GB2455508A

GB2455508A - Plastic roof spacer component

Info

Publication number: GB2455508A
Application number: GB0724073A
Authority: GB
Inventors: Stuart Ian Brown; Lee Andrew Davies; Mark Alan Forrester
Original assignee: C A GROUP Ltd
Current assignee: C A GROUP Ltd
Priority date: 2007-12-10
Filing date: 2007-12-10
Publication date: 2009-06-17
Also published as: GB0724073D0

Abstract

The invention relates to a spacer component 100 for forming a gap between a first roof component 210 and second roof components 208. The spacer component comprises an elongate body (102 figure 2) of thermally insulating material which is adapted to be mounted to the first lower roof component. The body has a first end (104 figure 2) adapted to contact the first roof component, and a second end (106 figure 2) which has a first engaging portion (108 figure 2) adapted to be mounted to the second upper roof component such that forces urging the second roof component towards the first roof component do not cause bending moments that are capable of moving the body out of engagement with the first roof component. The component may be made from nylon or similar materials by injection moulding. The component is fastened to the first roof member by self tapping, self drilling screws 214.

Description

ROOF SPACER COMPONENT AND ASSEMBLY

Technical field

The present invention relates to roofing assemblies, and relates particularly to a spacer component and assembly for a "twin-skin" type roof.

Background of the invention

"Twin-skin" type roofs are roofing assemblies where an inner liner panel and an outer sheet panel, each made of steel or some other rigid material, are spaced apart at a predetermined distance having a layer of insulating material interposed between the inner and outer panel.

Various styles of roofing assemblies of the "twin-skin" type are known and are generally satisfactory in use. However, increasing concern for the conservation of energy has led to a demand for improved U-values (heat transfer coefficient W/Km2) of, inter alia, the roofing assemblies to be over and above those required in current building regulations. In order to meet those demands, the thickness of the layer of insulating material will have to be increase causing currently used spacer assemblies to become unstable and fail.

Figure 1 shows an example of a typical spacer assembly used in the prior art, as described in the UK patent GB2306981A. The spacer assembly comprises a support block (10) made of heat-insulating material and a purlin (20), which is mounted to the top end of the block (10) via a slot (30). The purlin (20) has a Z'-shaped cross-section, wherein the lower horizontal limb (40) is inserted into the slot (30) and the upper horizontal limb (50) is fixed to an outer roof panel by means of self-tapping screws (70). The support block (10) is mounted onto the inner roof panel (80) by means of further self-tapping screws (90). Because the longitudinal axis of the self-tapping screw (90) fixing the support block to the inner roof panel (80) does not coincide with the longitudinal axis of the self-tapping screw (70) fixing the upper limb (50) of the purlin (20) to the upper roof panel (60), a bending moment exists as a result of the weight of the upper roof panel (60) or foot-traffic or wind forces acting on either outer roof panel (60) or inner roof panel (80). Sufficient force may cause the metal purlin (20) to touch the metal self-tapping screw (90) to establish thermal bridging between the outer roof panel (60) and the inner roof panel (80), thereby making the thermal insulation ineffective. Also, the bending moment makes the spacer assembly unstable to external forces.

Preferred embodiments of the present invention seeks to provide a spacer assembly having improved stability as well as reduced overall thickness while having improved U-values at reasonable cost.

Summary of the invention

According to an aspect of the present invention, there is provided a spacer component for forming a gap between a first and second roof component of a roof assembly, said spacer component comprising: an elongate body of thermally non-conductive material adapted to be mounted to said first roof component, the body having a first end adapted to contact said first roof component, and a second end having a first engaging portion adapted to be mounted to said second roof component such that forces urging said second roof component towards said first roof component do not cause bending moments capable of moving the body out of engagement with said first roof component.

This provides a simple and inexpensive solution for a roofing assembly. The invention provides a simple design of a spacer component having a length predetermined according to the desired U-factor, which requires fewer parts and minimizes or even eliminates the likelihood of thermal bridging.

The first engaging portion may be tapered towards said second end and broadened towards said first end, thereby forming a step portion on opposite sides of said body.

This provides the advantage that a continuous rail can be used from verge to verge, therefore, providing more stability and reducing the number of spacer components required.

The body of the spacer component may further comprises a recess for receiving a fixing component for mounting said body to said first roof component.

This provides the advantage that any metal to metal contact between secondary steelwork, the inner roof panel and the outer roof panels is eliminated and thermal bridging is minimized.

The recess may comprise a second engaging portion for engaging said fixing component.

The second engaging portion may be located nearer than said first engaging portion to said first end.

is provides the advantage that the fixing component, which may be made of metal or any other heat conducting material, is embedded fully within the insulating material of the spacer component body, therefore, minimizing the likelihood of thermal bridging due to, for example, metal to metal contact between the secondary steelwork, the inner roof panel through to the outer roof panel via the spacer component.

The recess may comprise a first portion extending from said second end to said second engaging portion, and a second portion extending from said second engaging portion to said first end.

The second portion may comprise an axial bore and said first portion may be wider than said first portion.

This provides the advantage that standard fixing components, such as self-tapping screws, can be used to mount the spacer component to the inner roof panel.

The second engaging portion may be tapered.

The spacer component may further comprise at least one cavity located between said first end and said second engaging portion.

This provides the advantage that material and weight can be reduced without reducing the mechanical strength of the spacer component, therefore, reducing the overall weight of the roof assembly and reducing cost.

According to another aspect of the present invention, there is provided a support assembly for a roof, the assembly comprising: a spacer component as defined above; and a second roof component adapted to be mounted to said first engaging portion.

The second roof component may be a support rail for supporting an outer roof panel.

The support rail may be adapted to be resiliently mounted to said first engaging portion.

The support rail may include a pair of flanges for engaging the step portion.

This provides the advantage that any lateral and/or axial movement of the support rail with regards to the spacer component is prevented, therefore, improving stability and durability of the support assembly.

The support assembly may further comprise at least one fixing component for mounting said body to a first roof component.

T e support assembly may be symmetrical.

This provides the advantage that the support assembly can be installed in either direction and will not be affected by the roof pitch, therefore, reducing additional labour time and subsequent costs.

According to a further aspect of the present invention, there is provided a roof assembly comprising: a support assembly as defined above; a first roof component comprising an inner roof panel; an outer roof panel; and a layer of insulating material located between said inner and outer roof panels.

This provides the advantage that the roof assembly has an increased stability, improving, for example, the safety of the installation team, and an improved U-value, reducing cost of manufacture, installation and maintenance.

A preferred embodiment of the present invention will now be described, by way of example only and not in any limitative sense, with reference to the accompanying drawings in which: Figure 1 is a cross-sectional side-view of a known support assembly for a roof; Figure 2 is a perspective view of a spacer component embodying the present invention; Figure 3 is a sectional side-view of the spacer component of Figure 2; Figure 4 is a (a) side-, (b) front-, (c) top-and (d) bottom- view of the spacer component of Figure 2; Figure 5 is a cross-sectional side-view of a roof assembly; and Figure 6 is a partially cut-away perspective view of the roof assembly of Figure 5;

Detailed description of the embodiment

Referring to Figure 2, the spacer component (100) comprises a body (102) made of an elongated cuboid formed by injection moulding in, for example, Nylon or any other similar material. The spacer component (100) has a lower first end (104) and a top second end (106). The top second end (106) includes a first engaging portion (108) that is tapered towards the top second end (106) and broadened towards the bottom first end (104) forming a step portion (1 10) on two opposite sides of the spacer component body

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(102). The bottom first end (104) has a generally flat square base that can be placed on and fixed to an inner roof panel (210).

As shown in Figure 3, the spacer component (100) further comprises a first bore (116) having a first diameter and that extends generally axially from the top second end (106) to a depth D'. A second bore (118), having a diameter substantially smaller than the first bore (116), extends generally axially and concentric with the first bore (116) from the depth D' through to the bottom first end (104). The diameter of the first bore (116) is dimensioned such that, for example, the head of a self-drilling, self-tapping fastener (214) (e.g. TSC2OG19) can be pushed through to engage with a second engaging portion (114) of the spacer component (100) at the depth D'. The diameter of the second bore (11 8) is dimensioned such that the shaft, but not the head of the fastener (214) can be pushed through, so that the head of the fastener (214) engages with the second engaging portion (114) of the spacer component (100).

Four internal cavities (120) are located circumjacent and substantially parallel to the second bore (118) between the second engaging portion (114) at depth D' and the bottom first end (104) of the spacer component (100). The cavities (120) help to reduce material and weight without significantly affecting the mechanical strength of the spacer component (100). However, number, size and shape of the cavities (120) are variable depending on required weight and strength of the spacer component (100).

Furthermore, a rectangular recess (122) is formed on the two flat side surfaces of the spacer component body (102), extending from the top second end (106) down to the depth D', providing a visual aid to where the head of the fastener (214) engages with the second engaging portion (114) of the spacer component (100). Thus, the recesses (122) provide an indication of how long the fastener (214) has to be to enable engagement with the inner roof panel (210) and/or secondary steelwork (212) (e.g. roof purlin).

Referring now to Figures 5 and 6, the roof assembly (200) employs a number of spacer components (100) having a predetermined length according to the U-value requirements of the roof assembly (200) and which are aligned directly above the roof purlin (212) and secured onto the inner roof panel (210). The fasteners (214) secure the spacer component (100) to the inner roof panel (210) and to the purlin (212). An insulation layer (216) is rolled out and pushed over the spacer components (100), thereby ensuring continuity of the insulation layer (216) and avoiding any gaps or holes. A rail (204) and outer roof panel fixings (206) are mounted onto the first engaging portion (108) of the spacer components (100) and secured with two fixings (202) per spacer component (100). Also, the rail (204) has two flanges (205) on either

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side providing a snap-fit over the engaging portion (108) of the spacer component (100) preventing any axial and/or lateral movement even without the fixings (202). The external roof panel (208) and all relevant sealants are then installed over the rails (204) and outer roof panel fixings (206).

The roof assembly is symmetrical and can be installed in either direction and will not be affected by the roof pitch.

It will be appreciated by persons skilled in the art that the above embodiment has been described by way of example only, and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by appended claims. ) ROOF SPACER COMPONENT AND ASSEMBLY