GB2518518A

GB2518518A - Spacer

Info

Publication number: GB2518518A
Application number: GB1414588.2A
Authority: GB
Inventors: Kevin Frederick Carey
Original assignee: KDC HOLDINGS AUST Pty Ltd
Current assignee: KDC HOLDINGS AUST Pty Ltd
Priority date: 2013-08-19
Filing date: 2014-08-18
Publication date: 2015-03-25
Anticipated expiration: 2034-08-18
Also published as: NZ628936A; GB201414588D0; GB2518518B; AU2014213575A1; AU2014213575B2

Abstract

A roofing insulation spacer, comprising a crossbar 110, with an upper mounting surface (111, fig 3) and two side walls 113, adapted to be parallel to and spaced apart from a purlin, and a plurality of leg members 120, fixable to the purlin and passing through 114a one or both side walls of the cross-bar, to prevent uplift of the crossbar. The legs may be c-shaped and may possess a strengthening rib 125. The crossbar and legs may have holes to allow fastening to the purlin. The leg members may possess supplementary bracing between upright (122, fig 6) and lower portions (121), possibly in the form of a cross-brace (130). The crossbar is used to fix roofing sheets or cladding so that insulating material between the purlins and the roofing sheets is not compressed.

Description

SPACER

Field of the Invention

[0001] The present invention relates to roofing and in particular to an improved device for attaching a metal roof to a purlin lying therebeneath.

Background to the Invention

[0002] Metal roofing sheets are used in many applications and most commonly in factory roofs. Since metal is a good conductor of heat, it is desirable to include some type of insifiating material beneath the metal roofing sheets. To this end, a wire mesh is typically positioned on the purlin to which the roofing sheets are attached and a layer of insulating material is positioned on top of the mesh, with the roof shccts being laid on top of the insulating material. A problem with insulating a roof in this manner is that areas of the insulating material, which directly overlie the purlins, are compressed between the purlins and the roof sheets. Such an arrangement dramatically reduces the thermal effectiveness of the insulating material in those compressed areas.

[0003] In the past, several attempts have been made to overcome this problem. for example, by increasing the thickness of the insifiating material. However, this can result in the roofing sheets being difficult to properly secure because the bulk of the insulating material must be compressed before the roofing sheets can be secured to the purlin.

[0004] A further previous option has been to p'ace a spacer between the purlin and the roofing sheets. In particular, by placing blocks of polystyrene on top of the insulating material where the roofing sheets are to be secured. Although these blocks also compress the insulating material by virtue of being thcated between the roofing sheets and the purlin, the thermal efficiency of the polystyrene to some degree compensates for the reduced thermal efficiency in the insulating material due to its compression. While this is quite an effective solution, polystyrene is relatively lightweight and the blocks are readily blown out of position on top of the insulating material prior to being secured in place.

This also results in an increase in the installation time of roofing sheets and therefore results in increased costs associated with preparing a roof in this manner. In yet a further variant, a crossbar including legs has been used. The legs are used to space the crossbar above the insulating material and the roofing sheets are attached to the crossbar. This type oi arrangement is effective, hut the currently availahle versions have certain shortcomings; the present invention seeks to overcome at least some oi these shortcomings.

Summary of the Inveiltion

[0005] The present invention provides a roofing spacer comprising: a crossbar, wherein the crossbar comprises two side walls and is adapted to be spaced apart from, and substantially parallel to. a purlin; and a plurality of leg members, wherein each of the leg members: (i) is adapted to he fixable to the purlin, and (ii) passes through one or both side walls of the crossbar, whereby uplift of the crossbar is substantially prevented.

[0006] In one embodiment, each of the plurality of leg members passes through an opening and/or a respective opening comprised in one andlor both ci the side walls of the crossbar. The opening or respective opening may he adapted to receive the respective leg member. The adapted opening may comprise a profile complementary to the respective leg member. The complementary profile may comprise one or more grooves, each to substantially match a strengthening ridge in the leg member.

[0007] The leg members preferably comprise a substafflially "C-shape". The leg members may be bent from a single piece of metal comprising a planar structure into the substantially C-shape.

[0008] The leg members may compnse three structural sections: a lower portion; an upright portion; and an upper portion. The upper portion may comprise a tab portion wherein when the leg member is bent into a substantially "C-shape" the tab portion comprises a lip. The lip may he a turned lip.

[0009] One or more of the plurality of leg members may. optionally, further comprise one or more strengthening ridges that may be pressed into the leg member prior to the leg members being bent or folded into the substantially C-shape or modified "C-shape".

[0010] One or more of the plurality of leg members may. optionally, further comprise one or more strengthening pieces that connect the lower portion and the upright portion.

The one or more strengthening piece may comprise supplemental bracing such as a cross-brace.

[0011] The upper portion of the leg member may be adapted to pass through the opening or respective opening.

[0012] The crossbar may comprise holes which align with corresponding holes in one of the plurality of leg members to allow a user to pass a fastener and/or a tool through the hole in order to fix the spacer to a purlin. The holes may be comprised in the upper portion.

[0013] The crossbar may further comprise a first connector end and a second connector end, whercin thc first connector end is adapted to receive the second connector end of an adjacent spacer, whereby a plurality of roofing spacers may be joined end-to-end.

[0014] The present invention a'so provides a roof comprising a roofing spacer as described herein. Preferably the roof further comprises metal roofing sheets secured, directly or indirectly, to the crossbar of the spacer. Preferably the roof further comprises insulting material located between the roofing sheets and the purlin, wherein the insulating material is substantiafly non-compressed.

[0015] The present invention also provides a roofing spacer kit comprising: one or more crossbars adapted to be spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members fixed to or adapted to he fixable to the crossbar, each of the plurality of leg members adapted to be secured to the purlin and pass through the crossbar, whereby in use, uplift of the crossbar is substantially prevented.

[0016] The present invention also provides a rooling spacer substantially as herein defined with or without respect to the figures.

[0017] Accordingly, the spacer of the present invention allows attachment of roofing sheets to a purlin of a roof structure whilst at the same time minimising the regions of insulation material which arc compressed between the purlin of the roof structure.

Furthermore, the roof sheets can be rapidiy and efficiently installed, thereby reducing labour costs. In addition, the insulating material is advantageously able to maintain an overall higher thermal efficiency (R-value) than insulation material installed in

accordance with the prior art.

Brief Description of the Figures

[0018] Figure 1 shows a view of an embodiment of a crossbar of a spacer according to (he present invention. Panel A shows a view from above; panel B, from a side; panel C, from an end; and pane] D shows a c]ose up view of an opening which inc]udes grooves for accommodating strengthening ridges.

[0019] Figure 2 shows a leg member according to an embodiment of the present invention. Panel A shows a cross-section through the leg member; and panel B shows a plan view of a leg member prior to bcnding and installation.

10020] Figure 3 shows views of an embodiment of a spacer according to the present invention, which may be of any length, as indicated by the break in the drawing. Panel A shows a view from a side; panel B, from above; and panel C shows a cross section through a leg member when fixed to the crossbar.

[0021] Figure 4 shows a perspective view of the embodiment of the spacer illustrated in Figure 3.

[0022] Figure 5 shows a perspective view of the receiving end of the embodiment of the spacer illustrated in Figure 4.

[0023] Figure 6 shows a leg member according to an embodiment of the present invention. Panel A shows the leg member engaged with the crossbar: and pane] B shows an exploded view of the eg member showing the nature of an embodiment of the strengthening piece.

[0024] Figure 7 shows a leg member according to an embodiment of the present invention, and il]ustrates another embodiment of the strengthening piece.

Detailed Description of the Invention

[0025] RefelTing to all the Figures wherein like reference numerals designate like or corresponding parts throughout the several views. The Figures show exemplary embodiments of the present invention. It is to he understood that these embodiments are not intended to limit the scope of the present invention. The skilled addressee will readily recognise alternative embodiments that may be used to put the present invention into practice. such embodiments are equally understood to be encompassed by the present invention. Accordingly. the Following description refers to a specific embodiment of the present invention and is in no way intended to limit the scope of the present invention to that specific embodiment.

0026] The present invention provides a roofing spacer 100 including a crossbar 110 and a plurality of leg members 120 fixed thereto, wherein the crossbar 110 is adapted to be spaced apart. from, and substantially parallel to, a purlin. The crossbar 110 preferably comprises an upper mounting surface 111, a First side wall 112 and a second side wall 113, wherein the side walls 112,113 extend substantially perpendicular to the mounting surface 111. Each of the leg members 120 is adapted to be secured to the purlin and passes through an opening 114 in the first and second side walls 112.113 of the crossbar 110. Advantageously, the present invention substantially prevents uplift of the crossbar 110. Preferably. the openings 114 in the first and second side walls 112,113 of the crossbar 110 are adapted to receive a leg member 120.

0027] In use, the roofing spacer 100 is intended to raise the fixing point of roofing sheets above the underiying purlin so that insifiating material placed between the purlin and the roofing sheets is substantially non-compressed. thereby retaining its effective insulating properties. Accordingly, in use, roof securing means (not shown) may be attached to an upper mounting surface Ill of the crossbar 110. Roof securing means typically include roof clips, to which roofing sheets are attached without the need for screws or bolts. Roofing sheets are typically metal roofing sheets. Such sheets are available in many different profiles and each profile requires its own specific roof clip.

Accordingly, provision of a spacer 100 having roof clips pre-instal led is an impractical option. Attachment of the roof clips to the crossbar 110 may he done direefly, or more conveniently, by using a rail of clips. A rail of clips is commonly purchased off-the-shelf and includes roof clips mounted to a metal rail at the correct spacing to suit the profile of particular roof sheets being used. The rail of clips may then be fastened to the upper surface 112 of the crossbar 110, preferably with screws, prior to securing the roof sheets thereon. Accordingly, the roofing sheets may he secured, directly or indirectly, to the crossbar 110.

[0028] Attachment of the leg members 120 to the crossbar 110 is of importance to the present invention. Tn particular embodiments, the leg members 120 are substantially "C-shape" (Figure 2A) and bent into shape from a single piece of metal (Figure 2B). As shown in Figure 2B the single piece of metal may be bent from a planar structure into the substantially "C-shape".

[0029] Each lcg mcmbcr 120 comprises thrcc structural sections: a lowcr portion 121; an upright portion 122; and an upper portion 123. The upper portion 123 optionally further includes a tah portion 124. In embodiments that include tab portion 124, the leg members 120 may he bent into a modified "C-shape" which has a lip comprising tab portion 124. In the embodiment shown in FIGS. 3 and 5. the lip is a turned lip, wherein tab portion 124 is turned at an angle to upper portion 123.

[0030] In preferred embodiments, each leg member 120 further includes strengthening rdges 125 that may be pressed into the leg member 120 prior to being bent or folded into its substantially C-shape or modified "C-shape".

[0031] The upper portion 123 is adapted to pass through openings 114 located in the side walls 112,113 of the crossbar 110. Such an ammgement provides the spacer with resistance to being lifted and/or being forced downwards. Holes 117 in the crossbar 110 align with holes 127 in the upper portion 123. This alignment allows a user to pass a fastener and/or tool through the hole in order to fix the spacer to a purlin.

[0032] In a preferable embodiment upper portion 123 includes the optional tab portion 124. When the upper portion 123 is in position and passing through the side walls 112,113 of the crossbar 110, the tab portion 124 protrudes and may he bent (see Figures 3C and 5), whereby it is used to fix the upper portion 123, and thereby the entire leg member 120 to the crossbar 110.

[0033] As noted above, in the embodiment shown in FIGS. 1-5. die openings 114 in the first and second side walls 112,113 of (lie crossbar 110 are adapted to receive a leg member 120. In particular. openings 114 may be arranged in pairs being positioned directly opposite in opposing side walls 112,113. Further, the openings 114 in the side walls 112,113 may be different and may be adapted to match the cross-section of the leg member 120. For example. in an embodiment of (lie invention wherein the leg member includes strengthening ridges 125, at least one of the openings 1 14a in a pair may include grooves 116 that closely match awl accommodate the strengthening ridges 125.

Accordingly, in such an embodiment, the tab portion 124 of the leg member 120 is first passed through the groove-containing opening I 14a and then through the non-groove-containing opcning. Since thc tab portion 124 does not contain strengthcning rdgcs 125, it may pass through both openings 114 unhindered. However, the strengthening ridges may only pass through the groove-containing opening I 14a. Once die tab portion 124 has passed through the two side walls 112.113, it may he bent over to prevent withdrawal of the leg member 120 and substantially fix the leg member 120 to the crossbar 110.

[0034] The upright portion 122 of the leg member 120 is used to position the crossbar above the purlin. The length of the upright portion 122 defines the height of the crossbar 110 and thus, the thickness of insulating material that may be positioned between the purlin and the crossbar 110. As such, upright portion 122 may comprise a variable length. From the teaching herein a skilled person is readfly able to select a suitable kngth for upright portion 122.

[0035] The lower portion 121 of the leg member 120 includes an opening 126 through which a fastener, such as a screw, is passed to fasten the roofing spacer 100 to the purlin.

In certain embodiments of the present invention, the lower portion 121 may incorporate a captured, or pre-installed, fastener, whereby the user simply has to screw the fastener into the underlying purlin.

[0036] The spacer 100 of the present invention has leg members 120 that have a single upnght portion 122, or "leg". In order to remain evenly balanced when in use, it is preferable have some "legs" situated on each side of the crossbar 110. In the illustrated embodiments, the legs are on alternating sides of the crossbar 110. This prefelTed arrangement provides a more stable spacer 100.

[0037] As noted above, the leg members 120 pass through the crossbar 110 and are secured thereto by the tab portion 124. By fitting the leg members 120 to the crossbar 110 in this manner, considerable resistance to uplift is achieved. Accordingly, any roofing material secured to die spacer 110 will he well secured to the underlying purlin. In particular, such an arrangement may allow a roof, which incorporates a spacer 110 of the present invention to achieve a rating to resist strong winds, preferably gale force winds and most preferably cyclones. It is envisaged that further embodiments of the present invention may include leg members 120 with supplementary bracing 130 between the lower portion 121 and the upright portion 122 whercby additional strcngth is imparted upon the leg member.

[0038] For example, the bend between the upright portion 122 and the lower portion 121 may be strengthened by supplemental bracing which is fixed to the two portions. As illustrated in Figure 6. the supplemental bracing may be in the form of a cross-brace 130 and may include flanges 132 that facilitate joining the cross-brace to both the upright portion 122 and the lower portion 121 by, for example. spot welding.

[0039] In an alternative embodiment, the cross-brace 130 may be ARC-welded to both the upright portion 122 and the lower portion 121, as illustrated in Figure 7.

[0040] In order to providc some flexibility in use, the roofing spacers of the present invention may be used in a modular manner whereby several spacers can be linked together to provide various effective lengths of roofing spacer. Thus, in use, a large number of spacers 100 may he required. Speciuically, the spacers are preferably linkable whereby several spacers 100 may be joined end-to-end. Preferably, the crossbar 110 includes a first connector end 115 and a second connector end 116, whereby the first connector end 115 is adapted to receive the second connector end 116 of an adjacent spacer 100. This arrangement allows the spacing of the leg members 120 to remain constant along the length of the end-to-end-joined spacers 100.

[0041] The spacers according to the present. invention may have dimensions that are suitable icr mounting the spacer on a purlin, supporting rool sheeting above the spacer and resisting uplilt during strong winds. The number and spacing oldie leg members may be adapted to suit different applications, as may the length of the roof spacer. Preferably, the length of the roof spacer is between about 750mm and about 2000mm. The number and spacing of leg members will be determined by the length of the roof spacer and by (lie amount of strength required. The spacing is prelerably regular. hut maybe irregular if a particular application requires such an alTangement. In the illustrated embodiments of the present invention, there are six leg members, spaced at approximately 200mm intervals, such that the spacer has an overall length of approximately 1200mm.

[0042] The height of the upright portion of the leg members determines the height of the crossbar above the purlin, and thus the thickness of material that may be positioned therehetween. Preferally, the top oi the crossbar is raised between about 70mm and about 150mm above (lie underlying purlin. For example. prelerred heights include approximately 75mm. approximately 100mm and approximately 120mm.

[0043] The width of the crossbar must he sufficient to support roof clips or a rail of roof clips. Preferahly the crossbar is between about 75mm and 40mm. In the illustrated embodiments of the present invention, the crossbar is approximately 52mm wide.

OO44j The height of thc side walls of the crossbar must he sufficient to accommodate the kg members passing therethrough and provide sufficient strength and resistance to tearing or brcakage such that the roof spacer remains fixed to the purlin during strong winds. Preferably. the side walls are between about 8mm and about 25mm high. In the iflustrated embodiments of the present invention, the side walls are approximately 11mm high.

100451 Accordingly, a roof incorporating a spacer of the present invention will include roofing sheets secured, directly or indirectly, to the crossbar; and insulating material between the roofing sheets and the purlin, wherein thc insulating material is substantially non-compressed. Uplift of the roofing sheets in strong winds is substantially prevented by the leg members. hi particular. by passing the leg members through the crossbar, the crossbar may be more securely fastened to the purlin than if the legs were simply spot wdded to the underside of the crossbar.

[0046] Exemplary roofing spacers according to the present invention may be made of a metal such as, but not limited to, aluminium.

[0047] The present invention is not to he limited in scope by the specific embodiments and Figures described herein, which are intended as single illustrations of individual aspects of the invention, and functionally equivalent methods and components are within the scope of the invention. Indeed, various modifications of the invention, in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and accompanying Figures. Such modifications are intended to fall within the scope of the present invention.

10048] Where the terms "comprise", comprises", "comprising". "indude", "indudes".

"included' or "including" are used in this specification. they are to be interpreted as specifying the presence of the stated features, integers, steps or components refelTed to, hut not to preclude the presence or addition of one or more other feature, integer, step, component or group thereof [0049] Further, any prior art reference or statement provided in the specification is not to be taken as an admission that such art constitutes, or is to be understood as constituting, part of the common genera] knowledge.

[0050] One of ordinary skill in the art will appreciate that materials and methods, other than those specifically exemplified can be employed in the practice of the invention without resort to undue experimentation. All art-known functional equivalents, of any such materials and methods are intended to be included in this invention. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, hut it is recognized that various modifications are possible within the scope of the invention claimed. Thus. it should be understood that although the present invention has been specifically disclosed by examples. prefelTed embodiments and optional features, modification and variation of the concepts herein disclosed may he resorted to by those skilled in the art, and that such modifications and variations are considered to he within the scope of this invention as defined by the appended Claims.

Claims

CLAIMS: 1. A roofing spacer comprising: a crossbar, wherein the crossbar comprises an upper mounting surface and two side walls and is adapted to he spaced apart from, and substantially parallel to, a purlin; and a plurality of leg members, wherein each of the leg members: U) is adapted to be lixable to the purlin. and (ii) passes through one or both side walls of the crossbar, whereby uplift of the crossbar is substantially prevented.
2. The roofing spacer of claim 1, wherein each of the plurality of leg members passes through or is adapted to pass through an opening or a respective opening comprised in one or both of the side wails of the crossbar.
3. The roofing spacer of any one of the preceding claims, wherein each of the plurality of leg members comprises a substantially C-shape, and optionally further comprises one or more strengthening ridge that may be pressed into each leg member pror to each leg member being bent or folded into the substantially C-shape.
4. Thc roofing spaccr of any onc of thc prcccding claims. whcrein thc crossbar comprises holes which align with corresponding holes in each of the leg members which allows a user to pass a fastener and/or a tool through the hole in order to fix the spacer to the purlin.
5. The roofing spacer of any one of the preceding claims, wherein one or more of the plurality of leg members optionally includes supplementary bracing between the upright portion of the leg member and the lower portion of the leg member.
6. The roofing spacer of claim 5, wherein the supplementary bracing is a cross-brace.
7. A roof comprising a roofing spacer according to any one of the preceding claims, optionally further comprising any one or more of: roofing sheets secured, directly or indirectly, to the crossbar; and insulating material bctwccn the roofing sheets and thc purlin. whercin the insulating material is substantially non-compressed.