AU722751B2 - Rear receiver apparatus and roofing method - Google Patents

Description

1 "REAR RECEIVER APPARATUS AND ROOFING METHOD" This invention relates to rear receiver apparatus and a method of roofing.

This apparatus has particular reference to rear receiver apparatus and roofing methods suitable for use in the construction of domestic patios and the like and for illustrative purposes reference will be had to this application. However, this invention may find use in other applications such as lean-to structures generally.

In general, where roof additions are made to structures such as to provide covering for patios, the roof material is generally affixed to an existing wall or fascia by means of a rear receiver, which generally comprises a channel member supporting the roofing material at the fascia or wall end.

The roofing material of choice is profiled roofing sheet material, the profiling providing the relatively thin sheet with stiffness suitable for roofing over battens or joists.

Pre-painted steel rear receivers may be used, although the lower flange has a tendency to try to "hinge" unless the section is relatively heavy. Extruded alloy rear receivers are relatively rigid for their weight and generally comprise oa.

an elongate C-channel section adapted to be affixed to the fascia. Whatever the material of the rear receiver, the a affixed receiver is adapted to receive the roofing sheet edge into the open face of the C-channel.

The sheet is then generally installed with sealant into the channel in an attempt to prevent water passing to the 2 covered area from the rear receiver. The grouting may be used in conjunction with a sheet-profiled insert as a void filler.

The disadvantage of the grouted approach is that it depends absolutely on the integrity of the grouted seal.

Shrinkage of sealant and imperfections in workmanship result in a leak that is difficult or impossible to locate due to tracking and is difficult to repair. The sealing is also labour intensive in an industry where labour is generally quite unskilled.

In addition to sealing with sealant, a closed cell foam sealing strip may be adapted to be compressed by the sheet edge against the rear wall of the rear receiver. Where sealing foam is used, the sealing of the sheet edge may depend on the closed cell foam to provide a seal. If there is any imperfection, or if the sheet edge cuts into the foam, the leakage through to the patio space beneath may also be irreparable without dismantling the roof structure.

Use of closed cell foam in the C-channel requires great care on the part of the installer. Mounting screws tend to 20 interfere with the foam by causing locally raised portions which results in impaired sealing at these critical points.

Additionally, prior art methods and apparatus do not particularly seal in the optimum positions for sealing such as at the bottom or top portions of the sheet profile.

The present invention aims to substantially alleviate at least one of the above disadvantages and to provide rear receiver apparatus and roofing methods which will be reliable a..

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a. 3 and efficient in use. Other objects and advantages of this invention will hereinafter become apparent.

With the foregoing and other objects in view, this invention in one aspect resides broadly in a method of roofing including the steps of:providing rear receiver apparatus including mounting means for weatherproof attachment to a fascia or the like, roofing member support means, sealing means adapted to engage said roofing member, and drain means disposed between said sealing means and said mounting means; securing said rear receiver apparatus to the fascia or the like, and securing a roofing member on said support means in engagement with said sealing means.

In a further aspect, this invention resides broadly in a rear receiver apparatus including:aaci a mounting means for weatherproof attachment to a fascia or the like; roofing member support means; S 20 sealing means adapted to engage said roofing member, and drain means disposed between said sealing means and said a.° mounting means.

The rear receiver apparatus may comprise an integrally formed or fabricated rear receiver body portion. The body portion may be formed by any suitable means including -o continuous roll formed or extruded metal section. Whilst the body member may be roll formed in steel or aluminium, or cast or formed in plastics or the like, it may comprise an aluminium alloy extrusion to provide the body member.

The mounting member may comprise for example an integrally formed continuous web portion of the rear receiver apparatus or alternatively may comprise a separable mounting bracket or the like. The mounting of the mounting member in weatherproof fashion to a fascia or the like may take any suitable form.

For example the mounting member may be configured with a bonding surface capable of being adhered to the fascia or the like with or without additional fixings.

However, the use of sealants or adhesives renderers the apparatus difficult to remove for maintenance or replacement, and depends for its sealing integrity on the skill of the installer. Accordingly it may be that the rear portion be adapted to make weatherproof connection with the fascia or the like by means of sealing members adapted to be interposed therebetween. The sealing members may provide the weatherproof seal as a consequence of the act of fixing the mounting member to the fascia or the like.

The preferred extruded aluminium alloy rear receiver members may comprise a mounting member portion including one or more longitudinal channel portions adapted to receive one or more corresponding sealing members. The sealing members may comprise a resilient materials rugged enough to survive the installation and the environment whilst being sealably effective in use. For example, the sealing member may comprise a stabilized natural rubber or synthetic rubber elongate member adapted to engage the aforementioned channels in the rear portion and adapted to be compressed by fixing means passing through the mounting member portion and into the fascia or the like.

Advantageously, the inner surface of the mounting member portion is provided with indicia providing an indication of the preferred site for such fixings. For example, there may be provided marked centres or the like, although it is preferred that there be provided a V-groove or the like disposed substantially along the centreline of the mounting member portion to provide both a line for the fixings and a start for the installer's drill.

The roofing member support means may comprise a flange extending out from the mounting member, and may include a substantially flat bearing surface upon which the roofing material may bear. The bearing surface may be substantially perpendicular to the mounting member portion, although it is envisaged that the flange portion may be inclined to the mounting member portion accommodating any selected pitch of 20 the roof portion to be supported thereby. Additionally the supporting portion may be profiled to accord to a selected roofing material profile.

The support member may be provided with indicia providing the installer with the line of the preferred fixing location to the sheet roofing material. If desired the region of the fixing may be provided with additional sealing means adapted to substantially prevent leakage into the patio or the like 6 through the fixings. For example, the fixing may be of a self sealing nature such as grommetted PK or other self tapping fixings.

Alternatively or additionally the support member may be adapted to receive a fixing sealing member adapted to prevent leaks past the fixings from passing to the covered space beneath the roofing sheet. For example, the preferred extruded support member may include a longitudinal channel adapted to receive a line of fixings and to additionally support a resilient sealing strip, the strip in use providing a draining means to convey such leaks as may occur about the fixings to the ends of the sealing strip.

The sealing means adapted to engage said roofing member, and the drain means disposed between said sealing means and said mounting means, provide in combination the principle means whereby rain and run off are kept from the covered area.

The drain means may comprise any suitable means of entrapping casual leakage past the sheet edge and may at least in part be determined as to form by the sealing means selected.

The sealing means may for example comprise a longitudinally disposed bead of a curable or settable sealing material adapted to be disposed between the support member for the roofing material. However, it is preferred that the sealing means comprise a deformable sealing member associated with the support member and adapted in use to at least partially conform to the sheet profile. Preferably, the sealing member comprises a longitudinal resilient sealing r 7 member adapted to sealingly engage the support member and adapted to be engaged by the undersurface of the sheet material in use, the lands of the sheet material compressing the sealing member in sealing engagement, the portions of the sealing member between the lands being resiliently upstanding into the spaces beneath the upwardly directed ridges in the sheet material.

Preferably, the sealing member comprises a longitudinal seal member of section including a mounting portion for sealing engagement with the support member and an tapered upstanding sealing portion. Preferably, the tapered upstanding sealing portion is inclined toward the drain means such as casual water from the drain means may be directed back by the sealing portion.

The drain means preferably comprises a longitudinal drain or drains formed with or in the receiver assembly in the region of the junction of the mounting member and the support •member. In the case of the preferred extruded aluminium receiver assembly, the drain means may constitute an 20 integrally extruded drain which may also function as a stiffener for the receiver assembly. The drain means preferably drains to one or both ends of the receiver assembly, although it is also envisaged that the drain means may be provided with one or more spouting means adapted to convey drainage to a selected outlet or outlets such as a storm water drain.

The roof member support means may comprise one of a pair The roof member support means may comprise one of a pair 8 of such flanges provided on the preferred extrusion such that the apparatus is reversible in use. However, it is preferred that the roof member support means comprise the lower of a pair of opposed flanges adapted to receive the sheet edge therebetween, the upper of the flanges being adapted to engage and retain baffle means disposed in the valleys of the sheet profile in use and adapted to keep bulk runoff and debris out of the interior of the receiver assembly.

The roofing material may engage compressible sealing means disposed in the rear receiver assembly and adapted to engage the sheet edge. The edge sealing means may comprise material resistant to being cut by the roofing material edge in compression. For example, the edge sealing means may comprise a sealing member which is of a relatively tough resilient material and wherein the deformability and hence sealability of the member is provided by the physical form thereof.

The edge sealing member may comprise a sealing face adapted to substantially cover the cut profile of the roof material and being integrally formed with a plurality of 20 compressible structures of the same material. For example, the edge sealing member may comprise a substantially continuous extrusion of resilient or elastomeric material having said sealing face and having extruded therein a plurality of parallel tubular compressible portions adapted to bear on the mounting member portion.

The receiver body member may be configured to receive the edges of the edge sealing member such that the edge sealing edges of the edge sealing member such that the edge sealing 9 member is substantially supported thereby and preferably sealed thereto in use. For example, the edge sealing member may be bonded to the mounting member portion of the receiver body member. Alternatively, the rear receiver body member may be provided with opposed channel means adapted to receive opposed upper and lower edges of the edge sealing member in substantially sealed relation thereto.

In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:- FIG. 1 is a cross-sectional view through receiver apparatus in accordance with the present invention; FIG. 2 is a facie sealing member adapted for use in conjunction with the receiver apparatus of Fig 1; FIG. 3 is a cross-section through a sheet edge sealing member suitable for use in conjunction with the rear receiver apparatus of Fig 1; FIG. 4 is a partial section of the apparatus of FIG. 1, 20 illustrating an alternative sealing method for fixings; FIG. 5 is a cross section through alternative receiver apparatus in accordance with the present invention; FIG. 6 is a cross section through the receiver apparatus of Fig 1 in use; 25 FIG. 7 is a perspective view of the apparatus in use of FIG. FIG. 8 is a perspective view of the apparatus of FIG. 4;

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a 0 b 0* 0 0 *006.0 0 46 *00w 0000 O 0 0 S and FIG. 9 is a partial end view of the apparatus of FIGS. to 9.

In the figures 1 to 4, there is provided rear receiver apparatus comprising an extruded aluminum alloy rear receiver section 10 as illustrated in Fig 1 and comprising a fascia bearing portion 11 having mounting lands 12 adapted to bear up against a facie to support the patio roof. A groove 13 is provided to start and locate holes (not shown) to receive fixing means such as a screw to affix the rear receiver body to the fascia. The join between the rear receiver body and the fascia is sealed against the passage of water thereby by the sealing means illustrated in Fig. 2 and comprising an elongate resilient deformable seal 14 comprising a tubular 15 seal portion 15 adapted to be supported in channels 16 provided in the rear receiver body portion 10 by way of engagement flange 17 integrally formed with the seal 14.

The rear receiver body member 10 is extruded symmetrically for ease of production and installation in that it may be installed in one of two orientations without penalty.

-Accordingly, the extrusion of the rear receiver body member includes channel portions 20 from which extend roofing sheet supporting flanges 21 between which flanges 21 is define a space 22 adapted to receive the profiled edge of a profiled or corrugated roofing sheet (not shown).

The opposed channels 20 are adapted to receive the sealing element illustrated in Fig. 3, which comprises an integrally 11 moulded seal assembly 23 comprising a sealing surface portion 24 behind which are integrally formed tubular resilient members 25 adapted to resiliently urge the surface portion 24 into sealing engagement with the profiled edge of the profiled or corrugated roofing sheet in response to insertion of the roofing sheet into the space 22, and fixing of the roofing sheet therein by fixing means (not shown) disposed in longitudinal groove 26 disposed on the flanges 21.

The upper and lower edges of the sealing member 23 are provided with an engagement portion 27 adapted to firmly support the sealing member 23 in the opposed channels In the embodiment of Fig. 4, the outer end portion 30 of the flanges 21 are provided with a modified securing portion for securing the flanges 21 to the roofing material and o 15 comprising a dovetail section recess 31 having a longitudinal groove 32 adapted to receive the aforementioned fixing means to secure the profiled or corrugated sheet material, the dovetail section being adapted to receive a sealing member 33 thereby sealing the fixing means which in penetrating the sheet, may otherwise promote leakage to the interior of the patio or corrosion of the fixing means, or sheet material.

In the embodiments illustrated in Figs 5 to 9, there is provided rear receiver apparatus comprising an aluminium extruded section 40 including a mounting portion 41 having an upper seal retaining channel 42 adapted to retain an upper fascia seal 43, and a lower seal retaining channel 44 adapted to receive a lower fascia seal 45. The upper 43 and lower 12 fascia seals each comprise a compressible elastomeric material adapted to provide sealing engagement of the mounting portion 41 with a fascia or other substrate 46.

The mounting portion 41 is adapted to be secured to the fascia or the like 46 by means of a fixing screw 50 or the like, the fixing 50 being adapted to urge the mounting portion 41 towards the fascia 46 or the like such that the upper and lower fascia seals 43, 45 make sealing engagement with the fascia 46 or the like.

A support portion 51 extruded integrally with the mounting portion 41 is adapted to support roofing material 52. The support portion 51 is provided with a longitudinal seal .retaining channel 53 adapted to receive a resilient sealing member 54. Between the seal retaining channel 53 and the 15 mounting portion 41, the support portion 51 and the mounting portion 41 form an integral drain 55 disposed below the level of the roofing material 52.

Outboard of the resilient sealing member 54 the support portion 51 is provided with a fixing groove 56 having a fixing positioning groove 57 adapted to provide an effective drill starter and positioner for the insertion of fixings 60 adapted oooo to retain the sheet material 52 to the support portion 51.

The section of the fixing groove 56 is configured to retain a resilient channel seal 61 adapted to receive any weeping past the fixing 60 and convey such weeping as does pass to the ends of the assembly. The resilience of the channel seal 61 enables the seal to be deformed for insertion in the fixing 13 groove, the resilient recovery of the seal causing the seal to be retained in the groove.

An upper flange 62 is formed integrally with the support portion 51 and is provided with an upper sealing member retaining channel 63 adapted to retain an upper sealing member 64. The upper sealing member is adapted to sealingly engage upper portions of the roofing material 52.

The upper and lower resilient sealing members 54, 64 are adapted to be compressed by the tops of the ridges and bottoms of the troughs of the roofing material 52 respectively, and thereby form a compression seal therewith. However, the resilience of the sealing members 54, 64 is such that between the compressed portions of the sealing members, the sealing members are upstanding to form a partial dam.

15 The outboard edge of the upper flange 62 is adapted to receive press-on plastic baffle members 65 adapted to conform to the shape of the valleys in the sheet material 52.

In use the extrusion 40 is offered up with its mounting portion 41 adjacent to the fascia 46 in the position of installation whereupon the fixings 41 are tightened down to compress the upper and lower fascia seals 43, 45. The roofing material 52 is inserted between the support portion 51 and the upper flange 62 and pushed in towards the mounting portion whereby the upper 64 and lower 54 resilient sealing members are passed by the sheet edge. Appropriate holes are drilled through the support portion 51 at the fixing's positioning groove 57 and thence through the roofing material 52 to permit the installation of fixings 60, whereafter the channel seal 61 is installed. The baffle members 65 are then clipped in position in the valleys in the sheet material 52 by engagement with the outboard edge of the upper flange 62.

Apparatus in accordance with this embodiment has the advantages of not requiring skilled labour for its installation and effective avoidance of curable sealants which would make dismantling and repair difficult. The upper and lower fascia sealing members are complementary but account for defects in the fascia by providing that any minor amount of leakage past the upper seal will be trapped and conveyed by the lower seal, the spaces behind the mounted portion in use functioning as an effective drain for such minor leakage. By not committing the waterproofing of the join to any sealant 15 material, the combination of reduction of water passage into the receiver by the use of baffles and resilient sealing members provides for the use of a reasonably proportioned drain that could easily handle any reasonable roof water loadings.

.o*e It will of course be realised that while the above has been given by way of illustrative example of this invention, •all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as defined in the claims appended hereto.

Claims (12)

1. A method of roofing including the steps of:- providing rear receiver apparatus including mounting means for weatherproof attachment to a fascia or the like, roofing member support means, sealing means adapted to engage said roofing member, and drain means disposed between said sealing means and said mounting means; securing said rear receiver apparatus to the fascia or the like, and securing a roofing member on said support means in engagement with said sealing means.

2. Rear receiver apparatus including:- mounting means for weatherproof attachment to a fascia or the like; roofing member support means; sealing means adapted to engage said roofing member, and drain means disposed between said sealing means and said mounting means.

3. Rear receiver apparatus according to Claim 2 and comprising an extruded aluminium body portion integrating said roofing member support means and said drain means.

4. Rear receiver apparatus according to Claim 3, wherein said mounting means comprises an integrally formed continuous web portion of the body portion. Rear receiver apparatus according to Claim 4, wherein said weatherproof connection is made by a sealing member supported on said mounting means.

6. Rear receiver apparatus according to Claim 5, wherein said mounting means comprises one or more longitudinal channel portions adapted to receive one or more corresponding said sealing members.

7. Rear receiver apparatus according to any one of Claims 4 to 6, wherein said mounting means includes an inner surface of the mounting member portion having indicia providing an indication of the preferred site for fixings.

8. Rear receiver apparatus according to any one of Claims 2 to 7, wherein said roofing member support means comprises a .ooo. flange extending out from the mounting means and having a substantially flat bearing surface upon which the roofing material may bear.

9. Rear receiver apparatus according to Claim 8, wherein said support means is provided with indicia providing the installer with the line of the preferred fixing location to the sheet roofing material. 17 Rear receiver apparatus according to Claim 9, wherein said support means is adapted to receive a fixing sealing member adapted to prevent leaks past the fixings from passing to the covered space beneath the roofing sheet.

11. Rear receiver apparatus according to any one of Claims 2 to wherein said sealing means comprises a deformable sealing member associated with the support means and adapted in use to at least partially conform to the sheet profile.

12. Rear receiver apparatus according to Claim 11, wherein the i sealing member comprises a longitudinal resilient sealing member adapted to sealingly engage the support means and adapted to be engaged by the undersurface of the sheet material in use, said sheet profile comprising upwardly directed ridges spaced apart by flat lands, the lands of the sheet material compressing the sealing member in sealing engagement, the portions of the rooo :oo: sealing member between the lands being resiliently upstanding into the spaces beneath the upwardly directed ridges in the sheet material. ooo•

13. Rear receiver apparatus according to any one of Claims 2 to 12, wherein said drain means comprises a longitudinal drain or drains integrally formed with and between said mounting means and said support means.

14. Rear receiver apparatus substantially as hereinbefore defined, with reference to the accompanying drawings. DATED THIS TENTH DAY OF JANUARY 1997. 4OWL. FREDERIGN KING 173 PIZZEYS PATENT AND TRADE MARK ATTORNEYS q a a a a. a 4