GB2603544A

GB2603544A - An eaves beam assembly

Info

Publication number: GB2603544A
Application number: GB2104344.3A
Authority: GB
Inventors: Crohill Jonathan
Original assignee: Garner Aluminium Extrusions Ltd
Current assignee: Garner Aluminium Extrusions Ltd
Priority date: 2021-02-09
Filing date: 2021-03-26
Publication date: 2022-08-10
Anticipated expiration: 2041-03-26
Also published as: GB2603544B; GB202104344D0; GB202101781D0

Abstract

Herein disclosed is an eaves beam assembly 14 for supporting a lower margin of a glazing unit 17 of a fixed pitch roof 10, the eaves beam assembly comprises a structural support member 18 with an exterior surface 19 arranged to be remote from the apex of the roof and extending transverse to a direction of slope of the roof , a thermal insulating assembly 20 arranged to be mounted to the exterior surface of the structural support member, and an edge trim 22 configured to receive at least an end edge of the glazing unit, wherein the end trim comprises an engagement formation 24 for securing the end trim to the thermal insulating assembly. The insulating assembly may comprise a fascia trim 28 arranged to be mounted to the exterior surface of the support and an infill trim 30 mounted above the facia trim and the support member. Also disclosed is a frame assembly comprising the described eaves assembly, at least one glazing unit and at least one rafter. Further disclosed is a method of assembling the eaves beam assembly described for a lantern or conservatory roof.

Description

An Eaves Beam Assembly

FIELD

The present teachings relate to an eaves beam assembly for a fixed pitched roof, for example a lantern roof or a conservatory roof, a frame assembly including said eaves beam assembly and a method of assembled the beam assembly.

BACKGROUND

Fixed pitched roofs typically comprise a frame assembly, onto which a panel, such as a glass pane, or a sealed double glazing unit is inserted. Examples of fixed pitched roofs include lantern roofs, conservatory roofs and orangery roofs.

Typically, eaves beams are fitted around the perimeter of an opening in the roof, and an assembly of rafters and a ridge beam is lowered on to the opening. Glazing units are then assembled between the rafters to complete the roof.

The present applicant has recognised that these types of roofs may be susceptible to unauthorised entry by burglars and the like. This is because typically, the glazing unit is simply lowered onto the eaves beam and then fitted with an end cap extending around the edges of the glazing unit. To gain entry through the roof, the burglar simply has to remove the end cap and pivot the glazing unit out of the roof.

Additionally, since the components of the roof have poor insulation properties, a separate thermal break or alternative insulating material has to be incorporated into the design. This can lead to poor insulation and/or may be complex to assemble with the additional insulation components.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

A first aspect of the teachings provides an eaves beam assembly for supporting a lower margin of a glazing unit of a fixed pitched roof for example a lantern roof or a conservatory roof, the eaves beam assembly comprising: a structural support member having an exterior surface arranged to be remote from an apex of the roof and extend transverse to a direction of slope of the roof; a thermal insulating assembly arranged to be mounted to the exterior surface of the structural support member; and an end trim configured to receive at least an end edge of the glazing unit, wherein the end trim comprises an engagement formation for securing the end trim to the thermal insulating assembly.

Advantageously, the arrangement of the thermal insulating assembly, structural support member and end trim improves the security of the corner. Using such an end trim that is connected to the remainder of the assembly restricts access to the assembly for unauthorised access from the exterior. Additionally, the provision of both the structural support member and the thermal insulating assembly improve insulation of the eaves beam without the need for a conventional "dog bone" thermal break between adjacent structural portions or additional insulating material. Such dog bone thermal breaks add additional steps to the assembly process and may introduce inaccuracy into the alignment of the finished structural assembly.

The eaves beam assembly may comprise an adhesive connection between the thermal insulating assembly and the glazing unit.

Further improvement to security as access to the adhesive is blocked by the end trim.

The thermal insulating assembly may comprise a fascia trim arranged to be mounted to the exterior surface of the structural support member and an infill trim arranged to be mounted above the fascia trim and the structural support member and support the glazing unit.

This arrangement further enhances insulation between the glazing unit and the structural support member and permits the glazing unit to be evenly supported over a large area.

The infill trim may have the adhesive connection thereon.

As the infill trim is in place prior to mounting of the glazing the adhesive can be put into place prior to the glazing unit being fitted, the end trim can be aligned with the glazing unit and the glazing unit lowered into place in a simple manoeuvre that mounts the end trim to the thermal insulating assembly and at the same time secures the glazing unit to the infill trim.

The infill trim may be arranged to engage the structural support member and the fascia trim to at least resist removal of the fascia trim from the structural support member in at least a direction away from the apex of the roof.

This arrangement further enhances the security of the eaves beam assembly in relation to unauthorised disassembly from the exterior thereof.

The engagement may be a push-fit. The engagement may be a snap-fit engagement between the infill trim and at least one of the structural support member or fascia trim.

Advantageously this simplifies the assembly of the eaves beam.

The end trim may be configured to extend partially over an exterior surface of the glazing unit.

Advantageously, this arrangement helps to prevent the glazing unit from being lifted out of the end trim and therefore increases security. Additionally, this may reduce the ingress of moisture into the end trim.

The engagement formation of the end trim may comprise a push-fit formation, e.g. a hook arranged to engage a complementary formation of the thermal insulating assembly.

Advantageously, this shape is simple to manufacture and assemble.

The engagement formation may be inaccessible from the exterior side of the thermal insulating assembly.

Advantageously, this arrangement improves security of the eaves beam assembly as there are no locations where for example a lever can be inserted to pry the two components apart. The arrangement may also improve weather-proofing and the visual appearance of the eaves beam assembly.

The complimentary formation of the thermal insulating assembly may be in the form of a channel located on the fascia trim, and the hook may engage with the channel.

Advantageously, providing the complimentary formation on the fascia trim as opposed to the infill trim provides additional security benefits because the glazing unit is secured to both the infill trim (via the adhesive) and to the fascia trim. A channel is simple to manufacture e.g. by extrusion.

The fascia trim may comprise a gasket extending along an elongate edge of the fascia trim, and the gasket may be configured to create a seal between the elongate edge of the fascia trim and an exterior surface of the roof of a structure below the pitched roof, for example an upstand of a flat roof.

Advantageously, this arrangement helps to prevent the ingress of moisture and foreign matter underneath the thermal insulation assembly.

The gasket may be manufactured using a thermoplastic elastomer (TPE), and the gasket may be coextruded with the fascia trim.

Advantageously, this removes the need for a separate gasket, thereby reducing the number of steps in the manufacturing process and possibly speeding it up. Using a TPE enables the gasket to be coextruded with the fascia trim due to its ability to chemically bond to the fascia trim.

The structural support member may be manufactured from metal, and the structural support member may be manufactured from an aluminium alloy.

Advantageously, a metal structural support member provides the required structural strength and durability to support the components of the roof.

The thermal insulating assembly may be at least partially manufactured from a plastics material.

Advantageously, plastic is an insulating material, meaning the insulation requirements of the roof without the need for a separate thermal break.

Additionally, the amount of aluminium required is reduced, which lowers the cost.

Since plastic is able to elastically deform, it may be easier to remove the thermal insulating assembly from the structural support member without inflicting damage. Since plastic is more flexible than aluminium, it may also be easier to attach the thermal insulating to the structural support member. The plastics material may be readily manufactured with multiple discrete chamber to further enhance the insulating properties, e.g. in an extrusion process.

A further aspect of the present teachings provides a frame assembly for a fixed pitched roof, for example a lantern roof or a conservatory roof, the frame assembly comprising: at least one eaves beam assembly according to any preceding claim; at least one glazing unit, wherein an edge of the glazing unit is received by the end trim; and at least one rafter extending at a non-zero angle above the horizontal relative to the eaves beam assembly.

The rafter may comprise a ridge for supporting a second edge of the glazing unit adjacent to the first edge.

Advantageously, this supports the glazing unit in the correct alignment, and enables the glazing unit to extend at the same angle relative to the longitudinal axis of the eaves beam assembly.

The frame assembly may further comprise at least one corner assembly, and each corner assembly may comprise a first eaves beam assembly and a second eaves beam assembly which interface at a corner.

The first eaves beam assembly and the second eaves beam assembly may be in mitred abutment and may be connected by an L-shaped corner connector (not shown), with one leg extending into a first hollow profile of the first eaves beam assembly and a second leg extending into a second hollow profile of the second eaves beam assembly.

Advantageously, this creates a secure connections at the corners of the frame which is difficult to access from the outside as the thermal insulating assembly forms a cover over structural support member.

The rafter may be secured in abutment to an interior face of the first structural support member and to an interior face of the second structural support member at the corner assembly, and the rafter may extend from the corner at a non-zero angle with respect to the longitudinal axes of both the first eaves beam and the second eaves beam.

The rafter may be secured to the corner assembly by at least one fastener extending through the structural support member.

The thermal insulating assembly may block access to the at least one fastener when fitted to the structural support member.

Advantageously this further enhances the security of the eaves beam assembly.

The first infill trim may abut a first side of the rafter, and the second infill trim may abut an opposing second side of the rafter.

Advantageously, this forms a cover over an entirety of the structural support members.

The structural support member may be secured to an upper surface of a structure below the pitched roof, for example an upstand of a flat roof, using a fastening member, and the fastening member may be a screw.

Advantageously, this means that neither the first and second screws nor the fastening member are easily accessible as the thermal insulating assembly would need to be removed to gain access to the screws/fastening member.

A further aspect of the present teachings provides a method of assembling an eaves beam assembly according to any of claims 1 to 16 of a fixed pitched roof, for example a lantern roof or a conservatory roof, the method comprising the steps of: a) fitting an end trim to an edge of a glazing unit, wherein the end trim comprises an engagement formation; b) securing a first surface of the thermal insulating assembly to an exterior surface of the structural support member; c) securing the engagement formation of the end trim to a second surface of the thermal insulating assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is an isometric view of a fixed pitched roof according to an embodiment of the present teachings in a fully assembled state, having an eaves beam assembly; Figure 2 is an exploded view of a rafter and a structural support member of the eaves beam assembly of Figure 1; Figure 3 is cross-sectional view of the eaves beam assembly on the plane z-z of Figure 1; Figure 4 is a cross-sectional view of an end trim, a thermal insulating assembly and the structural support member of the eaves beam assembly of Figure 1; Figure 5 is a cross-sectional view of the rafter, the structural support member and a fascia trim of the eaves beam assembly of Figure 1; Figure 6 is a cross-sectional view of the structural support member, an infill trim and the fascia trim of the eaves beam assembly of Figure 1; Figure 7 is a cross-sectional view of a glazing unit and the end trim of the eaves beam assembly of Figure 1; and Figure 8 is a cross-sectional view of the glazing unit, the end trim, the structural support member and the thermal insulating assembly of the eaves beam assembly of Figure 1.

DETAILED DESCRIPTION OF THE DRAWINGS

Figure 1 shows a fixed pitched roof of an embodiment of the present teachings generally indicated at 10, having a frame assembly 12 which supports at least one panel 17a-d. Typically, the frame assembly 12 includes at least one eaves beam assembly 14a-d. The fixed pitched roof 10 of this embodiment is a lantern roof, however in alternative embodiments the fixed pitched roof may be a conservatory roof or an orangery roof.

The panel 17a-d may be a pane of glass, a double glazing unit or a triple glazed sealed unit, or a panel of wood, aluminium or other suitable material. The glazing unit 17a-d in this embodiment are double glazing units. In this embodiment, four glazing units 17a-d are provided, however in alternative embodiments any number of glazing units may be provided depending on the desired aesthetic, for example six glazing units.

Roofs 10 of this type are typically used in roofs of domestic buildings. It is therefore necessary that the roof 10 meets the necessary security requirements, as well as the requirements for thermal insulation, sealing against water ingress, draughts 30 etc. Typically, in addition to the at least one eaves beam assembly 14a-d and the glazing unit 17a-d, the frame assembly 12 is constructed from a ridge beam 11 and at least one rafter 16a-d. The at least one rafter 16a-d and the eaves beam assembly 14a-d form a corner assembly 42a-d.

In this embodiment, the fixed pitched roof is rectangular, meaning four eaves beam assemblies 14a-d are provided along each edge of the fixed pitched roof 10. However, in alternative embodiments, any suitable number of eaves beams assemblies may be provided. For example, if the desired roof was hexagonal, then six eaves beam assemblies would be provided.

Each of the eaves beam assemblies 14a-d interface at a corner with the adjacent eaves beam assembly 14a-d. An end of the glazing unit 17a is received by the end trim. In this embodiment, adjacent eaves beam assemblies 14a-d are in mitred abutment so as to form four corners of the roof 10. The eaves beam assemblies 14a-d are secured together using L-shaped corner connectors (not shown), with one leg extending into a first hollow profile of the eaves beam assembly 14a-d, and a second leg extending into a second hollow profile of the adjacent eaves beam assembly 14a-d.

The frame assembly 12 of this embodiment includes four rafters 16a-d and one ridge beam 11. The ridge beam 11 is secured to the rafters 16a-d via a first connecting member 21a and a second connecting member 21b. In alternative embodiments, any suitable number of rafters and ridge beams may be used depending on the required aesthetics of the fixed pitched roof. The ridge beam 11 has a first end 15a and a second end 15b. The rafters 16a-d each have a first end and a second end.

The rafter 16a comprises a structural portion 23b, of e.g. a metallic material which forms a hollow profile, and a glazing receiving portion with greater thermal insulating properties of e.g., plastics material in this embodiment. The structural portion 23b is secured to the glazing receiving portion 23a a snap-fit arrangement, however in alternative embodiments any suitable fixing may be used. The glazing receiving portion 23a includes a first and second ridge 40a, 40b extending from opposing elongate sides of the rafter 16a to support respective glazing units 17a-d.

The rafters 16a-d extend from the corner formed between adjacent eaves beam assemblies 14a-d. The rafters 16a-d each extend from the corners of the roof 10 at a non-zero angle with respect to longitudinal axes of the eaves beam assemblies 14a-d. The rafters 16a-d extend from the corners in an upwardly inclined direction and towards the centre of the roof 10. In this embodiment, rafters 16a and 16b extend towards the same point (at the first end 15a of the ridge beam 11), and rafters 16c and 16d extend towards the same point (at the second end of the ridge beam 11). Such rafters 16a-d may be referred to as hip rafters as they define a vertex of a hipped roof structure.

In an alternative embodiment of the roof (not shown), there may be multiple rafters which extend from the corners formed by the eaves beam assemblies to form a pyramid shaped roof. The shape of the base of the pyramid may vary based on the number of rafters, for example four rafters would result in a square-based pyramid. In this embodiment, the ridge beam may be in the form of a smaller support piece located at the point where the rafters meet, or the ridge beam may be omitted and replaced by a single connecting member that connects all four rafters. Further rafters (not shown) may extend from points along the length of an eaves beam assembly 14a-d to either the ridge beam 11 or one of the hip rafters 16a-d depending upon the size and layout of the roof 10.

It shall be appreciated that the term 'exterior' refers to an area outside of the fixed building, and the term 'interior' refers to an area within the building. Therefore, for example 'exterior side' refers to the side closest to the outside of the building, and the term 'interior side' refers to the side closest to the inside of the building.

It shall be appreciated that the term 'axis of slope' refers to an axis parallel to the pane of the glazing unit 17a and extending towards the ridge beam 11, labelled as x. The term 'transverse axis of slope' refers to an axis transverse to the pane of the glazing unit 17a extending towards the eaves beam assembly 14a, labelled as y.

Figure 2 shows an isometric view of the partially assembled corner assembly 42a. It shall be appreciated that the corner assemblies 42b-d are of substantially the same configuration. The eaves beam assemblies 14a, 14b each include an exterior surface 19a, 19b. The exterior surfaces 19a, 19b are remote from the apex of the roof and extend transverse to the axis of slope x of the respective glazing units 17a, 17b.

The rafter 16a is secured to the exterior surface 19a, 19b of the eaves beam assemblies 14a, 14b.The glazing receiving portion 23a of the rafter 16a extends a greater distance along a longitudinal axis of the rafter 16a than the structural portion 23b. This enables the glazing receiving portion 23a to extend over the exterior surfaces 19a, 19b and the structural portion to abut against an interior surface 19c, 19d of the eaves beam assemblies 14a, 14b. Since the glazing receiving portion 23a is at least partially plastic, this improves insulation at the corners and maintains the weatherproofing of the roof 10.

The rafter 16a is secured to the corner formed by the eaves beam assemblies 14a, 14b using a securing member 48. In this embodiment, the securing member 48 is an L-shaped bracket 48. A first arm of the bracket 48 is secured to the exterior surface 19a, and a second arm of the bracket 48 is secured to exterior surface 19b.

A first fastener 52a extends through a first hole 50a in the first arm of the bracket 48, through a corresponding hole 46 in the eaves beam assembly 14a and through a corresponding hole 54 in an end of the structural portion 23b of the rafter 16a. A second fastener 52b extends through a second hole 50b in the second arm of the bracket 48, through a corresponding hole (not shown) in the eaves beam assembly 14b and through a corresponding hole (not shown) in an end of the structural portion 23b of the rafter 16a.

Figure 3 shows a cross-sectional view of the eaves beam assembly 14a along a plane z-z of Figure 1. Whilst only one eaves beam assembly 14a is illustrated in Figure 3, it shall be appreciated that at each perimeter edge of the roof 10 there is one eaves beam assembly 14b-d of substantially the same configuration. Therefore, for reasons of conciseness and brevity, only eaves beam assembly 14a shall be described herein.

The eaves beam assembly 14a is screwed into an upstand 9 of a flat roof underlying and supporting the roof 10 using a fastener 56, in this embodiment a threaded fastener. The fastener 56 extends through a hole (not shown) in the eaves beam assembly 14a and through a corresponding hole in the upstand 9. In some embodiments the fastener 56 includes a non-standardized head so that standard screwdrivers cannot remove the fastener 56 from the upstand 9. This provides additional security benefits.

It will be appreciated that if the roof 10 forms part of a conservatory, the eaves beam assembly may only be supported at certain points e.g. by columns at the ends thereof and infill windows or doorways may be provided under the remainder thereof.

In this embodiment, the eaves beam assembly 14a include a structural support member 18a, a thermal insulating assembly 20, an end trim 22, an adhesive connection 26 and a gasket 36.

The gasket 36 extends along an elongate edge of the eaves beam assembly 14a.

The gasket 36 creates a seal between the eaves beam assembly 14a and the upstand 9 of the underlying roof. In alternative embodiments, the gasket may create a seal between the eaves beam assembly and any suitable exterior surface of the underlying structure (such as door or window frames of underlying conservatory walls). The gasket is manufactured using a thermoplastic elastomer (TPE), and in this embodiment the gasket is coextruded with the thermal insulating assembly to form one part during the manufacturing process. Alternatively, the gasket may be manufactured as a separate component.

The components of the eaves beam assembly 14a inter-engage so as to improve the security of the roof 10, as described in more detail below.

A cross-sectional view of the eaves beam assembly 14a is illustrated at Figure 4.

The structural support member 18a provides the structural strength required to support the roof 10. The structural support member 18a is manufactured from a metallic material, in this embodiment an aluminium alloy, however in alternative embodiments any material with suitable strength may be used. The structural support member 18a is manufactured using extrusion, however any suitable process may be used, for example injection moulding.

In this embodiment, the structural support member 18a includes at least one hollow profile 27a, 27b, the interior surface 19b and the exterior surface 19a described above. Therefore, the threaded fasteners 52a, b, 56 extend through the structural support member 18a so as the secure the structural support member 18a to the upstand 9 of the roof 10 and to the structural portion 23b of the rafter 16a.

The structural support member 18a also includes first, second and third engagement formations 32b, 33b, 35b for releasably mounting the thermal insulating assembly 20 to the exterior surface 19a of the structural support member 18a.

In this embodiment, the structural support member 18a includes a first hollow profile 27a and a second hollow profile 27b which extend along the longitudinal axis of the structural support member 18a. In alternative embodiments, any number of hollow profiles may be used, or the hollow profile may be omitted. The first hollow profile 27a receives an arm of the connector (discussed above), and so its shape is dependent on the shape of the connector. In this embodiment, the first hollow profile 27a includes projections which engage with corresponding grooves in the connector, however any suitable shape of hollow profile may be used.

The hollow profiles 27a, 27b also reduce the mass of the structural support member 18a and therefore the amount of aluminium required. The reduction in material is more cost effective, and a lighter structural support member is easier for the fitter to manoeuvre.

The interior surface 19b of the structural support member 18a extends in a direction parallel to the transverse axis of slope y. The interior surface 19b also includes a channel 64 extending along the longitudinal axis of the structural support member 18a. The channel 64 sits against the upstand 9. The channel 64 may receive cabling or lighting, for example LED lighting strips.

The exterior surface 19a includes a recessed portion 25a and a first and second ledge 25b, 25c, which extend along the longitudinal axis of the structural support member 18a. The first ledge 25b extends from an upper edge of the recessed portion 25a, and the second ledge 25c extends from a lower edge of the recessed portion 25a. The first and second ledge 25b, 25c extend in a direction parallel to the axis of slope x.

In this embodiment, the first engagement formation 32b is used to mount the thermal insulating assembly 20 to the first ledge 25b of the structural support member 18a. The first engagement formation 32b is a groove located towards an upper edge of the first ledge 25b. The second engagement formation 33b is used to mount the thermal insulating assembly 20 to the recessed portion 25a of the structural support member 18a. The second engagement formation 33b is a protrusion 33b located on an underside of the first ledge 25b. The third engagement formation 35b is used to mount the thermal insulating assembly 20 to the second ledge 25c of the structural support member. The third engagement formation 35b is a protrusion 35b located towards a lower edge of the second ledge 25c.

It shall be appreciated that in alternative embodiments, any suitable number of engagement formations may be used, and they may be located at any suitable location of the structural support member 18a.

The thermal insulating assembly 20 is at least partially manufactured from a plastics material, for example uPVC. As uPVC is resilient, this eases the installation and removal of the thermal assembly whilst minimising the risk of damage to the structural support member 18a. Additionally, since plastic is an insulating material, the insulating properties of the eaves beam assembly 14a are improved. The thermal insulating assembly 20 is manufactured using an extrusion process.

The thermal insulating assembly 20 includes a plurality of securing features and engagement formations. In this embodiment, the thermal insulating assembly 20 includes the adhesive connection 26, an end trim engagement formation 34 and a first, second and third engagement formation 32a, 33a, 35a which correspond to the engagement formations 32b, 33b, 35b of the structural support member 18a.

The first engagement formation 32a is a protrusion 32a for engagement with the groove 32b. The protrusion 32a is located on an interior surface of the thermal insulating assembly 20. The protrusion is substantially L-shaped, and the groove 32b of the structural support member 18a includes a shoulder. Upon assembly, a transverse leg of the protrusion 32a abuts behind the shoulder of the groove 32b in order to retain the protrusion 32a within the groove 32b using a snap-fit connection.

The second engagement formation 33a is a groove 33a for engagement with the protrusion 33b. Upon assembly, the protrusion 33b engages with a side wall of the groove 33a so as to form a push-fit connection.

The third engagement formation 35a is a protrusion 35a for engagement with the protrusion 35b. Both protrusions 35a, 35b include a shoulder. The shoulders of the protrusions 35a, 35b engage upon assembly, and the shoulder of the protrusion 35b acts as a stop to prevent the protrusion 35a from sliding away from the structural support member 18a under gravity.

The end trim engagement formation 34 facilitates the securing of the end trim 22 to the thermal insulating assembly 20. In this embodiment, the end trim engagement formation 34 is in the form of a channel 34 extending along the longitudinal axis of the thermal insulating assembly 20. In alternative embodiments, the engagement formation may be any fastening, for example an adhesive or a threaded/non-threaded fastener. The engagement formation 34 is greater in width and depth than the engagement formations 32a, 32b, 33a, 33b, 35a, 35b. This helps to provide a strong engagement between the end trim 22 and the thermal insulating assembly 20 to help prevent the end trim 22 being removed.

In alternative embodiments, any suitable form of mechanical fastening could be used in place of the first, second and third sets of engagement formations and the channel 34, or an adhesive.

In this embodiment, the adhesive connection 26 is a continuous adhesive strip 26, however in alternative embodiments any number of discrete adhesive members may be used, for example two adhesive member located at opposing ends of the thermal insulating assembly 20. In this embodiment, the adhesive connection 26 is located on an exterior surface 30a of the thermal insulating assembly. In alternative embodiments, the adhesive connection/connections may be located at any suitable location on the eaves beam assembly. The adhesive connection 26 includes a backing material (not shown) which is removed during the assembly of the roof 10.

The adhesive connection 26 engages with an interior face of the glazing unit 17a.

The adhesive connection 26 and the glazing unit 17a form an adhesive bond that meets the necessary strength requirements to prevent a burglar from easily prising the glazing unit 17a away from the thermal insulating assembly 20.

In this embodiment, the thermal insulating assembly 20 includes a fascia trim 28 and an infill trim 30, however in alternative embodiments the thermal insulating assembly 20 may be a single component, or the thermal insulating assembly may include more than two components.

Although not illustrated, the fascia trims 28 of adjacent eaves beam assemblies 14a-d interface at a corner in the same way as the structural support members 18a, 18b of the corner assembly 42a. The infill trim 30 of adjacent eaves beam assemblies 14a-d are not in direct contact. Instead, the infill trims 30 abut against opposing elongate sides of the rafters 16a-d. Put another way, the rafter 16a-d extend between adjacent infill trims 30.

In this embodiment, the first engagement formation 32a is located on the infill trim 30, and the second and third engagement formations 33a, 35a are located on the fascia trim 28. Upon assembly, the infill trim 30 sits partially upon the first ledge 25b and partially upon the fascia trim 28, and the fascia trim 28 is partially located within the recess 25a of the structural support member 18a.

An interior surface of the infill trim 30 is mounted to an exterior surface of the fascia trim 28 via a fourth set of engagement formations 37a, 37b, as illustrated in Figure 6. When assembled, the infill trim 30 is mounted above the fascia trim 28. The fourth set of engagement formations 37a, 37b are of the same configuration as the first set of engagement formations 32a, 32b and so form a snap-fit connection. The protrusion 37a is located on the infill trim 30, and the groove 37b is located on the fascia trim 28. The engagement formations 32a, 32b, 37a, 37b enable the fascia trim 28 to at least resist removal from the structural support member 18a in at least a direction away from the apex of the roof 10.

The fascia trim 28 includes the engagement formation 34, the gasket 36, a hollow profile and at least one internal stiffening rib 58a-c. The gasket 36 extends along an elongate edge of the fascia trim 28, however in alternative embodiments the gasket may be located at any suitable location on the eaves beam assembly. A longitudinal axis of the fascia trim 28 extends in a direction generally parallel to the axis of slope x.

The engagement formation 34 is located on the fascia trim 28 adjacent to the infill trim 30, in this embodiment adjacent the fourth engagement formations 37a, 37b. In alternative embodiments, the engagement formation 34 may be located on the infill trim 30.

The positioning of the engagement formations 32a, 32b, 33a, 33b, 35a, 35b, 37a, 37b, 24, 34 enable the inter-engagement of the components of the eaves beam assembly 14a. The structural support member 18a is secured to both the infill trim 30 and the fascia trim 28. The fascia trim 28 is secured to both the infill trim 30 and the end trim 22.

The hollow profile of the fascia trim 28 extends along the longitudinal axis of the fascia trim 28. This reduces the mass of the fascia trim 28 whilst increasing the flexibility, which is beneficial to the assembly process. Additionally, the hollow profile increases the insulation properties of the thermal insulating assembly 20. The hollow profile is separated into four chambers by the internal ribs 58a-c. In this embodiment, there are three ribs 58a-c extending between opposing faces of the fascia trim 28 in a direction parallel to the transverse axis of slope y. Each of the ribs 58a-c is located adjacent to one of the engagement formations 33a, 33b, 35a, 35b, 37a, 37b respectively. This provides increased structural strength to the fascia trim 28 and helps prevent the fascia trim from buckling when it is attached to the structural support member 18a, infill trim 30 and end trim 22.

The infill trim 30 includes an exterior surface 30a, an interior surface 30b, first and second side walls 30c, 30d, a hollow profile, at least one internal rib 60a, 60b and the adhesive connection 26 thereon. In alternative embodiments, any of these components may be omitted and variations may be used.

The adhesive connection 26 is located on the exterior surface 30a of the infill trim at a central location.

In this embodiment, the infill trim 30 is substantially rectangular in cross section. The interior surface 30a of the infill trim is substantially planar aside from the engagement formations 32a, 33a. The exterior surface 30a and the interior surface 30b are coplanar. In this embodiment, in the assembled state, the interior and exterior surfaces 30a, 30b extend in a directions parallel to the direction of slope x.

The first and second side walls 30c, 30d extend between the exterior and interior surfaces 30a, 30b. In this embodiment, the first and second side walls extend from opposing elongate edges of the exterior and interior surfaces 30a, 30b. A width of each of the interior and exterior surfaces 30a, 30b is significantly greater than a width of the first and second side walls 30c, 30d. This increases the flexibility of the infill trim 30 and therefore makes the infill trim 30 easier to install/remove from the thermal insulating assembly 20 and the structural support member 18a.

The exterior surface 30a, interior surface 30b and first and second side walls 30c, 30d define the hollow profile of the infill trim 30. The hollow profile extends along the longitudinal axis of the infill trim 30. The hollow profile increases the insulation properties of the thermal insulating assembly 20. The hollow profile is separated into three chambers by the internal ribs 60a, 60b. In this embodiment, there are two ribs 60a, 60b extending between the exterior and interior surfaces 30a, 30b of the infill trim 30. Each of the ribs 60a, 60b is located adjacent elongate edges of the adhesive connection 26 in order to provide increased structural support when the glazing unit 17a is pressed against the adhesive connection 26.

The end trim 22 and the glazing unit 17a are illustrated in Figures 7 and 8. The end trim 22 includes a cover wall 22a, first and second ledges 22b, 22c, a stop 62a, 62b and an engagement formation 24 for securing the end trim 22 to the fascia trim 28. In alternative embodiments, any of these components may be omitted and variations may be used. In alternative embodiment, the end trim 22 may be provided as part of the thermal insulating assembly 20.

The end trim 22 is manufactured from a plastics material using an extrusion process, however in alternative embodiments any suitable material and manufacturing process may be used.

The glazing unit 17a is positioned between the first and second ledges 22b, 22c, in a channel defined by the first and second ledges 22b, 22c. In this embodiment, the first ledge 22b extends partially over the interior surface 29b of the glazing unit 17a, and the second ledge 22c extends partially over the exterior surface 29a of the glazing unit 17a. The first and second ledges 22b, 22c extend in a direction parallel to the pane of the glazing unit 17a. In alternative embodiments, the first and/or second ledges may be omitted and any suitable means of positioning the glazing unit relative to the end trim may be used.

In this embodiment, the stop 62a, 62b is a first and second protrusion 62a, 62b extending from the first and second ledges 22b, 22c in a direction parallel to the transverse axis of slope y. The glazing unit 17a rests against the stop 62a, 62b when assembled to the end trim 22. This helps to correctly position the glazing unit 17a relative to the end trim 22 and prevents the glazing unit 17a from being over inserted into the end trim 22.

The end trim 22 and the glazing unit 17a form a cover over the structural support member 18a and the thermal insulating assembly 20. In this embedment, the cover wall 22a forms the cover by extending in a direction parallel to the transverse axis of slope y and overlying the fascia trim 28. The width of the cover wall 22a in a direction parallel to the transverse axis of slope y is greater than the width of the fascia trim 28 in the same direction, so that the fascia trim 28 is not visible from the exterior side of the roof. In this embodiment, the end trim 22 overlies the fascia trim 28, however in alternative embodiments the end trim may overlie any surface of the eaves beam assembly.

The engagement formation 24 engages with the corresponding end trim formation 34 of the thermal insulating assembly 20. In this embodiment, the engagement formation 24 is a hook 24. The hook 24 extends from the second ledge 22b in a direction parallel to the transverse axis of slope y. The engagement formation 24 and the end trim formation 34 are secured together using a push-fit connection. In alternative embodiments, any suitable form of mechanical/non-mechanical connection may be used, for example a snap-fit, at least one threaded fastener or an adhesive.

To assemble the roof 10, the four structural support members 18a, 18b of the four eaves beam assemblies 14a-d are assembled to the four sides of the opening into which the roof 10 is being installed. The L-shaped connectors are applied at the corners to secure adjacent structural support members 18a, 18b. The legs of the L-shaped corner connectors are inserted into the hollow profiles 27a of the structural support members 18a, 18b. The structural support members 18a, 18b are secured to the sides of the opening of the roof via threaded fasteners 56. Any suitable number of fasteners may be used depending on the size and shape of the roof.

The rafters 16a-d and the ridge beam 11 are then assembled. The first and second connecting members 21a, 21b are secured to the first and second ends 11a, llb respectively of the ridge beam 11 using threaded fasteners (not shown), however any suitable securing arrangement may be used. In this embodiment, this step happens offsite, however the assembly may also happen onsite. The rafters 16a, 16b are then secured to the first connecting member 21a, and the rafters 16c, 16c are secured to the second connecting member 21b.

Once the rafters 16a-d and the ridge beam 11 are assembled, the assembly is lowered onto the rectangular frame formed by the structural support members 18a-d. In order to secure the rafter 16a to the corner 42a formed by the structural support members 18a, 18b, the first arm of the securing member 48 is secured to the first recessed portion 25a, and the second arm of the securing member 48 is secured to the second recessed portion. The first fastener 52a is inserted into the first hole 50a, through the corresponding hole 46 in the structural support member 18a and through the corresponding hole 54 in the structural support portion 23b of the rafter 16a and tightened. This process is repeated for the second fastener 52b.

Three securing members are secured in the same way to form the three remaining corner assemblies 42b-d.

Next the fascia trim 28 is secured to the structural support member 18a via the engagement formations 33a, 33b, 35a, 35b, as illustrated in Figure 5. The direction of insertion of the fascia trim 28 is approximately parallel to the axis of slope x.

This process is repeated for the remaining three structural support members and fascia trims.

To complete the thermal insulating assembly 20, the infill trim 30 is secured to the fascia trim 28 and to the structural support member 18a via the engagement formations 32a, 32b, 37a, 37b, as illustrated in Figure 6. The direction of insertion of the infill trim 30 is approximately parallel to the transverse axis of slope y. This process is repeated for the remaining three infill trims to complete the four thermal insulating assemblies 20a-d. The adjacent infill trims 30a-d are not in direct contact. Instead, the infill trims 30a-d abut against opposing sides of each of the rafters 16a-d.

The end trim 22 is secured to the edge of the glazing units 17a-d by inserting the glazing unit into the channel formed between the first and second ledges 22b, 22c, as illustrated in Figure 7. In this embodiment, this step happens onsite, however the securing may also happen offsite.

The backing material is removed from the adhesive connection 26. The glazing unit 17a fitted with end trim 22 is lowered onto the rafters 16a, 16b as illustrated in Figure 8. The glazing unit 17a is positioned so that opposing edges of the glazing unit 17a sit upon the ridges 40a, 40b of the rafters 16a, 16b. The engagement formation 24 of the end trim 22 is push-fitted into the end trim formation 34 of the fascia trim 28. The glazing unit 17a is pressed onto the adhesive connection 26 to form the required adhesive bond. To complete the frame assembly 12, the remaining three glazing units 17b-d and corresponding end trims are lowered into the correct positions.

Once the roof 10 has been assembled, the inter-engagement of the structural support member 18a, thermal insulating assembly 20 and end trim 22 make it difficult to gain unauthorised access to the opening of the roof 10, especially if a burglar does not have specialist tools.

The securing of the thermal insulating assembly 20 and the end trim 22 to the exterior surface 19a of the structural support member 18a block access to the fasteners 52a, 56. This means the frame assembly 12 cannot easily be unscrewed from the roof 10 and lifted out to access the opening.

It is also difficult to remove the glazing unit 17a from the eaves beam assembly 14a. Due to the adhesive connection 26, the glazing unit 17a and end trim 22 cannot simply be lifted out of the thermal insulating assembly 20. Additionally, due to the second ledge 22c of the end trim extending over the exterior surface of the glazing unit 17a, the glazing unit 17a cannot be pivoted out of the end trim 22.

The engagement of end trim formation 34 and engagement formation 24 prevent the end trim 22 from being removed from the glazing unit in a direction parallel to the axis of slope. Additionally, the engagement of the formation 24 within the corresponding formation 34 makes it difficult to access the adhesive connection 26, for example with a tool, to try and prise the glazing unit 17a away from the thermal insulating assembly 20 and gain axis in this way. This results in significant security benefits to the roof 10 of the present teachings.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

Claims 1. An eaves beam assembly for supporting a lower margin of a glazing unit of a fixed pitched roof for example a lantern roof or a conservatory roof, the eaves beam assembly comprising: a structural support member having an exterior surface arranged to be remote from an apex of the roof and extend transverse to a direction of slope of the roof; a thermal insulating assembly arranged to be mounted to the exterior surface of the structural support member; and an end trim configured to receive at least an end edge of the glazing unit, wherein the end trim comprises an engagement formation for securing the end trim to the thermal insulating assembly.
2. The eaves beam assembly of claim 1 further comprising an adhesive connection between the thermal insulating assembly and the glazing unit.
3. The eaves beam assembly of claim 1 or claim 2 wherein the thermal insulating assembly comprises a fascia trim arranged to be mounted to the exterior surface of the structural support member and an infill trim arranged to be mounted above the fascia trim and the structural support member and support the glazing unit.
4. The eaves beam assembly of claim 3 when dependent on claim 2 wherein the infill trim has the adhesive connection thereon.
5. The eaves beam assembly of claim 3 or claim 4 wherein the infill trim is arranged to engage the structural support member and the fascia trim to at least resist removal of the fascia trim from the structural support member in at least a direction away from the apex of the roof.
6. The eaves beam assembly of claim 5 wherein the engagement is a push-fit, optionally a snap-fit engagement between the infill trim and at least one of the structural support member or fascia trim.
7. The eaves beam assembly of any preceding claim wherein the end trim is configured to extend partially over an exterior surface of the glazing unit.
8. The eaves beam assembly of any preceding claim wherein the engagement formation of the end trim comprises a push-fit formation, e.g. a hook arranged to engage a complementary formation of the thermal insulating assembly.
9. The eaves beam assembly of any preceding claim wherein the engagement formation is inaccessible from an exterior side of the thermal insulating assembly.
10. The eaves beam assembly of claim 9 when dependent on claim 8 wherein the corresponding formation of the thermal insulating assembly is in the form of a channel located on the fascia trim, and wherein the hook engages with the channel.
11. The eaves beam assembly of any preceding claim wherein the fascia trim comprises a gasket extending along an elongate edge of the fascia trim, wherein the gasket is configured to create a seal between the elongate edge of the fascia trim and an exterior surface of the roof of a structure below the pitched roof, for example an upstand of a flat roof.
12. The eaves beam assembly of claim 11 wherein the gasket is manufactured using a thermoplastic elastomer (TPE), optionally wherein the gasket is coextruded with the fascia trim.
13. The eaves beam assembly of any preceding claim wherein the structural support member is manufactured from metal, optionally wherein the structural support member is manufactured from an aluminium alloy.
14. The eaves beam assembly of any preceding claim wherein the thermal insulating assembly is at least partially manufactured from a plastics material.
15. A frame assembly for a fixed pitched roof, for example a lantern roof or a conservatory roof, the frame assembly comprising: at least one eaves beam assembly according to any preceding claim; at least one glazing unit, wherein an edge of the glazing unit is received by the end trim; and at least one rafter extending at a non-zero angle above the horizontal relative to the eaves beam assembly.
16. The frame assembly of claim 15, wherein the rafter comprises a ridge for supporting a second edge of the glazing unit adjacent to the first edge.
17. The frame assembly of claim 15 or 16 further comprising at least one corner assembly, wherein each corner assembly comprises a first eaves beam assembly and a second eaves beam assembly which interface at a corner.
18. The frame assembly of claim 17 wherein the first eaves beam assembly and the second eaves beam assembly are in mitred abutment and are connected by an L-shaped corner connector, with one leg extending into a first hollow profile of the first eaves beam assembly and a second leg extending into a second hollow profile of the second eaves beam assembly.
19. The frame assembly of claim 17 or 18 wherein the rafter is secured in abutment to an interior face of the first structural support member and to an interior face of the second structural support member at the corner assembly, and wherein the rafter extends from the corner at a non-zero angle with respect to the longitudinal axes both the first eaves beam and the second eaves beam.
20. The frame assembly of any one of claims 17 to 19 wherein the rafter is secured to the corner assembly by at least one fastener extending through the structural support member.
21. The frame assembly of claim 20 wherein the thermal insulating assembly blocks access to the at least one fastener when fitted to the structural support member.
22. The frame assembly of any one of claims 17 to 21 when dependent on claim 3 wherein the first infill trim abuts a first side of the rafter, and the second infill trim abuts an opposing second side of the rafter.
23. The frame assembly of any of claims 17 to 22, wherein the structural support member is secured to an upper surface of a structure below the pitched roof, for example an upstand of a flat roof, using a fastening member, optionally wherein the fastening member is a screw.
24. A method of assembling an eaves beam assembly according to any of claims 1 to 16 of a fixed pitched roof, for example a lantern roof or a conservatory roof, the method comprising the steps of: a) fitting an end trim to an edge of a glazing unit, wherein the end trim comprises an engagement formation; b) securing a first surface of the thermal insulating assembly to an exterior surface of the structural support member; c) securing the engagement formation of the end trim to a second surface of the thermal insulating assembly.