the roof cladding sheets 9. More specifically, as can be seen in Figure 3, the battens 19 are formed so that when the battens 19 are mounted to the trusses 17, the flat mounting surfaces of the ribs 61 forms a plane that is at a required angle a to the trusses for mounting the roof cladding sheets 9 on the roof frame.
The partial construction shown in Figures 1 to 3 reveals the location of the roof cladding sheets 9 on the underlying roof frame.
The roof cladding sheets 9 are arranged to run horizontally across the roof.
With reference particularly to Figures 5 and 6, each roof cladding sheet 9 is rollformed or pressed from steel strip and is generally quadrilateral in shape and of any suitable length and width, typically at least 2 m long and at least 250 mm wide, and includes:
(a) a pair of parallel sides 21, (b) a pair of parallel ends 23, (c) a reinforcing rib 25 in the form of a channel extending along one side 21, with the rib 25 including a top wall 31 and two side walls 33, (d) a downtumed lip 27 extending along the other side 21, and (e) a mounting section 29 in the form of a flat surface for mounting a solar roof panel 15 on the sheet between the sides 21, with the flat surface maximizing the surface area of contact between the solar roof panel 15 and the mounting section 29, and with the flat surface being at least 85%, typically at least 90%, of the total upper surface of the roof cladding sheet 9.
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The roof cladding sheet 9 is not formed as a structural member in the sense that it can support without significant deformation the weight of a person standing on the sheet when the sheet 9 is mounted to the trusses 17 of the roof frame. The battens 19 are provided in the roof structure to provide the additional support required so that the assembly of the trusses 17, the battens 19 and the roof cladding sheets 9 can support without significant deformation the weight of a person standing on the sheets 9.
The reinforcing rib 25 of the roof cladding sheet 9 strengthens the sheet. In addition, the reinforcing rib 25 contacts the roof frame.
The reinforcing rib 25 and the downtumed lip 27 of the roof cladding sheet 9 are 10 formed to facilitate mounting adjacent roof cladding sheets 9 in overlapping relationship on the roof frame, as shown in Figures 1 to 4. As can best be seen in Figure 3, the downtumed lip 27 of one roof cladding sheet 9 overlaps the channelshaped reinforcing rib 25 of an adjacent roof cladding sheet 9 and thereby ensures continuous coverage at the overlap.
The reinforcing ribs 25 and the battens 19 are advantageous because they provide the stiffness that enables the roof cladding sheets to withstand wind loading and point loading associated with installation.
It is evident from Figures 1 to 3 that the area the solar roof panels 15 occupy is a substantial part of the area of roof cladding sheets 9 on which they are mounted. This is 2 o important from a perspective of optimizing solar collection. It is noted that the area may be any suitable area.
Each solar roof panel 15 includes (a) a photovoltaic cell module formed as a flexible film for converting solar energy into electrical energy and (b) electrical components, such as a wiring junction box and electrical cables and other devices for 2 5 transferring electrical energy from the solar roof panel for use in an electrical system of the building or a local electrical network.
With particular reference to Figure 2, the flashing sheet 11 includes a reinforcing rib 37 extending along one side of the sheet and a flat section 41.
Typically, the following steps are followed to install roof cladding sheets 9 on a 30 roof frame.
• The battens 19 and the spacer members 43 (described below) are installed as part of the roof frame.
11243549_1 (GHMatters
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PCT/AU2015/000048 • The flashing sheet 11 is positioned on the roof frame so that the flat section 41 extends over the channel defined by the gutter 7.
• A first line of roof cladding sheets 9 (only one of which is shown in the Figures) is then positioned so that the downturned lip 27 of each sheet overlies the reinforcing rib 37 of the flashing sheet 11. The roof cladding sheets 9 in the first line partially cover the roof frame, with the sheets 9 contacting and being supported by a lower line of battens 19 of the roof frame and the reinforcing ribs 25 of the sheets 9 also contacting and being supported by the trusses 17 of the roof frame. The reinforcing ribs 25 of the roof cladding sheets 9 in this first line provide effective reference points for locating the next line of roof cladding sheets (only one of which is shown in the Figures) on the roof frame.
• A second line of roof cladding sheets 9 (only one of which is shown in the Figures) is positioned on the roof frame. The downturned lip 27 of each roof cladding sheet 9 in the second line of sheets is positioned to overlie the reinforcing ribs 25 of the roof cladding sheets 9 in the first line of sheets and thereby provide continuous coverage at the overlap. Hence, the reinforcing ribs 25 of the roof cladding sheets in the first line of sheets cooperate with the downturned lips 27 of the roof cladding sheets 9 in the next line of sheets to locate the next line of sheets 9 on the roof frame.
• Each successive line of roof cladding sheets 9 is installed in the same way up the roof frame to the ridge of the roof.
• When roof cladding sheets 9 are installed on both sides of the hip roof shown in the Figures, a ridge cap is positioned on the roof ridge to complete the installation.
The partially-constructed hip roof, including the separate components of the roof, in accordance with another, although not the only other, embodiment of the invention shown in Figures 7 to 15 is very similar to the embodiment of the invention shown in Figures 1 to 6 and the same reference numerals are used to describe the same structural features of (a) the roof frame and (b) the roof cladding sheets.
It is noted that the solar roof panels 15 are not shown located on the roof cladding sheets 9 in order to simplify the drawings.
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In addition to the components of the roof frame shown in Figures 1 to 6, the roof frame shown in Figures 7 to 15 also includes a plurality of batten spacer members 43 which extend between and are secured to adjacent battens 19 and set the spacing of the battens 19 with respect to each other. The time required for installing the battens 19 can be reduced by means of the spacer members 43 and the spacer members are advantageous on this basis. In addition, the spacer members 43, if positioned correctly, can provide additional support for the roof cladding sheets 15, particularly at the end laps of successive sheets 15 in a line of the sheets 15.
Figure 7 shows four spacers members 43 in a line at a location of the roof frame o that coincides with end laps of successive roof cladding sheets 9 in each horizontal line of sheets 9 across the roof.
With reference to Figures 7 to 15, particularly Figures 12 to 15, the spacer members 43 are formed so that elongate sections 47 of the members 43 are platforms on which the overlapping ends of successive roof cladding sheets 9 in each line can be supported directly.
Each spacer member 43 includes ends 49 that are shaped to conform to a rib section of the profile of the battens 19 so that the ends 49 overlie the rib sections of the battens 19.
With reference to Figures 9 to 12, and as is the case with the embodiment shown
0 in Figures 1 to 6, the battens 19 include a pair of parallel ribs 61 separated by a central pan 65. In addition, the battens 19 include cut-out sections 45, which could be described as notches, in both sides of the battens 19 at spaced intervals along the length of the battens 19. The cut-out sections 45 facilitate locating the spacer members 43 in relation to the battens 19.
With reference to the embodiments shown in Figures 1 to 6 and Figures 7 to 13, the reinforcing ribs 25 and the downtumed lips 27 of the roof cladding sheets 9 are advantageous in terms of facilitating mounting adjacent roof cladding sheets 9 in overlapping relationship on the roof frame.
The reinforcing ribs 25 and the downturned lips 27 of the roof cladding sheets 9 o are also advantageous components because installing roof cladding sheets 9 with the downtumed lips 27 of the sheets on the gutter line provides an opportunity, in
WO 2015/113111
PCT/AU2015/000048 conjunction with the flashing sheet 11, to close the roof at the gutter line and minimise the risk of ember entry into a roof space at the gutter line of the roof.
In addition, the combination of the reinforcing ribs 25 of the roof cladding sheets 9 and the battens 19 and the trusses 19 of the roof frame provides effective support for the roof cladding sheets 9 on the roof frame and provides an opportunity for a roof to be constructed that can carry a trafficable load in situations where the roof cladding sheets 9 are not structural members. This is an advantage in terms of installation of the roof cladding sheets 9 on the roof frame.
In addition, the roof cladding sheets 9, in conjunction with the battens 19 of the roof frame, can be used without the support of plywood or other structural sheeting substrate that is required for other horizontal roof cladding sheet systems known to the applicant.
In addition, the roof cladding sheets 9 can be manufactured as modular, i.e. preset stock, lengths and hence can be manufactured to stock, with a small selection of stock lengths, ahead of time and drawn from that stock as required. This enables shorter lead times to meet customer requirements.
Many modifications may be made to the embodiments of the invention described herein without departing from the spirit and scope of the invention.
By way of example, whilst the embodiments of the invention described in
0 relation to the Figures include particular profiles for the roof cladding sheets 9, it can readily be appreciated that the invention is not limited to these particular profiles and extends to any suitable profiles.
In addition, by way of example, whilst the embodiments of the invention described in relation to the Figures include particular roof configurations, it can readily
5 be appreciated that the invention is not limited to these configurations.
In addition, by way of example, whilst the embodiments of the invention described in relation to the Figures include roof frames having a plurality of parallel upright A-frame assemblies, it can readily be appreciated that the invention is not limited to this arrangement.
0 In addition, by way of example, whilst the embodiments of the invention described in relation to the Figures include battens 19 having profiles in the form of a
WO 2015/113111
PCT/AU2015/000048 pair of ribs separated by a central pan, it can readily be appreciated that the invention is not limited to this arrangement and extends to any suitable batten profile.
In addition, by way of example, whilst the spacer members 43 of the embodiment of the invention described in relation to Figures 7 to 15 is formed to span a pair of adjacent battens 19 only, it can readily be appreciated that the invention is not limited to this arrangement and the spacer members may be formed to span multiple battens 19.
In addition, by way of example, whilst the spacer members 43 of the embodiment of the invention described in relation to Figures 7 to 15 have end formations that overlap adjacent battens 19 and the battens 19 have cut-out sections 45 in the sides of the battens 19 to facilitate this arrangement, it can readily be appreciated that the invention is not limited to this arrangement and extends to other arrangements such as tongue and slot arrangements in the ends of the spacer members 43 and in the battens 19. By way of particular example, the battens 19 may be formed with a series of slots in the ribs 61 of the battens 19 at spaced intervals along the length of the ribs and the ends of the spacer members 43 may be formed with tongues that can extend into the slots to interconnect the battens 19 and the spacer members 43.
In addition, by way of example, whilst the embodiments of the invention described in relation to the Figures include solar roof panels 15, it can readily be appreciated that the invention is not limited and extends to roofs that do not include any solar roof panels 15 and to arrangements that provide alternative functionality (acoustics, thermal storage, fire solutions) with or without solar functionality.
In the claims which follow, and in the preceding description, except where the context requires otherwise due to express language or necessary implication, the word “comprise” and variations such as “comprises” or “comprising” are 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 end lap system and components of the end lap system as disclosed herein.
Claims (18)
1. A roof that includes a roof frame and a plurality of roof cladding sheets secured to the roof frame, with the roof cladding sheets being quadrilateral and having two
5 opposed sides and two opposed ends, with the roof frame including a plurality of trusses extending between a gutter and a ridge of the roof and a plurality of horizontally-extending battens secured to the trusses, with each batten including at least one rib extending along the length of the batten that contributes to the rigidity of the batten, with the rib or ribs of each batten including a flat mounting surface that forms a
1 o plane that is at a required angle to the trusses for securing the roof cladding sheets to the roof frame, with the roof cladding sheets extending horizontally across the roof and at least one of the sides of the two sides of the sheets being secured directly to the trusses by a fastener system and supported by the flat mounting surfaces of the battens, and with the roof cladding sheets being positioned so that the flat mounting surfaces of the
15 battens support the sheets between the sides of the sheets.
2. The roof defined in claim 1 wherein the battens are formed from steel strip.
3. The roof defined in preceding claim 1 or claim 2 wherein the battens and the roof cladding sheets are positioned so that the battens are mid-way between the sides of the roof cladding sheets.
2 0
4. The roof defined in any one of the preceding claims includes a spacer member setting the spacing of the battens with respect to each other.
5. The roof defined in claim 4 wherein the the spacer member is an elongate member having ends that are shaped to conform to a least a section of the profile of the battens so that the ends overlie the sections of the battens.
2 5
6. The roof defined in claim 4 or claim 5 wherein the spacer member is detachably secured to the battens.
7. The roof defined in any one of claims 4 to 6 wherein the battens are formed to facilitate locating the spacer member in relation to the battens.
8. The roof defined in claim 7 wherein each batten includes a cut-out section that
30 defines a location for the spacer member at spaced intervals along the length of the batten.
11243549_1 (GHMatters
2015213247 08 Apr 2019
9. The roof defined in any one of the preceding claims wherein the sides of adjacent roof cladding sheets are in overlapping or abutting relationship.
10. The roof defined in any one of the preceding claims wherein each roof cladding sheet is at least 2 m in length and at least 250 mm in width.
5
11. The roof defined in any one of the preceding claims wherein each roof cladding sheet is profiled to include a pan section and side edge formations that enable a plurality of the sheets to be positioned side by side in abutting or overlapping relationship.
12. The roof defined in claim 11 wherein the side edge formations include a reinforcing rib extending along one side and a downturned lip extending along the other
1 o side of the roof cladding sheet.
13. The roof defined in claim 12 wherein the reinforcing rib is in the form of an elongate channel.
14. The roof defined in claim 12 or claim 13 wherein the sides of adjacent roof cladding sheets are in overlapping relationship with the downturned lip along the side
15 of one roof cladding sheet overlapping the reinforcing rib along the side of an adjacent roof cladding sheet.
15. The roof defined in any one of claims 11 to 14 wherein the pan section of each roof cladding sheet is a mounting section for a solar roof panel on the sheet between the side edge formations.
2 0
16. The roof defined in any one of claims 11 to 15 wherein the pan section of the roof cladding sheet is at least 85% of the total upper surface of the roof cladding sheet.
17. The roof defined in any one of the preceding claims includes a plurality of solar roof panels mounted to at least some of the roof cladding sheets.
18. The roof defined in any claim 17 wherein each solar roof panel includes (a) a
2 5 photovoltaic cell module for converting solar energy into electrical energy and (b) electrical components, such as a wiring junction box and electrical cables and other devices, for transferring electrical energy from the solar roof panel for use in an electrical system of the building or a local electrical network.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015213247A AU2015213247B2 (en) | 2014-01-31 | 2015-01-30 | A roof |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2014900291 | 2014-01-31 | ||
| AU2014900291A AU2014900291A0 (en) | 2014-01-31 | A roof | |
| PCT/AU2015/000048 WO2015113111A1 (en) | 2014-01-31 | 2015-01-30 | A roof |
| AU2015213247A AU2015213247B2 (en) | 2014-01-31 | 2015-01-30 | A roof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU2015213247A1 AU2015213247A1 (en) | 2016-08-18 |
| AU2015213247B2 true AU2015213247B2 (en) | 2019-05-02 |
Family
ID=53756039
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2015213247A Active AU2015213247B2 (en) | 2014-01-31 | 2015-01-30 | A roof |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU2015213247B2 (en) |
| WO (1) | WO2015113111A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2019163768A1 (en) * | 2018-02-20 | 2019-08-29 | シャープ株式会社 | Solar cell module and solar photovoltaic power generation system |
Citations (4)
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|---|---|---|---|---|
| US2626577A (en) * | 1948-05-15 | 1953-01-27 | Gen Building Units Inc | Roof panel |
| EP0126719A2 (en) * | 1983-05-19 | 1984-11-28 | Kamino Ab | A roofing element |
| EP1336698A1 (en) * | 2002-02-18 | 2003-08-20 | S.A. Coversys International | Plain tile or slate type roof element |
| FR2963035A1 (en) * | 2010-07-26 | 2012-01-27 | Joseph Nappo | Rectangular shaped panels assembling system for use on battens of roof, has high upstream part engaged between batten and downstream rib of tab, and downstream part curved downward and backward and engaged with extension of another tab |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3284967A (en) * | 1964-03-18 | 1966-11-15 | Us Plywood Corp | Laminated cover elements and flashing and sealing means therefor |
| US3380214A (en) * | 1966-04-11 | 1968-04-30 | Perma Shake Mfg Corp | Metal shingle support clip |
| GB1353902A (en) * | 1970-04-29 | 1974-05-22 | Mcknight D | Cladding of buildings |
| US4379381A (en) * | 1980-06-05 | 1983-04-12 | Emerson H. Mizell | Roof insulation system |
| JPS61287278A (en) * | 1985-06-14 | 1986-12-17 | Takenaka Komuten Co Ltd | Roof unit with solar battery |
| US4715156A (en) * | 1986-09-02 | 1987-12-29 | Duke Insulation Company, Inc. | Support structure for roof insulation in metal buildings |
| US5058352A (en) * | 1990-10-01 | 1991-10-22 | Loiselle Scot D | Barrier system |
| JPH05202578A (en) * | 1992-01-28 | 1993-08-10 | Ig Tech Res Inc | Valley finishing construction |
| GB2267718A (en) * | 1992-06-05 | 1993-12-15 | Steadman & Son Ltd A | Formed metal slate strip |
| WO1999058784A1 (en) * | 1998-05-14 | 1999-11-18 | Rheinzink Gmbh | Covering system for roofs |
| AUPP663998A0 (en) * | 1998-10-21 | 1998-11-12 | Smith, Lachlan Kerry Oliver | A roof and wall sheeting system |
| US20110162301A1 (en) * | 2008-09-10 | 2011-07-07 | Keneka Corporation | Solar Cell Module and Solar Cell Array |
| US20120291382A1 (en) * | 2011-05-18 | 2012-11-22 | Cool Roof Innovations Inc. | Cool roof batten assembly |
-
2015
- 2015-01-30 AU AU2015213247A patent/AU2015213247B2/en active Active
- 2015-01-30 WO PCT/AU2015/000048 patent/WO2015113111A1/en active Application Filing
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2626577A (en) * | 1948-05-15 | 1953-01-27 | Gen Building Units Inc | Roof panel |
| EP0126719A2 (en) * | 1983-05-19 | 1984-11-28 | Kamino Ab | A roofing element |
| EP1336698A1 (en) * | 2002-02-18 | 2003-08-20 | S.A. Coversys International | Plain tile or slate type roof element |
| FR2963035A1 (en) * | 2010-07-26 | 2012-01-27 | Joseph Nappo | Rectangular shaped panels assembling system for use on battens of roof, has high upstream part engaged between batten and downstream rib of tab, and downstream part curved downward and backward and engaged with extension of another tab |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2015113111A1 (en) | 2015-08-06 |
| AU2015213247A1 (en) | 2016-08-18 |
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