AU2018200682A1 - Ridge beam for use in a set of components for constructing a modular roof - Google Patents

Abstract

A ridge beam 5 for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure, for example a garden shed, granny flat, carport or garage. The ridge beam 5 including: an elongate main body 11 having opposing sides for connecting the ridge beam 5 to one or more prefabricated roof panels, and an elongate protective cap member 13 overlying the main body 11 with a gap being provided between the main body 11 and the cap member 13, such that a portion of an adjacent ridge beam 5 is insertable into the gap to interconnect adjacent ridge beams 5. The interconnection of the adjacent ridge beams is advantageously able to be performed without the assembler needing to climb the roof structure being assembled. Fig. 1

Description

FIELD OF THE INVENTION [0001] The present invention relates building components that may be selectively combined to construct a roof of a modular structure, for example a garden shed, granny flat, garage, carport. More specifically, the present invention relates to a ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure.

BACKGROUND TO THE INVENTION [0002] Garden sheds, carports, green houses, gazebos, cubbies, animal cages, aviaries, granny flats and the like are structures which can in some instances be purchased in modular kit form from a retailer and assembled by the consumer at home as a DIY project. The components of kits are often prefabricated to some degree and specially designed and dimensioned for the kit structure to be assembled. This requires retailers to stock a vast array of components are most components are able to be used interchangeably in the construction of different structures. As a result retailers tend to stock only those kits and components which are popular with consumers. This leads to a decrease in consumer choice and a lack of flexibility in design construction.

[0003] A further issue with modular DIY kit structures is that they typically require the installer to climb the structure during construction to assemble the roof components. This can be particularly hazardous and lead to accidents and falls.

[0004] Any discussion of documents, devices, acts or knowledge in this specification is included to explain the context of the invention. It should not be taken as an admission that any of the material formed part of the prior art base or

2018200682 30 Jan 2018 the common general knowledge in the relevant art on or before the priority date of the claims herein.

SUMMARY OF THE INVENTION [0005] In accordance with a first aspect of the invention, there is provided a ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure. The ridge beam including an elongate main body having opposing sides for connecting the ridge beam to one or more prefabricated roof panels, and an elongate protective cap member overlying the main body with a gap being provided between the main body and the cap member, such that a portion of an adjacent ridge beam is insertable into the gap to interconnect adjacent ridge beams.

[0006] The interconnection of adjacent ridge beams in the above manner is advantageously able to be performed when constructing a modular roof without the assembler needing to climb the roof structure being assembled. This advantageously minimises the potential hazards of climbing a structure during assembly.

[0007] The cap member is preferably substantially V-shaped in transverse cross-section and ideally has a length greater than the main body. In one embodiment, the cap member is positioned with respect to the main body such a portion of the cap member overhangs at least one end of the main body to define an overhanging portion, the overhanging portion of an adjacent ridge beam being said portion of an adjacent ridge beam insertable into the gap to interconnect adjacent ridge beams. In a particularly preferred embodiment, the cap member is positioned with respect to the main body such than an overhanging portion is provided at both ends of the main body. This advantageously enables either end of the main body to be inserted into the gap of an adjacent ridge beam.

2018200682 30 Jan 2018 [0008] Each overhanging portion of the cap member has a length and the gap between the cap member and the main body is preferably sized to accommodate within the gap the length of an adjacent ridge beam’s overhanging portion.

[0009] The opposing sides of the main body preferably each include an inwardly projecting flange. The cap member is preferably attached to the flanges by a plurality of fasteners extending through the cap member and the main body. The fastening is preferably performed during manufacturing which advantageously reduces assembly time for the end consumer.

[0010] The fasteners extending through the cap member and main body are preferably spaced from the ends of the main body by a distance greater than the length of the overhanging portion. This advantageously ensures that the fasteners do not impede upon an adjacent ridge beam’s overhanging portion when being inserted into the gap.

[0011] The cap member is preferably made of sheet material having a thickness of about 0.5 mm and the gap between the cap member and the main body is preferably about 1.5 mm. In this regard, a spacer, if required, may be inserted between the cap member and the main body in order to increase the gap between the cap member and the main body to accommodate sheet material of greater thickness.

[0012] The main body of adjacent ridge beams preferably abut one another when the ridge beams are interconnected. This advantageously ensures that the opposing sides of the main body provide a continuous substantially uninterrupted surface on the opposing sides of the main body for connecting prefabricated roof panels to the ridge beam.

[0013] In accordance with a second aspect of the invention, there is provided a set of prefabricated building components for constructing a modular roof of a modular structure, the set including at least two prefabricated roof panels and one

2018200682 30 Jan 2018 or more interconnectable ridge beams in accordance with the first aspect of the invention. The roof panels each have upper ends which are securable to the opposing sides to the main body to define a roof sloping downwardly away from the ridge beam. The cap member of the ridge beam advantageously protects the upper ends of the roof panels from the elements and prevents water entering between the ridge beam and roof panels without requiring any form of adhesive sealant.

[0014] The roof panels preferably each include a frame structure and overlying sheet material secured to the frame structure. The sheet material is preferably positioned such that at least one longitudinal side edge and at least one lateral edge of the sheet material lies flush with a corresponding longitudinal side edge and lateral edge, respectively, of the frame structure. In this respect, the at least one lateral edge of the frame structure is preferably a top edge of the frame structure located at the upper end of the roof panel. The top edge preferably includes one or more fastener holes for securing the roof panel to the main body of the ridge beam.

[0015] A portion of the sheet material preferably extends beyond a longitudinal side edge of the frame structure and overlaps with a portion of the sheet material of an adjacent roof panel when the longitudinal side edges of two of said panels are connected together laterally. In this regard, the longitudinal side edges of the frame structure preferably include one or more fastener holes such that adjacent roof panels are connectable laterally by positioning the longitudinal side edges of adjacent frames in abutment and securing fasteners through said fastener holes. The interconnection of adjacent roof panels in this manner is advantageously able to be repeated to extend the roof dimensions.

[0016] In a further embodiment, the set of prefabricated building components may further include at least two gable members. The gable members being positionable at opposite ends of the roof to provide an enclosed roof cavity underneath the roof panels and ridge beams.

2018200682 30 Jan 2018 [0017] In accordance with a further aspect of the invention there is provided a set of components for constructing a modular structure including:

a set of prefabricated building components in accordance with the second aspect of the invention;

a plurality of prefabricated wall panels each having an upper end securable to the roof panels; and a plurality of corner posts for attaching to wall panels positioned at about 90° to one another.

[0018] The set of components for constructing a modular structure may further include a plurality of base panels. Each base panel including a base frame and at least one floor panel for covering the base frame. The base panels being connectable to the wall panels. In addition, each base panel may further include a plurality of leg members for supporting the base frame.

[0019] To assist the further understanding of the invention, reference will now be made to the accompanying drawings which illustrate preferred embodiments. It is to be appreciated that these embodiments are given by way of illustration only and that the invention is not to be limited by these illustrations.

BRIEF DESCRIPTION OF THE DRAWINGS [0020] Figure 1 is an exploded perspective view of a modular structure in the form of a shed incorporating a modular roof constructed with a set of prefabricated building components including a plurality of ridge beams in accordance with an embodiment of the invention;

[0021] Figure 2 is a perspective view of the shed illustrated in Figure 1 in a fully assembled state;

[0022] Figure 3 is an exploded perspective view of a ridge beam in accordance with an embodiment of the invention;

2018200682 30 Jan 2018 [0023] Figure 4 is an exploded end view of the ridge beam shown in Figure 3;

[0024] Figure 5 is an end view of the ridge beam shown in Figure 3 in a fully assembled state;

[0025] Figure 6 is an enlarged view of a portion of the ridge beam illustrated in Figure 5 detailing the gap between the main body and ridge cap;

[0026] Figure 7 is a side view of the ridge beam in a fully assembled state;

[0027] Figure 8 is a perspective view illustrating the manner in which two adjacent ridge beams are moved longitudinally when being interconnected together;

[0028] Figure 9 is a perspective view of the two ridge beams illustrated in Figure 8 when interconnected together;

[0029] Figure 10a is a perspective view of two adjacent roof panels being connected together;

[0030] Figure 10b is a side view of the two panels illustrated in Figure 10a being connected together;

[0031] Figure 10c is an enlarged view of a portion of the two panels illustrated in Figure 10b illustrating the overlapping of the sheet material of adjacent beams;

[0032] Figure 11a is a perspective view of the underside of a roof illustrating the manner in which two roof panels are attached to opposing sides of a ridge beam;

2018200682 30 Jan 2018 [0033] Figure 11 b is a perspective view of the two panels and ridge beam illustrated in Figure 11a illustrating the connection of the two roof panels to the ridge beam.

DESCRIPTION OF PREFERRED EMBODIMENTS [0034] With reference to Figures 1 and 2 of the accompanying drawings there is shown a modular structure in the form of a shed 1. The shed 1 includes a modular roof 3 which is constructed from a set of prefabricated building components including a plurality of ridge beams 5 which are interconnected end to end. The set of prefabricated building components used to construct the shed 1 further includes at a plurality of prefabricated roof panels 7 securable to the ridge beams, and at least two gable members 9. The gable members 9 being positioned at opposite ends of the modular roof 3 to provide an enclosed roof cavity underneath the ridge beams 5 and roof panels 7.

[0035] With reference to Figures 3 to 9 of the accompanying drawings, each ridge beam 5 includes an elongate main body 11 having opposing sides for connecting the ridge beam 5 to the prefabricated roof panels 7. The ridge beam 5 further includes an elongate protective cap member 13 which overlies the main body 11 with a gap 15 being provided between the main body 11 and the cap member 13 such that a portion of an adjacent ridge beam 5 is insertable into the gap 15 to interconnect adjacent ridge beams 5.

[0036] As best shown in Figures 3, 4 and 5, the cap member 13 is preferably substantially V-shaped in transverse cross-section and has a length greater than the main body 11. As best shown in Figures 3 and 4, opposing sides of the main body 11 each include an inwardly projecting flange 17 which extends along the length of the main body 11 to facilitate fastening of the cap member 13 to the main body 11. In this regard, the cap member 13 is attached to the projecting flanges 17 by a plurality of fasteners 19 which extend through the cap member 13 and main body 11, as best shown in Figure 5. The fasteners 19 are

2018200682 30 Jan 2018 advantageously spaced from the ends of the main body as best shown in Figures 3 and 7.

[0037] With reference to Figure 7, the cap member 13 is preferably positioned with respect to the main body 11 such that a portion of the cap member 13 overhangs at least one end of the main body 11 to define an overhanging portion. In this regard, it is preferred that the positioning of the cap member 13 with respect to the main body 11 is such that an overhanging portion 21 is provided at both ends of the main body 11, as illustrated in Figure 7. The overhanging portion of a ridge beam 5 is able to be inserted into the gap 15 of an adjacent ridge beam 5 in order to interconnect the ridge beams 5 together.

[0038] The gap 15 provided between the cap member 13 and main body 11 is limited by the positioning of the fasteners 19 extending through the cover member into the main body 11. The fasteners 19 are therefore positioned a sufficient distance from the ends of the main body 11 such that the gap 15 provided at both ends of the main body 11 is sized to accommodate within the gap 15 the full length of an adjacent ridge beams overhanging portion 21. In other words, the fasteners 19 are spaced from the ends of the main body 11 by a distance greater than the length of the overhanging portion 21.

[0039] With reference to Figure 6 of the accompanying drawings, the gap 15 between the cap member 13 and the main body 11 is preferably about 1.5 mm which is generally sufficient to accommodate the cap member 13. In this respect, the cap member 13 is preferably made of a sheet material having a thickness of about 0.5 mm. Accordingly, the overhanging portion 21 is in most instances readily able to be accommodated within the gap 15 of an adjacent ridge beam 5. If a gap 15 of greater size is required, one or more spacer washers 23 may be positioned between the cap member 13 and the main body 11 as shown in Figure 4.

2018200682 30 Jan 2018 [0040] With reference to Figures 8 and 9 of the accompanying drawings, adjacent ridge beams 15 are interconnected by the overhanging portion of one ridge beam 5 overlapping with the overhanging portion of an adjacent ridge beam 5 with the subsequent insertion of one or the overhanging portions 21 into the gap 15 of the other ridge beam 5. When the ridge beams are fully interconnected, the main body 11 of the adjacent ridge beams 5 preferably abut one another with opposing ends of the main bodies 11 making contact. This advantageously results in the opposing sides of the main body 11 providing a continuous surface with the opposing side of the main body 11 of the adjacent ridge beam 5, which is particularly advantageous for connecting the roof panels 7 to the ridge beams 5.

[0041] The ridge beams 5 are preferably incorporated in a set of prefabricated building components for constructing a modular roof 3 of a modular structure, for example a shed 1. In this regard, the set of prefabricated building components for the modular roof 3 include two or more prefabricated roof panels 7 and one or more interconnectable ridge beams 5. The roof panels 7 preferably have upper ends securable to the opposing sides of the main body 11 to define a roof sloping downwardly away from the one or more interconnected ridge beams 5. Figures 11a and 11b illustrate the underside of such a roof wherein fasteners are provided at upper ends of the roof panels 7 to secure the roof panels 7 to opposing sides of the main body 11 of the cap member 13. The roof panel 7 preferably each include a frame structure 25 and overlying sheet material 27 secured to the frame structure 25 by a plurality of fasteners extending through the sheet material 27 and into the frame structure 25.

[0042] As shown in Figures 10b and 10c, the sheet material 27 may be corrugated and positioned such that a portion of the sheet material 27 extends beyond a longitudinal side edge of the frame structure 25 such that the portion of sheet material 27 overlaps with a portion of the sheet material 27 of an adjacent roof panel 7 when the longitudinal side edges of two of said panels 7 are connected together side by side, as shown in Figure 10c.

2018200682 30 Jan 2018 [0043] The roof panels 7 are preferably prefabricated in that the corrugated sheet material 27 is attached to the hollow frame structure 25 during manufacturing. Accordingly, an end user only need to attach the roof panels 7 side by side and to the ridge beams 5 during installation. The frame structure 25 is also fully welded with pre-punched fastener holes ready for quick installation using self tapping screw fasteners. The roof panels 7 preferably have a width of approximately 1 metre and are provided in 1 metre and 1.5 metre lengths to suit a variety of applications. The roof panels 7 can be connected to each other about their longitudinal side edges to increase the overall length of the roof to the desired length. For example, four roof panels 7 are provided side by side on both sides of the ridge beams 5 in the shed 1 illustrated in Figures 1 and 2.

[0044] The modular roof 3 constructed using the set of prefabricated building components can be used for any one of a number of different modular structures including sheds, garages, carports, green houses, animal cages, aviaries, horse stables, gazebos, cubby houses and granny flats. The components used in constructing the shed 1 illustrated in Figures 1 and 2 include a plurality of prefabricated wall panels 29 each having an upper end securable to the roof panels 7. The components further include a plurality of corner posts 31 for attaching to wall panels 29 positioned at approximately 90° to one another. In addition, the set of components may further include a plurality of base panels 33. Each base panel 33 includes a base frame 35 and one or more floor panels 37 for covering the base frame 35. The base panels 33 are connectable to the wall panels 29. Each base panel 33 may further include a plurality of leg members 39 for supporting the base frame 35.

[0045] The base frames 35 of the base panels 33 preferably have a width of approximately 1 metre and are provided in 2 or 3 metre lengths. A plurality of base frames 35 is preferably provided with the frames being connectable to one another to provide a base panel of the desired size.

2018200682 30 Jan 2018 [0046] The floor panels 37 of the base panels 33 cover the base frames 35 and may be constructed of a variety of materials including timber, particle board, plywood, plastic or the like. Each floor panel 37 is approximately 1 metre by 1 metre and is secured to the underlying base frame 35 with screws. Additional floor coverings may also be provided on top of the floor panels 37, for example tiles.

[0047] The leg members 39 are each connected to the base frame 35 and vary in length from about 70 mm up to 1000 mm. The leg members 39 are preferably screwed to the base frame 35. When the modular structure is being constructed on a sloped surface, a combination of leg members 39 of appropriate length can be screwed to the base frame 35 in order to provide a level base upon which to construct. Each leg member 39 may include an adjustable foot portion to provide more accurate levelling of the base panels 33.

[0048] In regards to the walls panels 29, each wall panel 29 preferably includes a steel frame which is constructed of rectangular hollow section tube welded together with pre-punched holes. Each frame of the wall panel 29 includes an upper end for securing to the roof panels 7, longitudinal side edges for attaching to adjacent wall panels 29, and a bottom edge for securing to base panels 33. The frame of the wall panels 29 can be made out of other materials such as timber, MDF, plywood, plastic, aluminium and the like. Each wall panel 29 preferably further includes exterior cladding which may be screwed or riveted to the frame of the wall panel 29. The exterior cladding can be made of a variety of materials including timber, weatherboards, plywood, corrugated sheet material, plastic, and the like.

[0049] The components for constructing a modular structure are advantageously able to be assembled by a consumer having minimal technical skills. In this respect, the components are all easily assembled with basic tools such as screwdrivers, spanners and alien keys. Further, each component preferably has a weight of no greater than 15 kg with no drilling, nailing, sawing,

2018200682 30 Jan 2018 welding or digging required to assemble the modular structure. The components are also advantageously able to be disassembled relatively easily when the modular structure is no longer required.

[0050] The set of components for constructing the modular structure are also able to accommodate changes in the required dimensions of the modular structure. All components for constructing the modular structure are also advantageously designed to not exceed 6 metres in length, 0.8 metres in width and 0.1 metres in height. This advantageously assists consumers in transportation of the required components with a trailer or van.

2018200682 30 Jan 2018

Claims (19)

1. CLAIMS:

   1. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure, the ridge beam including:

   an elongate main body having opposing sides for connecting the ridge beam to one or more prefabricated roof panels, and an elongate protective cap member overlying the main body with a gap being provided between the main body and the cap member, such that a portion of an adjacent ridge beam is insertable into the gap to interconnect adjacent ridge beams.
2. 2. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 1 wherein the cap member is substantially v-shaped in transverse crosssection and has a length greater than the main body.
3. 3. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 2 wherein the cap member is positioned with respect to the main body such that a portion of the cap member overhangs at least one end of the main body to define an overhanging portion, the overhanging portion of an adjacent ridge beam being said portion of an adjacent ridge beam insertable into the gap to interconnect adjacent ridge beams.
4. 4. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed 3 wherein the cap member is positioned with respect to the main body such that an overhanging portion is provided at both ends the main body.

   2018200682 30 Jan 2018
5. 5. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claims 3 or 4 wherein each overhanging portion has a length and the gap between the cap member and the main body is sized to accommodate within the gap the length of an adjacent ridge beam’s overhanging portion.
6. 6. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in any one of the preceding claims wherein the opposing sides of the main body each include an inwardly projecting flange, the cap member being attached to the flanges by a plurality of fasteners extending through the cap member and main body.
7. 7. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 6 wherein the fasteners are spaced from the ends of the main body by a distance greater than the length of the overhanging portion.
8. 8. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in any one of the preceding claims wherein the cap member is made of sheet material having a thickness of about 0.5mm and the gap between the cap member and main body is about 1,5mm.
9. 9. A ridge beam for use as a component in a set of prefabricated building components for constructing a modular roof of a modular structure as claimed in any one of the preceding claims wherein the main body of adjacent ridge beams abut one another when the ridge beams are interconnected.
10. 10. A set of prefabricated building components for constructing a modular roof of a modular structure, the set including at least two prefabricated roof panels and one or more interconnectable ridge beams as claimed in any one of the preceding

    2018200682 30 Jan 2018 claims, the roof panels having upper ends securable to the opposing sides of the main body to define a roof sloping downwardly away from the ridge beam wherein, in use, the cap member of the ridge beam protects the upper ends of the roof panels.
11. 11. A set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 10 wherein the roof panels each include a frame structure and overlying sheet material secured to the frame structure, the sheet material being positioned such that at least one longitudinal side edge and at least one lateral edge of the sheet material lies flush with a corresponding longitudinal side edge and lateral edge, respectively, of the frame structure.
12. 12. A set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 11 wherein the at least one lateral edge of the frame structure is a top edge of the frame structure located at the upper end of the roof panel, the top edge including one or more fastener holes for securing the roof panel to said main body of the ridge beam.
13. 13. A set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 12 wherein a portion of the sheet material extends beyond a longitudinal side edge of the frame structure and overlaps with a portion of the sheet material of an adjacent roof panel when the longitudinal side edges of two of said panels are connected together laterally.
14. 14. A set of prefabricated building components for constructing a modular roof of a modular structure as claimed in claim 13 wherein the longitudinal side edges of the frame structure include one or more fastener holes, adjacent roof panels being connectable together laterally by positioning the longitudinal side edges of adjacent frame structures in abutment and securing fasteners through said fastener holes.

    2018200682 30 Jan 2018
15. 15. A set of prefabricated building components as claimed in any one of claims 10 to 14 further including at least two gable members, the gable members being positionable at opposite ends of the roof to provide an enclosed roof cavity underneath the roof panels.
16. 16. A set of components for constructing a modular structure including:

    a set of prefabricated building components as claimed in any one of claims 10 to 15;

    a plurality of prefabricated wall panels each having an upper end securable to the roof panels, and a plurality of corner posts for attaching to wall panels positioned at about 90° to one another.
17. 17. A set of components for constructing a modular structure as claimed in claim 16 further including a plurality of base panels, each base panel including a base frame and at least one floor panel for covering the base frame, the base panels being connectable to the wall panels.
18. 18. A set of components for constructing a modular structure as claimed as claim 17 wherein each base panel further includes a plurality of leg members for supporting the base frame.
19. 19. A set of components as claimed in any one of claims 16 to 18 wherein the modular structure is a shed, garage, green house or granny flat.

    AMIR HOSSEIN MALEKI

    WATERMARK INTELLECTUAL PROPERTY PTY LTD

    P41167AU00

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