GB2545162A

GB2545162A - Improvements in batten end fittings

Info

Publication number: GB2545162A
Application number: GB1520091.8A
Authority: GB
Inventors: Fifield John
Original assignee: Forticrete Ltd
Current assignee: Forticrete Ltd
Priority date: 2015-11-13
Filing date: 2015-11-13
Publication date: 2017-06-14
Anticipated expiration: 2035-11-13
Also published as: GB201520091D0; GB2545162B

Abstract

A batten end fitting 50 is suitable for fitting to an end of a batten 28 of a roof structure, the batten having a perimeter-facing end 78 and upper 80 and lower surfaces. The batten end fitting has a batten end plate 52 for at least partially covering the perimeter-facing end of the batten, and a fixing means 60 connected to the batten end plate for fixing the batten end fitting to the batten. The end fitting also has a retainer 56, 66 configured to retain the batten end plate at an angle that is perpendicular to the upper and/or lower surface of the batten when the batten end fitting is fixed to the batten. The fixing means may be in the form of a tab. Also disclosed is a batten end fitting having a batten end plate and a spacer for spacing the end plate form a gable wall.

Description

IMPROVEMENTS IN BATTEN END FITTINGS

TECHNICAL FIELD

The present disclosure relates to a batten end fitting.

BACKGROUND

Figure 1 illustrates in perspective view a pitched roof 20 for protecting a lower space below the roof from external elements such as wind and precipitation. The pitched roof 20 includes a plurality of parallel load-bearing rafters 22 that slope from a ridge 24 at the top of the roof structure to an eave 26 at a lowermost edge of the roof structure 20, and a plurality of parallel battens 28 disposed on top of, and extending orthogonally with respect to, the rafters 22 from a left-hand verge (not shown) at the left side of the roof to a right-hand verge 30 at the right side of the roof. Each verge defines a sloping perimeter of the roof 20 and overhangs a corresponding gable wall 32. An angle between the rafters 28 and a horizontal plane defines a pitch of the roof 20.

Roof-covering elements such as tiles 34 are affixed along the battens 28 in horizontally-extending rows or courses. As can be seen in Figure 1, each course of tiles underlaps the course of tiles directly above and overlaps the course of tiles directly below, such that the tiles 34 overlap in a ridge-to-eave direction. Precipitation falling on the roof 20 is generally directed down the roof 20 over the tile 34 to a gutter 36 at the eave 26.

Gaps 38 between the tiles 34 and the gable wall 32 can be sealed with mortar. This secures the gable end tiles in place, and acts as a barrier against precipitation and rodents that might otherwise enter the loft space via the gaps 38. However, applying the mortar is time-consuming, cumbersome, and requires a skilled worker.

So-called ‘dry verge’ systems have therefore been developed that do not require mortar. One example consists of verge caps, usually made from plastic, which can be placed over the side of each tile 34 at the verge 30, to embrace the tile 34 and close off the gaps 38 between the tiles 34 and the gable wall 32.

Such ‘dry verge’ systems are typically fixed to the verge-facing end of the batten, for example by nailing the cap to the end of the batten. However, driving a nail into the end grain of a batten is problematic, since the structure of the end grain means that the nail will often fail to hold.

To mitigate this problem, the batten end is provided with a batten end bracket that sits over the verge-facing end of the batten. Figure 2 illustrates such an arrangement in a cross-section along the line A-A of Figure 1. The end bracket 40 typically consists of an end plate 42 that covers the verge-facing end 44 of the batten, and a short tab 46 that is perpendicular to the end plate 42 and that extends over an upper surface 47 of the batten 28. The tab 46 has a nail hole (not visible) that allows the tab 46 to be fixed to the upper surface 47, thereby fixing the end bracket 40 to the batten 28. The verge cap 48 is nailed to the batten 28 through the batten end bracket 40, and the batten end bracket 40 guards against the nail being pulled out of the end grain.

Whilst the batten end bracket described is effective in providing a suitable fixing arrangement for the verge cap, the batten end bracket can create problematic rainwater flow at the batten end as will now be explained with reference to Figure 3.

When the roof structure is constructed, the rafters are first laid in place and the battens 28 are then laid over the rafters. At the left and right verges of the roof structure, the battens 28 must be cut by sawing off the batten by hand. Because the battens 28 are sawn by hand, the ends of the battens are often sawn at an angle, as shown in Figure 3 (i.e. not perpendicular to the upper and lower surfaces of the batten). This is particularly common when, for example, a right-handed workman saws off the battens at the left hand side of the roof or vice versa, since this requires the workman to cross the saw over his body, thereby encouraging sawing at an angle that runs generally downwardly and outwardly.

When the batten 28 is sawn off at an angle in this way and the batten end bracket 40 is pushed against the batten end 44, the end plate tends 42 to lie flush against the batten end 44, and hence tends to lie at an angle to the upper and lower surfaces 47 of the batten 28, such that the end plate 42 is not vertical. As a result, the verge cap 48 tends to adopt a similarly angled configuration when it is fixed to the batten end bracket 40. The lowermost wall 49 of the verge cap 48, which would ordinarily be parallel to the roof plane, is instead angled downwards towards the gable wall 32. Precipitation that is caught on either the outside or the inside of the verge cap 48 tends to follow the lower wall 49 of the verge cap 48 towards the gable wall (along arrows B and C in Figure 3), where it runs down the gable wall 32. Water running down the gable wall 32 in this way is undesirable since if left unchecked it can lead to damp in the gable wall 32. A further problem encountered with hand sawing of the battens is that it is difficult to cut every batten at precisely the same position. Thus, the battens will tend to protrude beyond the gable wall by slightly different amounts. The end plates therefore tend to be space apart from the gable wall by differing amounts, and therefore the verge units are not completely aligned in the ridge-to-eave direction. This misalignment can introduce sites for leakage, and if the misalignment is particularly severe, it can give a less appealing aesthetic at the verge of the roof.

The present invention has been devised to mitigate or overcome at least some of the above-mentioned problems.

SUMMARY OF THE INVENTION

According to an aspect of the present invention there is provided a batten end fitting for fitting to an end of a batten of a roof structure, the batten having a perimeter-facing end and upper and lower surfaces. The batten end fitting comprises: a batten end plate for at least partially covering the perimeter-facing end of the batten; a fixing means connected to the batten end plate for fixing the batten end fitting to the batten; and a retaining means configured to retain the batten end plate at an angle that is substantially perpendicular to the upper and/or lower surface of the batten when the batten end fitting is fixed to the batten.

By retaining the batten end plate at an angle that is substantially perpendicular to the upper and/or lower surface of the batten when the batten end fitting is fixed to the batten, any offset in the orientation of the batten end fitting which might for example arise as a result of cutting the perimeter-facing end of the batten at an offset angle that is not perpendicular to the upper and/or lower surfaces of the batten, is avoided. Any verge cap or other verge fitting that is fixed the batten end fitting will tend to adopt the same orientation as the batten end fitting, thus by virtue of the invention, any offset in the orientation of the verge cap or other verge fitting is also avoided. Such offsets in the verge caps could otherwise lead to water running down a gable wall of the roof structure, which is undesirable because it can lead to damp in the gable wall.

The retaining means may comprise a retainer wall that is substantially perpendicular to the batten end plate, and the retainer wall may configured to resist deflection away from the perpendicular orientation. In use, the retainer wall may be located between the gable wall and the batten, such that the retainer wall is forced against the lower surface of the batten by the gable wall, thereby retaining the retainer wall parallel to the lower surface of the batten and retaining the batten end plate perpendicular to the lower surface of the batten.

The retainer wall may extend rearwardly (i.e. when in fitted to the end of the batten, towards the roof) from the batten end plate by a distance of at least 25 mm, and preferably by a distance of at least 80 mm. A distance of at least 25 mm provides a significant lever effect if a user attempts to re-orient the batten end plate, such that small changes in orientation of the batten end plate result in large deflections at the end of the retainer wall, which encourages the batten end fixing to resist even small changes in orientation. A difference of at least 80mm was found to be particularly effective, especially when used in conjunction with a spacing means as will be described below.

The retaining means may comprise a tray having a base wall that defines the retainer wall, and at least one side wall. The side wall acts to stiffen the retainer wall to make it even more resistant to deflection.

The at least one side wall may meets the batten end plate. The at least one side wall may increases in height towards the batten end plate to provide particularly high stiffness in the vicinity of the batten end plate.

The fixing means and the retaining means may extend rearwardly from opposite edges of the batten end plate. In this way, the fixing means may be placed against an upper surface of the batten where it may be easily nailed to the batten, while the retaining means may be placed underneath a lower surface of the batten where it may be particularly effective in retaining the batten end plate in the desired orientation.

The fixing means may be a tab that is substantially perpendicular to the batten end plate. To facilitate fitting the batten end fitting to the batten, the tab may be capable of deflection.

The batten end fitting may further comprise a spacing means configured to space the batten end plate a predetermined distance from a gable wall structure of a roof structure. Such a spacing means can be used to maintain a pre-determined distance between the batten end plate and the gable wall structure irrespective of the length by which the batten itself overhangs the gable wall, thus ensuring all batten end plates are spaced from the gable wall structure by the same distance. In this way, verge caps or other verge pieces fitted to the batten ends will be correspondingly spaced from the gable wall structure all the way up the roof.

The spacing means may be configured to abut against the gable wall structure. The spacing means may comprise one or more formations that are offset with respect to the batten end plate. In this way, the amount of offset between the gable wall structure and the spacing means corresponds to the predetermined spacing between the gable wall structure and the batten end plate.

The or each formation may extend downwardly with respect to the batten end plate when the batten end fitting is installed in a roof structure. In this way, the formation may be easily made to abut the gable wall structure that lies below the batten.

The spacing means may comprise one or more legs.

The spacing means may be connected to the retaining means.

According to another aspect of the present invention there is provided a batten end fitting for fitting to an end of a batten of a roof structure, the batten having a perimeterfacing end and the roof structure comprising a gable wall structure. The batten end fitting comprises: a batten end plate for at least partially covering the perimeter-facing end of the batten, and a spacing means for spacing the batten end plate from the gable wall structure by a predetermined distance.

The spacing means maintains a pre-determined distance between the batten end plate and the gable wall structure irrespective of the length by which the batten itself overhangs the gable wall, thus ensuring all batten end plates in a roof structure are spaced from the gable wall structure by the same distance. In this way, verge caps or other verge pieces fitted to the batten ends will be correspondingly spaced from the gable wall structure all the way up the roof.

The spacing means may comprise one or more legs.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference has already been made to Figures 1 to 3 in the introduction. One or more embodiments of the invention will now be described, by way of example only, with reference to the remainder of the accompanying drawings, in which:

Figure 4 is a perspective view of a batten end bracket according to an embodiment of the invention;

Figure 5 is a perspective view of the batten end bracket of Figure 4 when fixed to a batten in a roof structure; and

Figure 6 is a perspective view of a roof structure having a batten end bracket of Figure 4 fixed to the end of each batten in the roof structure.

DETAILED DESCRIPTION

Referring to Figure 4, a batten end fitting in the form of a batten end bracket 50 comprises a batten end plate 52, a fixing means 54 attached to the batten end plate 52 and a retaining means 56.

The batten end plate 52 is generally rectangular and of slightly larger dimensions that the cross-section of a typical batten. In particular, the batten end plate 52 is slightly larger than 24mm x 48mm. An outward-facing surface of the batten end plate 52 is provided with a grid-like formation 58 that strengthens the batten end plate 52 while providing regions that are thin enough to allow a nail or screw to pass through the batten end plate 52.

The fixing means 54 is defined by a tab 60 that extends rearwardly from a top edge 61 of the batten plate 52, at an angle of around 90 degrees to the batten plate 52. In the embodiment illustrated, the tab 60 extends rearwardly by approximately 90 mm, although the tab 60 may extend rearwardly by any suitable length. The tab 60 is flexible, such that it can be deflected away from the 90 degree angle by at least a small amount. The tab 60 is provided with nail or screw holes.

The retaining means 56 comprises a retainer wall 66. The retainer wall is substantially perpendicular to the batten end plate 52, and is stiff, such that it cannot be deflected under forces that can typically be applied by hand.

More specifically, the retaining means 66 takes the form of a tray 62 that extends rearwardly from a base 64 of the batten end plate 52. The tray 62 comprises a base wall 66 and left and right side walls 68, 70. The base wall of the tray 62 defines the retainer wall 66. The tray extends rearwardly by approximately 105 mm, although the tray may extend by a shorter distance, for example by 25 mm or 80 mm.

The base wall 66 of the tray 62 is substantially perpendicular to the batten end plate 52 and meets the batten end plate 52 at a junction 71 that is at the lower edge of the batten end plate 52. The base wall 66 is provided with an aperture 72. The aperture 72 takes up the majority of the surface area of the base wall 66, such that the base wall 66 defines a border around the aperture 72. The aperture 72 reduces the amount of material required for the bracket, thereby reducing its weight and cost. The aperture also avoids the need to use a core puller to mould the rearward side of the batten end bracket 50, thereby making the batten end bracket 50 easier and hence cheaper to manufacture.

The left and right side walls 68, 70 project upwardly from left and right sides of the base wall 64 and meet left and right edges 74, 76 of the batten end plate 52. For the majority of their length, the side walls 74, 76 have a height that is approximately half the height of the batten end plate 52 (in this case, approximately 14 mm. However, the height of the side walls 74, 76 increases in the vicinity of the batten end plate 52 (in this case, to a height of approximately 20 mm). This increase in height means that the side walls are particularly resistant to torsion and bending adjacent to the batten end plate 52.

The batten end bracket 50 also comprises spacing means in the form of a pair legs 77 that depend downwardly from a lower surface of the base wall 66 of the batten end bracket 50. The legs 77 are positioned rearwardly of the batten end plate 52, such that the legs 77 and end plate 52 are offset and a horizontal spacing is defined between the batten end plate 52 and the legs 77.

The batten end bracket 50 may be made using any suitable material and any suitable method. For example, the batten end bracket 50 may be made from a suitable plastics material, and may be made by injection moulding. The batten end bracket 50 may be made from a single piece, or it may be made, for example, my joining multiple pieces together.

Figure 5 illustrates the batten end bracket 50 when it is installed on a roof. In this embodiment, the batten end bracket 50 is installed at end of a batten 28 at a verge 30 of a roof, above a gable wall structure 32. The gable wall structure could comprise, for example, bricks, blocks, render, stone work, barge board, or any combination of the above. However, the batten end bracket 50 could be used at any batten end in a roof structure, for example at other types of sloping perimeter such as an abutment wall.

To install the batten end bracket 50, the end bracket is placed over the end of the batten 28, so that the batten end plate 52 lies against the perimeter-facing end (in this case a verge-facing end 78) of the batten 28, the tab 60 of the fixing means 54 lies against an upper surface 80 of the batten 28, and the base wall 66 of the tray 62 of the retaining means 56 lies between a lower surface of the batten 28 (not visible in Figure 5) and an upper surface of the gable wall 32. If necessary, the tab 60 can be deflected to facilitate insertion of the batten 28. The batten end bracket 50 is pushed onto the batten 28 until the legs 77 hit the gable wall 32. Nails or screws are fixed through the nail or screw holes on the tab 60 to fix the batten end bracket 50 to the batten 28 and installation of the batten end bracket 50 is then complete.

In the case that the verge-facing end 78 of the batten 28 has not been cut so that it is substantially perpendicular to the upper and/or lower surfaces 80 of the batten 28, the construction of the batten end bracket 50 helps to guard against the batten end plate 52 being pushed into a position that is parallel to the verge-facing end 78, and thus helps to ensure that the batten end plate 52 stays substantially perpendicular to the upper and/or lower surfaces 80 of the batten 28.

In particular, the retaining means 56 is configured to retain the batten end plate 52 substantially perpendicular to the upper and lower surfaces of the batten 28 as will now be explained.

The tray 62 is highly resistant to bending in the longitudinal direction. This is achieved by several factors. Referring back to Figure 4, firstly, the base wall 66 itself is made of a rigid material and is of a sufficient thickness that it has a high stiffness in the longitudinal direction. Secondly, the left and right side walls 74, 76 which are perpendicular to the base wall 66, act to increase the longitudinal stiffness of the tray.

Because the tray 62 is highly resistant to bending, the base wall 66 and the batten end plate 52 remain substantially perpendicular under the forces that can typically be applied by hands. Thus it is particularly difficult to increase or decrease the angle between the base wall 66 and the batten end plate 52.

Referring again to Figure 5, when the batten end bracket 50 is installed for use, the base wall 66 of the tray 62 is arranged between the batten 28 and the gable wall 32. The base wall 66 is therefore tightly held against the lower surface of the batten 28 by the gable wall 32. In this way, the gable wall 32 forces the base wall 66 to lie parallel to the lower surface of the batten 28, and prevents the base wall 66 from being displaced into a different orientation.

Any change in orientation of the base wall 66 would apply a force that would tend to separate the gable wall 32 and the batten 28. Because the base wall 66 is relatively long compared to the height of the batten end plate 52, even a small change in angle of the batten end plate 52 would result in a large deflection at the end of the base wall 66, which would be resisted by the gable wall and the batten 28. Thus, even small changes in orientation are prevented.

Because the base wall 66 is fixed in an orientation that is parallel to the lower surface of the batten 28, and because the junction between the base wall 66 and the batten end plate 52 is substantially fixed at 90 degrees, the batten end plate 52 is fixed at an orientation that is substantially perpendicular to the base wall 66.

The batten end plate 52 cannot be distorted by hand to adopt any other orientation. Thus, if the verge-facing end 78 of the batten 28 is cut at an angle, the installer cannot force the batten end plate 52 to lie parallel to the verge-facing end 78, and the batten end plate 52 must instead adopt an orientation that is perpendicular to the lower surface of the batten.

When a verge cap (not shown) is subsequently fixed to the batten 28 via the batten end bracket 50, the verge cap will tend to be attached such that an outer surface of the verge cap lies flat against the end plate 52. Because the configuration of the batten end bracket 50 fixes the batten end plate 52 perpendicular to the lower surface of the batten 28, the outer surface of the verge cap will also lie perpendicular to the batten 28. Thus, the verge cap will be in its correct and intended orientation, In this correct orientation, the lower wall of the verge cap will be parallel to the plane of the roof, and the leak-proofing of the verge cap will not be compromised, thereby keeping the gable wall dry and mitigating the problem described above.

Referring now to Figure 6, in the case that battens 28 have been cut at different lengths, such that they overhang the gable wall 32 by different amounts, the spacing means 77 act to compensate for the differing overhangs to ensure that the batten end plates 52 are spaced the same predetermined distance from the gable wall, such that the batten end plates 52 align with one another up the roof.

In the roof structure of Figure 6 the lowest two battens 28a, 28b have been cut to different lengths. The lower batten 28a is longer than the higher batten 28b, such that the lower batten 28a defines a larger overhang.

The configuration of the batten end bracket 50 is such that the legs 77 are offset from the batten end plate 52. When the batten end bracket 50 is installed, the legs 77 are pushed against the gable wall 32. Since the spacing between the legs 77 and the batten end plate 52 is fixed, the spacing between the gable wall 32 and the batten end plate 52 is also fixed. Any overhang of the batten 28a, 28b is accommodated in the region that lies between the legs 77 and the batten end plate 52. In this way, the spacing between the gable wall 32 and the batten end plate 52 is not tied to the length of the batten 28.

Thus, the batten end plates 52 are at a constant spacing from the gable wall 32 all the way up the roof. Verge pieces (not shown) that are subsequently fixed to the battens 28a, 28a, 28b via the batten end brackets 50 are therefore aligned all the way up the roof, giving better leakage protection and a better aesthetic appearance.

In the event that the overhang is greater than the spacing between the legs 77 and the batten end plate 52, the legs 77 would not be able to pushed against the gable wall 32. This would be an indication to the workman that the batten 28 should be re-cut to a shorter length.

It is envisaged that the retaining means 56 and the spacing means 77 could be used separately from one another if desired, in accordance with different aspects. For example, in one aspect the spacing means could be omitted altogether. In another aspect, the retaining means may be omitted, but the spacing means may be maintained.

The retaining means may take any form that is capable of maintaining a 90 degree angle between the batten end plate and the upper or lower surface of the batten. For example, embodiments are envisaged in which the side walls of the tray are truncated or omitted. Embodiments are also envisaged in which the retainer means takes the form of, for example, a simple plate that defines the retainer wall, and the stiffness of the retainer wall alone is sufficient to maintain the required 90 degree angle.

Although in the described embodiment the fixing means and the retaining means are provided as separate features, embodiments of the invention are envisaged in which the fixing means and the retaining means are integrated together. For example, the tab may perform the function of both the fixing and retaining means, for example by making the tab suitably stiff and/or providing the tab with side walls that increase its stiffness.

The batten end plate may be any suitable size and shape. In the embodiment described the batten end plate is slightly larger than the verge-facing end of the batten such that the batten end plate covers the verge-facing end completely, though this need not be the case. For example, the batten end plate may only partially-cover the verge-facing end of the batten.

The aperture in the base wall of the tray may be any suitable shape or size. Embodiments are also envisaged in which the aperture is omitted.

Although in the embodiment described the batten end fitting takes the form of a batten end bracket, this need not be the case. The inventive features may be incorporated into any type of batten end fitting. For example, the inventive features may be incorporated into a verge piece, such as the verge piece described in the Applicant’s UK application GB1421804.4.

Many other modifications may be made to the above examples without departing from the scope of the present invention as defined in the accompanying claims.

Claims

1. A batten end fitting for fitting to an end of a batten of a roof structure, the batten having a perimeter-facing end and upper and lower surfaces, and the batten end fitting comprising: a batten end plate for at least partially covering the perimeter-facing end of the batten; a fixing means connected to the batten end plate for fixing the batten end fitting to the batten; and a retaining means configured to retain the batten end plate at an angle that is substantially perpendicular to the upper and/or lower surface of the batten when the batten end fitting is fixed to the batten.

2. The batten end fitting of Claim 1, wherein the retaining means comprises a retainer wall that is substantially perpendicular to the batten end plate, and wherein the retainer wall is configured to resist deflection.

3. The batten end fitting of Claim 2, wherein the retainer wall extends rearwardly from the batten end plate by a distance of at least 25 mm, and preferably by a distance of at least 80 mm.

4. The batten end fitting of Claim 2 or Claim 3, wherein the retaining means comprises a tray having a base wall that defines the retainer wall, and at least one side wall.

5. The batten end fitting of Claim 4, wherein the at least one side wall meets the batten end plate.

6. The batten end fitting of Claim 5, wherein the at least one side wall increases in height towards the batten end plate.

7. The batten end fitting of any preceding claim, wherein the fixing means and the retaining means extend rearwardly from opposite edges of the batten end plate.

8. The batten end fitting of any of Claims 1 to 7, wherein the fixing means is a tab that is substantially perpendicular to the batten end plate.

9. The batten end fitting of Claim 8, wherein the tab is capable of deflection.

10. The batten end fitting of any preceding claim, further comprising a spacing means configured to space the batten end plate a predetermined distance from a gable wall structure of a roof structure.

11. The batten end fitting of Claim 10, wherein the spacing means comprises one or more formations that are offset with respect to the batten end plate.

12. The batten end fitting of Claim 11, wherein the or each formation extends downwardly with respect to the batten end plate when the batten end fitting is installed in a roof structure.

13. The batten end fitting of any of Claims 10 to 12, wherein the spacing means comprises one or more legs.

14. The batten end fitting of any of Claims 10 to 13, wherein the spacing means is connected to the retaining means.

15. A batten end fitting for fitting to an end of a batten of a roof structure, the batten having a perimeter-facing end and the roof structure comprising a gable wall structure, and the batten end fitting comprising: a batten end plate for at least partially covering the perimeter-facing end of the batten; and a spacing means for spacing the batten end plate from the gable wall structure by a predetermined distance.

16. The batten end fitting of Claim 15, wherein the spacing means comprises one or more formations that are offset with respect to the batten end plate.

17. The batten end fitting of Claim 16, wherein the or each formation extends downwardly with respect to the batten end plate when the batten end fitting is installed in the roof structure.

18. The batten end fitting of any of Claims 15 to 17, wherein the spacing means comprises one or more legs.