GB2466272A

GB2466272A - Roofing/cladding system using elongate rectangular unit.

Info

Publication number: GB2466272A
Application number: GB0823098A
Authority: GB
Inventors: Frederick James Holme
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-12-18
Filing date: 2008-12-18
Publication date: 2010-06-23
Anticipated expiration: 2028-12-18
Also published as: GB0823098D0; GB2466272B

Abstract

A rectangular roofing unit 100 manufactured in reinforced plastic composite which has a short to long axis ratio of at least 1:8. The unit comprises a substantially planar weather exposed surface featuring a trough indent 130 along the long axis (X-Y Fig 1) parallel to the edge, positioned at one end of the short axis. The unit comprises an under surface with a plurality of integral supports running along the long axis parallel to the long axis edge. The unit is characterised by an anchor means 150, 170 running along its long axis which enables each unit to be securely anchored to further units on either side (shown in Fig 9). The extended nature of the unit allows it to extend over multiple roof trusses to be attached directly to the same, substantially removing the need to pre-batten the roof. The invention may also be used to clad vertical surfaces and is particularly useful for cladding acute angled and overhanging surfaces.

Description

An Easily Assembled and Secure Roofing/Cladding System Area of invention This invention concerns the design of materials and procedures used to roof buildings and clad substantially vertical or overhanging walls. The invention exploits the known benefits conferred by pultrusion/extrusion manufacturing techniques on fibre reinforced plastic composites and presents advantages in terms of reduced labour costs, increased safety, higher security and improved thermal insulation.

Background to Invention

It is known to reinforce plastic of various chemistries in order to form roofmg components of various forms with various benefits. Aragon (US 4226070) and Baker (US 3485002) have both addressed the process of creating a Spanish Mission roof appearance by using substantially weatherproof plastics, including glass reinforced plastics, to mould roof panels with the alternate arcuate and flat sections of a Spanish or Mission style roof In both cases the means of interlocking the panels is specific to the arcuate nature of the roof shape and unsuitable for substantially planar surface roofs. Furthermore, although the described roofmg panels accommodate the equivalent of multiple individual Spanish style tiles they require to be laid on a substantial sub-roof. Felton (US 2002/0040557) and Turek (US 3897667) both address the problem of reducing the assembly costs of roofing with small Shingle type tiles by extending the width of tiles formed of either polyethylenen or polyurethane. However in both cases the maximum extended width is about 100 cm, neither are suitable for pultrusion manufacture, Felton has no inter-tile anchoring mechanism and Turek requires pre-roofing preparation of the roof structure. Bowman (WO 2004/074594) discloses glass reinforced plastic roof panels which are "oversize" but which are not suitable for pultrusion manufacture and are limited to a size of 40 x 100 cm. Trabue & Schwarz (US 2008/0098683) also discloses "oversize" wall cladding panels fabricated from thermoplastic materials but again the panels are not suitable for pultrusion manufacture and are limited to a size of 30 x 100 cm. Medow (US 3621625) also teaches the use of synthetic resinous material impregnated with glass fibres to mould sheets simulating brick sidings but his means of interlocking the sheets would not be suitable for roofing purposes due to its lack of standing water tightness.

Pringle (US 2005/252139 Al) also discloses vertical wall cladding formed from panels of a Pultruded material with a means of interlocking designed specifically to accommodate size changes caused by thermal expansion and unlikely to withstand the wind forces experienced on a roof. Moreover, Pringle's cladding is designed for attachment to a solid sub-surface and not to conventional roof structures.

Berrut (FR 2639985) discloses the use of glass-fibre reinforced polyester in roofing but only as a backing and support for individual shingles. Glass reinforced plastic is also taught by Huaguang (CN 1031268) to fabricate a lightweight double skinned roof tile in the shape of double-curvature arch. 1-linterding (DE 19709139) discloses the use of a triple layered structure of large hard plastic foam tiles protected by a hard plastic or glass reinforced plastic top skin and an underside bonded to aluminium ties covered by aluminium foil. The result is a self-supporting roof not requiring a complete support frame but the structures intrinsic thickness renders it unsatisfactory for normal roof structures.

Wyatt (GB 2147332), Draper & Cunningham (GB 2245617) and Condron (GB 2309041) all claim oversize roofing tiles but none are wider than 50 cm and all require pre-preparation of the roof structure with battens. Condron (GB 2309041) has no inter-tile anchoring mechanism and does, in-fact, specify cement like non-organic materials of construction.

Chiba (JP 5239886) and Niki (JP 4222747) both teach the use of fibre reinforcement to strengthened cement tiles and permit the one shot moulding of "larger" roof tiles. However, the disclosure makes it clear that "larger" still only amounts to 70 cm x 50 cm.

The present invention overcomes the shortcomings of the prior art disclosures and provides a robust and weather proof roofing or cladding tile product in linear lengths up to 8 rn, capable of simple, safe and secure installation on traditional roof structures with minimum batten requirement. The invention may be manufactured by any known means but is particularly adapted to Extrusion or Pultrusion manufacturing techniques.

Summary of the Invention

The present invention overcomes the aforementioned problems by employing new materials of construction, a new design of the roofing or cladding components and a new Method of attaching said components to the roof sub-structure or other surface. The material of construction of the extended roofing or cladding units is selected from those materials with suitable linear strength, weather resistance and fire resistance which possess a sufficiently low specific gravity to facilitate the formation of extended width tiles capable of bridging across multiple roof trusses and being attached directly to the structural roof trusses.

Conventional roofing units (tiles) usually posses a "width" slightly less than their approximately 38 cm "length". The essential feature of the roofing units of the present invention is that their "width" is up to twenty-five times greater than their "length", in order to allow the bridging of multiple roof trusses, and that they incorporate a "tongue and groove" type two component co-operating anchor components to firmly anchor the units to each other and facilitate assembly of the units on the roof or other surface. Although not limited to any particular manufacturing technique the system has been designed to be manufactured by Pultrusion or Extrusion techniques. The method of fixing the units to the roof or other surface involves sliding the tongue, or second co-operating anchor component, of an overlapping (top) unit into a groove or slot, or first co-operating anchor component of the underlying unit formed by a lip on the underlying unit and the roof truss or surface on which it rests. The overlapping unit is then securely attached directly to the roof trusses or sub-surface by any conventional means (nail, screw). The process is repeated, moving up the roof and capped with a ridge and / or hip unit of similar material designed for the purpose.

Technical Benefits of the Invention The invention eliminates the need for a preliminary battening operation to bridge the roof trusses or key the sub-surface as the co-operating anchor joints act as an integral batten.

The elongated nature of the roofing or units spanning multi roof trusses and the procedure of fixed each unit to every roof truss as well as to each other renders such roofs a low security risk.

In addition to roofing, the elongated nature of the cladding units and the anchoring of the units to each other, as well as to the sub-structure is well suited to cladding overhanging surfaces.

Description of Drawings

Drawing I Drawing 1 shows a top view of an extended roofing or cladding unit of the invention (100) having a short axis of from 320 mm to 430 mm preferably from 350 mm to 400 mm, a short to long ratio of from 1:8 to 1:25, preferably 1:8 to 1:16 and an indented trough (130) rwming the length of the long axis on the otherwise planar upper surface at one end of the short axis.

A series of weakened (thinned) points or holes (131) at regular intervals in the range 90 mm to 110 mm runs along the bottom of the trough, to guide location and facilitate penetration by a fixing device such as a nail or screw to anchor the extended length roofing or cladding unit directly to the roof trusses or sub-surface.

Drawing 2 Drawing 2 shows a cross section through the short axis of the extended roofing or cladding unit of the invention (100). The Thickness of the unit may be from 2 mm to 10 mm preferably in the range 3 mm to 6 mm and most preferably from 4 mm to 5 mm. The indented trough (130) running along the long axis of the extended roofing unit at one end of the short axis forms a raised lip (140) which creates a first component of a co-operating anchor point, slot capable of accommodating the thickness of the unit, (150) between the underside of the unit and the surface to which it is attached (110).

At the end of the short axis opposite to the indented trough an appendage (160) is formed on the underside of the extended roofmg unit between a quarter and a half the width of the unit and extended a short distance toward the edge of the upper planar surface but not beyond to form a second component of a co-operating anchor point, slot capable of accommodating the thickness of the unit (170).

Drawing 2 also shows an appendage (180) which takes the form of a channel, capable of carrying fluid, built onto the underside of the extended roofing or cladding unit. In addition to their main function the two appendages (160, 170) and the indented trough (130) act as spacers between the underside of the extended roofing or cladding unit and the roof or other substructure surface on which it is laid, to ensure that the top surface of the unit is parallel to the underlying surface.

Drawing 3 Drawing 3 shows a top view of an alternative design of extended roofing or cladding unit (200) suitable for implementation of the present invention having a short axis of from 320 mm to 430 mm preferably from 350 mm to 400 mm, a short to long ratio of from 1:8 to 1:25, preferably 1:8 to 1:16 and a planar upper surface (200). At one end of the short axis and running the entire length of the long axis, a ledge (230) protrudes from the underside of the planar top surface, to which it is attached, effectively forming a first component of a two component co-operative anchor point, slot, capable of accepting the planar surface of another extended roofing or cladding unit, between the underside of the planar upper surface (210) and the ledge (230). A series of weakened (thinned) points or holes (231) at regular intervals in the range 90 mm to 110 mm runs along the length, long axis, of the protruding area of the ledge (230), to guide location and facilitate penetration by a fixing device such as a nail or screw for anchoring the extended roof tile directly to the roof trusses.

Drawing 4.

Drawing 4 shows a cross section through the short axis of the alternative design of the extended roofmg or cladding unit of the invention, as shown in top view in drawing 3, which exhibits a planar upper surface (200). The Thickness of the unit may be from 2 mm to 10 mm preferably in the range 3 mm to 6 mm and most preferably from 4 mm to 5 mm. In this alternative extended roofing or cladding unit design the tile is forked asymmetrically at both ends of the short axis to form receptor slots and components of a two component co-operative anchor point (250) and (270).

The first component of a co-operative anchor point (250), is formed by an appendage (230) dropped down from the underside of the planar unit and extending beyond the edge of the upper planar surface (200), effectively forming a first component of a co-operative anchor point (250) between the underside of the planar upper surface and the ledge (230) capable of co-operating with a second anchor component of a second unit.

The second component of a co-operative anchor point (270) is formed by an appendage (260) dropped down from the underside of the planar unit inset from a lower edge of the unit by between a quarter and a half the width of the unit and extended a short distance toward the edge of the upper planar surface but not beyond.

Drawing 4 also shows an appendage (280) which acts as a spacer between the underside of the extended roofing unit and the substructure on which it rests and takes the form of a channel, capable of carrying fluid, built onto the underside of the extended roofing or cladding unit. The distance between the upper planar surface (200) and the lower surface of ledge (260) is less than the distance between the upper planar surface (200) and the lower surface of ledge (230) by the thickness of the planar tile (220).

Drawing 5 Drawing 5 shows a combined view of two components of the ridge coping tile, the completed tile is in two sections (310, 320) which, when united together, can rotate within the top head section (330) to allow any degree or angle of roof pitch to be achieved when used on roofs with different pitch.

The ridge coping tile shown in drawing 5 is also an extended length with a long axis of up to 8 metres.

Drawing 6 Drawing 6 shows a rubber gasket used as a sealing joint between the short axis ends of two sections of extended roofing or cladding units of the invention when they need to be butted up to each other. The face side of the gasket (410) is smooth and coloured to match the colour and width size (short axis).

The underside of the gasket (420) is cut away to fit around the direct attachment and co-operating anchor points on the underside of the extended roofing or cladding unit. This also holds the gasket permanently in place.

Drawing 7 Drawing 7 shows in top view the independent batten that may be required to start a roofing or cladding operation when using roofing or cladding units as shown in drawings 1 and 2. The batten may be prepared by cutting roofing or cladding unit along the line X -Y shown in drawing 1.

Drawing 8 Drawing 8 shows in top view the independent batten that may be required to start a roofing or cladding operation when using roofing or cladding units as shown in drawings 3 and 4. The batten may be prepared by cutting a roofing or cladding unit along the line X -Y shown in drawing 3.

Drawing 9 Drawing 9 shows in cross section the "anchoring " mechanism by which roofing or cladding units of the invention, illustrated in drawings 1 and 2, are securely locked together, during their use, by means of the two component co-operating anchor points (first component 150, and second component 170) built into the design.

Materials of Construction of Extended Roof Tiling Component.

The preferred materials of construction are fibre reinforced resin composites due Co their generally low density, high strength and high environmental corrosion resistance. The reinforcing fibre may be selected from the wide range available but preferably glass fibre.

Any of the known thermosetting resins such as unsaturated polyester, vinyl ester, epoxy, methacrylate or phenolic resin. The composites my also contain "fillers" such as Talc and slate to adjust density and modify appearance, fire retardant agents such as aluminium trihydrate, magnesium hydroxide, intumescence/charring agents based on borates and phosphates, pigments, catalysts and accelerators. The roofing/cladding units may be produced in a wide range of colours and surface designs for aesthetic purposes, including markings to give the extended roofing or cladding unit the appearance of a row of conventionally sized tiles.

The components of the invention may be produced by any conventional means of moulding but preferably by a pultrusion process.

Detailed Description of Invention

The invention will now be described in more detail with reference to drawings I to 9.

Preferred Embodiments of the Invention and methodlslof implementation A first embodiment of the invention is as a roofing system. The implementation of the invention to roof a new build house and realise its benefits is now described with reference to drawings I to 9.

Each roof face requires the attachment ofj ust one batten fixed laterally across the roof trusses at its base. The batten (drawing 7) is derived from an extended roofing unit of the invention (100) by cutting along the line X -Y shown in drawing I and attached directly across the roof trusses around the basal perimeter of the roof with the lip (140) and the first component of a co-operating anchor, slot, (150) formed between the lip (140) and the roof trusses, facing up the roof. The batten is attached securely to the roof trusses using any means of direct attachment such as nails or screws, using the fixing guide marks or holes (131) in the base of the trough (130). The exact position of the cut line X -Y may be varied according to the guttering and soffit design of any particular roof and the length and shape of skirt required.

Once the basal batten is attached the next row of roofing unit(s) (as described in drawing 1) is attached to the batten by sliding the second component of the co-operative anchor (170) into the first component of the co-operative anchor (150) on the batten. The roofing unit is then attached to the roof trusses using any conventional means such as nails or screws and the guidance points or holes (131) running along the trough (130). The interlocking nature of the units of the invention is illustrated in drawing 9. This process is repeated until the apex of the roof is reached. The nature of the invention is such that each extended roofing tile stretches up to 8 meters in length and few will be required to fill a tile row. However, where a butted joint is necessary the joint would be sealed using the gasket shown in drawing 6.

Once the roof is filly covered, ridge coping units, as shown in drawing 5, are fixed over the apex to cap the ridge and hips of the roof and attached by any conventional means such as nails or screws, drilling through the top head section (330) to achieve the fixing to the roof and also fix the angle between the two components (310, 320).

The essential features of the invention are the secure interlocking of each roofing unit with the unit in the row below it as well as with the unit in the row above it in combination with its direct attachment to the roof substructure. Drawings 3, and 4 show an alternative tile design that incorporate the present invention and that may be used optionally to implement the invention.

In an optional configuration extended roofing units incorporating channels (drawing 2 (180) and drawing 4 (280)) capable of containing fluid may be built into a solar heating panel. In this configuration the channels (180, 280) are sealed off at each end of the extended roofing unit prior to roof assembly. Once assembled the channels may be tapped from the underside of the roof and plumbed to enable a fluid such as water introduced at the roof apex to trickle down the underside of the entire or portion of the roof to absorb solar heat impinging on the roof.

In a second embodiment of the invention the extended unit may be superficially modified for use as a weather proof cladding for walls. The unique attachment mechanism of the invention makes it particularly effective for cladding vertical, obliquely angled and overhanging surfaces. The procedure for cladding a wall is the same as described above for roofing.