GB2210648A

GB2210648A - Extruded cavity tray

Info

Publication number: GB2210648A
Application number: GB8823149A
Authority: GB
Inventors: Michael John Penny
Original assignee: Z LED
Current assignee: Z LED
Priority date: 1987-10-02
Filing date: 1988-10-03
Publication date: 1989-06-14
Also published as: GB8823149D0

Abstract

A cavity tray Fig. 1 12 comprises a body 22 having a base 23 and an inclined side wall 24. The body is produced in extruded lengths and its base has a number of formations including a dove-tail projection 26 onto which can be located a flashing 29 by means of a locking element 30. A moulded end wall 34 is mountable on an end of the base in accordance with whether a right-handed or left-handed tray is required. Similarly catchment or ridge trays can be manufactured. <IMAGE>

Description

Cavity Trays This invention relates to cavity trays or gutters and in particular, but not exclusively, to such trays or gutters which are sold with a depending flashing element.

Such trays or gutters have been known for sometime and until now have almost exclusively been formed from metal and particularly rolled sheet metal.

Recently a few manufacturers have turned to plastics and have moulded their trays. Either way the fabrication and stock costs are great because in many uses both right handed and left handed trays are required and in addition ridge trays and catchment trays are required. These together with trays of suitable dimensions for different block sizes and cavity sizes means that for a manufacturer to supply the complete range he must carry large stocks and, in the case of plastics, involve him in large tooling costs.

In those trays in which lead flashing is supplied as a part of the device the lead is either stapled into a groove (in the case of plastic trays) or slid into a turned over lip for rolled metal trays.

In either case there is no positive locking of the lead.

It is an object of the present invention to reduce or mitigate at least some of the above mentioned problems by providing a new and improved tray.

From one aspect this invention relates to a cavity tray having an extruded body including a base and an outwardly inclined side wall.

It will be appreciated that by extruding the main body element stock levels can immediately be decreased because the extrusion can be cut to any desired length.

In a preferred embodiment the tray has an end wall at least one end and the end wall may be provided with a groove for receiving and retaining the end edge of the body. Conveniently the end wall may be moulded from plastics and may be a friction fit on the body.

The tray may further include a further wall section mountable on the free edge of the first side wall and in this case a further side wall section may be mountable on the first side wall in two senses to achieve alternate angles between a further side wall section and the first side wall. This arrangement enables two different cavity widths to be catered for simply by assembling the further side wall section in the appropriate sense. Preferably the side wall section is also extruded.

The body may define a channel, recess or the like for receiving a part of the flashing section to hold the section pendant from the tray. In this case locking means for retaining the part of the section in the channel or the like may be provided, for example, the body may have a formation extending adjacent to and parallel to the channel or the like and the locking means may be constituted by an element slidably mountable on the formation to engage the flashing.

In any of the above cases the body and/or the further wall section is preferably extruded from plastics material and the locking means may also be so extruded.

From another aspect the invention consists in a method of manufacturing a cavity tray comprising extruding a body including a base and an outwardly inclined side wall, moulding or otherwise forming an end wall, cutting the extrusion to the desired length and mounting the end wall on the cut extruded body element.

In a preferred embodiment the method further includes extruding a further side wall section, cutting it to length and mounting it at the first side wall.

Preferably the further side wall is a srrnlretric so that it can be mounted in one or other sense so that it can be inclined at different angles to the first side wall.

Although the invention has been defined above it is to be understood that it includes any inventive combination of the features set out above or in the following description.

The invention may be performed in a number of ways and a specific embodiment will now be described,by way of example, with reference to the accompanying drawings, in which: Figure 1 is a schematic view of the roof lines of two abutting offset terraced houses showing one use of a cavity tray; Figure 2 illustrates a known cavity tray; Figure 3 is an exploded view of a cavity tray according to the invention; and Figure 4 is a perspective view of an end wall for use in the tray Figure 3.

Figure 1 illustrates a pair of offset roof pitches 10 which have a damp proof course 11 formed between them by a pitch of cavity trays 12 arranged in a cascade down either side but on opposite buildings.

It will be noted that there are "right hand" trays 13, catchment trays 15 and a ridge tray 16. Each of these trays is of a different construction. "Left hand" trays are also often required.

A known tray 17 is illustrated in Figure 2 and it will be seen that it comprises a base 18 and inclined wall 19, an end wall 20 and a dependant lead flashing 21. The inclined wall 19 is dimensioned to extend across the cavity to catch water and hence different trays 17 are needed for different cavity widths.

In complete contrast the Applicant proposes a new method of manufacture and construction as illustrated, by way of example, in Figures 3 and 4.

Thus in Figure 3 a body 22 having a base23 and an incline side wall 24 is produced in extruded lengths, preferably from plastics material. The underside of the base 23 has a number of formations including drip ridges 25, a dove-tail projection 26 and a turned over lip 27 which defines an inwardly facing channel 28.

The channel 28 is dimensioned to slidingly receive a lead flashing 29 which can then be located in the channel 28 by means of a locking element 30 which can be slid onto the dove-tail projection 26 to secure the flashing 29 in the channel 28.

The free edge 31 of the side wall 24 is formed with double arrowhead section construction to slidingly engage and receive a corresponding recess 32 formed on an extruded side wall extension element 33. As is indicated in dotted lines, the side wall extension element 33 can be mounted in the opposite sense on the side wall 24 to allow for different cavity sizes.

When a tray is required the body 22 is cut to the necessary length. If an extension is required a corresponding length of extension is cut and mounted on the body in the appropriate sense for the required use. An end wall element 34 (see Figure 4) can then be located on an end 35 of the cut body by locating the end edge 35 in groove 36 in the end wall 34. It will be understood that the groove 36 is preferably dimensioned or shaped to accommodate the projections on the underside of the base 23. Otherwise they can be cut off adjacent to the edge 35.

The end wall is preferably moulded from plastics material and both right and left hand end walls are required.

It can then be seen that any type of tray (whether right hand, left hand, catchment or ridge) can be manufactured from the kit of parts illustrated in Figures 3 and 4. This means that separate stocks are not required and hence stock levels can be reduced to a reasonable level.

Further non-standard sizes can easy be produced and materials can be used which will not corrode. Further the positive location of the flashing by the locking element 30 reduces any risk of the lead becoming free through wear and weather.

Claims

1. A cavity~tray having an extruded body including a base and an-outwardly inclined side wall.

2. A tray as claimed in Claim l wherein in the body defines a channel recess or the like for receiving a part of a flashing section to hold the section pendant from the tray.

3. A tray as claimed in Claim 2 further including locking means for retaining the part of the section in the channel or the like.

4. A tray as claimed in Claim 3 wherein the body has a formation extending adjacent and parallel to the channel or the like and wherein the locking means in constituted by an element slidably mountable on the formation to engage the flashing.

5. A tray as claimed in any one of the preceding claims further including a further wall section mountable on the free edge of the first side wall.

6. A tray as claimed in Claim 5 wherein the further side wall section can be mounted on the first side wall in two senses to acheive different angles between the further side wall section and the first side wall.

7. A tray as claimed in any one of the preceding claims further including an end wall at at least one end of the body.

8. A tray as claimed in Claim 7 wherein the end wall has a groove for receiving and retaining the end edge of the body.

9. A tray as claimed in Claim 7 or Claim 8 wherein the end wall is moulded from plastic material.

10. A tray as claimed in any one of the preceding claims wherein the body is extended from plastics material.

11. A method of manufacturing a cavity tray comprising extruding a body including a base and an outwardly inclined side wall, moulding or otherwise forming an end wall, cutting the extrusion to the desired length and mounting the end wall on the cut extruded body element.

12. A cavity tray substantially as herein before described with reference to the accompanying drawings.

13. A method of manufacturing a cavity tray substantially as herein before described with reference to the accompanying drawings.