GB2609526A

GB2609526A - A kit of parts

Info

Publication number: GB2609526A
Application number: GB2204923.3A
Authority: GB
Inventors: Hacking Steve; Watters David
Original assignee: Supalite Tiled Roof Systems Ltd
Current assignee: Supalite Tiled Roof Systems Ltd
Priority date: 2022-04-04
Filing date: 2022-04-04
Publication date: 2023-02-08
Anticipated expiration: 2042-04-04
Also published as: IE87410B1; GB2609526B; GB202204923D0; IE20230026A1

Abstract

A kit of parts for a lightweight roof construction comprises: an elongate structural frame member 22 having a first longitudinal axis, and comprising a first coupling portion 24; and an elongate batten 16 having a second longitudinal axis, and comprising a second coupling portion. The first coupling portion and the second coupling portion are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, an inter engagement between the first coupling portion and the second coupling portion couples the structural frame member and the batten to each other, such that relative movement between the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes is inhibited. The attachment may be via ribs and slots or channels allowing sliding engagement of the profiles. The frame member may be a rafter, eaves or ridge beam and the batten may present a flat outer surface for receipt and securement of roofing sheet.

Description

A KIT OF PARTS

FIELD

The present teachings relate to a kit of parts for a lightweight roof construction, an elongate structural frame member for a lightweight roof construction, and a method of coupling an elongate structural frame member and an elongate batten to each other.

BACKGROUND

Lightweight roof constructions are commonly opaque roofing structures, which have the appearance and function of a conventional roof construction, e.g. by being clad by tiles, but are configured to be of lighter weight compared to a conventional roof construction.

Due to their relatively lighter weight, lightweight roof constructions are typically used as a retrofitted roofing solution to buildings, typically domestic properties, that were originally provided with a glazed roof construction, such as conservatories, where the perimeter fenestration of the conservatory cannot support a conventional tiled roof, for example.

Since lightweight roof constructions tend to be opaque, and are able to accommodate heating insulation, they enable easier thermal management via better heat retention in winter and lower solar gain in summer.

A lightweight roof construction typically includes a plurality of elongate structural frame members, such as eaves beams, rafter beams and ridge beams, which together form the structural frame of the lightweight roof construction that is supported by the perimeter of a structure. Outer components of the lightweight roof construction are mounted to the structural frame via wooden battens, which are secured to the structural frame members via mechanical fixings such as nails or screws. A problem with such lightweight roof constructions is that securing the battens to the structural frame members using mechanical fixings is a time-intensive manual task, which can reduce the efficiency of constructing a lightweight roof construction.

If wooden battens are used, further issues may arise with warping, swelling or shrinkage and/or degradation of the wood due to moisture as ambient conditions vary in the roof.

The present teachings seek to overcome, or at least mitigate the problems of the prior art. 30 SUMMARY According to a first aspect of the present teachings, there is provided a kit of parts for a lightweight roof construction comprising: an elongate structural frame member having a first longitudinal axis, and comprising a first coupling portion; and an elongate batten having a second longitudinal axis, and comprising a second coupling portion. The first coupling portion and the second coupling portion are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, an inter-engagement between the first coupling portion and the second coupling portion couples the structural frame member and the batten to each other, such that relative movement between the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes is inhibited.

Advantageously, providing the structural frame member and the batten with interengageable coupling portions, enables the batten to be coupled to the structural frame member without requiring additional fixings, such as nails, screws and the like. As such, the time required to couple the batten and the structural frame member to each other may be reduced, increasing the efficiency of constructing a lightweight roof.

The first coupling portion may be arranged on an outer face of the structural frame member, the structural frame member configured such that said outer face forms an outer face of a structural frame for a lightweight roof construction, in use.

Advantageously, arranging the first coupling portion as such enables the batten, when coupled to the structural frame member, to act as a mounting platform for mounting components of a lightweight roof construction that are outward from the structural frame of the roof construction, such as fascia boards or roofing sheets for example, thereto.

The batten may be formed from a plastics material, such as polyvinyl chloride (PVC), for example, unplasticized polyvinyl chloride (uPVC).

Advantageously, forming the batten from a plastics material, such as PVC, helps to ensure that the batten is low-cost, lightweight, thermally insulative and not affected by corrosion or degradation, which can occur in other materials such as wood for example.

The structural frame member may be formed from a metallic material, such as aluminium.

One of the first and second coupling portions may form a male portion, and the other of the first and second coupling portion may form a female portion. The male portion and the female portion may have complementary profiles, such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion is receivable in the female portion, for coupling the structural frame member and the batten to each other.

Advantageously, such a configuration of the first and second coupling portions enables inter-engagement of the coupling portions by simply receiving the male portion into the female portion, providing rapid coupling of the structural frame member and the batten to each other.

The first coupling portion may comprise a rib. The second coupling portion may define a complimentary recess. The rib may be configured to be receivable in said complimentary recess to inter-engage the first coupling portion and the second coupling portion, for coupling the structural frame member and the batten to each other.

Advantageously, the configuration of the rib and the complimentary recess helps to interlock the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes, preventing relative movement along said direction.

The recess may be a groove or channel.

The first coupling portion may comprise two opposed ribs at least partially defining a cavity forming a female portion. The second coupling portion may comprise a male portion. The female portion and the male portion may have complimentary profiles such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion is receivable in the female portion, for coupling the structural frame member and the batten to each other.

The first coupling portion may comprise two opposed substantially parallel walls. Each rib may project from one of said walls. The walls and the ribs may at least partially define the cavity forming the female portion.

Advantageously, such a configuration of the first coupling portion may help to provide a strong inter-engagement with the batten, when the batten has corresponding opposed substantially parallel walls, which the batten would have if the batten had a substantially rectangular profile for example.

Each rib may project substantially perpendicularly from the corresponding wall. The two ribs may project in a common plane.

The first coupling portion and the second coupling portion may be configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, the first and second coupling portions inter-engage via translation of the first coupling portion and the second coupling portion together in a direction parallel to both the first longitudinal axis and the second longitudinal axis.

Advantageously, such a configuration of the first and second coupling portions enables the structural frame member and the batten to be coupled to each other by sliding the first and second coupling portions towards each other, enabling rapid coupling of the structural frame member and the batten to each other.

The first coupling portion and the second coupling portion may be configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, the first and second coupling portions inter-engage via translation of the first coupling portion and the second coupling portion together in a direction transverse to both the first longitudinal axis and the second longitudinal axis.

The first coupling portion and the second coupling portion may inter-engage via a snap-fit inter-engagement.

The structural frame member may be one of: an eaves beam; a rafter beam; or a ridge beam.

The batten may be formed as a solid block of material for receiving a mechanical fixing, such as a nail or screw, therein.

The batten may comprise a mounting face extending across a transverse width of the batten for mounting a roof component, such as a fascia board or roofing sheet, thereto.

The mounting face may be on an opposite side of the batten to the second coupling portion.

The mounting face may comprise a substantially planar surface for receiving the roof component thereon.

The planar surface may extend across the transverse width of the batten. The batten may have a substantially rectangular profile.

The first coupling portion may extend along at least a majority of a longitudinal length of the structural frame member.

Advantageously, such a configuration helps to provide a strong and robust coupling between the structural frame member and the batten.

The structural frame member may comprise a constant profile along the first longitudinal axis.

Advantageously, providing the structural frame member with a constant profile helps to simplify its manufacture, since the structural frame member may be formed via an extrusion process for example.

According to a second aspect of the present teachings, there is provided a lightweight roof construction comprising: the structural frame member and the batten of the kit of parts according to the first aspect of the present teachings; and a roof component, such as a fascia board or roofing sheet. The structural frame member and the batten are coupled to each other via inter-engagement between the first coupling portion and the second coupling portion. The roof component is mounted to the mounting face of the batten via one or more mechanical fixing components, such as nails or screws, passing through the roof component and received in the batten.

According to a third aspect of the present teachings, there is provided an elongate structural frame member for a lightweight roof construction, the structural frame member having a first longitudinal axis and comprising: a coupling portion configured for coupling the structural frame member to an elongate batten having a second longitudinal axis via inter-engagement between the coupling portion and the batten when the first and second longitudinal axes are aligned, such that relative movement between the structural frame member and the batten along a direction transverse to the longitudinal axes is inhibited. The coupling portion is arranged on an outer face of the structural frame member, the structural frame member configured such that said outer face forms an outer face of a structural frame for a lightweight roof construction, in use. The coupling portion comprises two opposed substantially parallel walls and two opposed ribs, each rib projecting from one of said walls. The walls and ribs at least partially define a cavity forming a female portion. The female portion is configured such that when the first longitudinal axis and the second longitudinal axis are aligned, a male portion of the batten is receivable in the female portion, for coupling the structural frame member and the batten to each other.

Advantageously, providing the structural frame member with a coupling portion which is inter-engageable with a batten, enables the batten to be coupled to the structural frame member without requiring additional fixings, such as nails, screws and the like. As such, the time required to couple a batten to the structural frame member may be reduced, increasing the efficiency of constructing a lightweight roof.

The coupling portion may extend along at least a majority of a longitudinal length of the structural frame member.

According to a fourth aspect of the present teachings, there is provided a method of coupling an elongate structural frame member for a lightweight roof construction having a first longitudinal axis and an elongate batten having a second longitudinal axis to each other, the structural frame member comprising a first coupling portion and the batten comprising a second coupling portion. The method comprises the steps of: (a) arranging the structural frame member and the batten such that the first longitudinal axis and the second longitudinal axis are aligned; and (b) inter-engaging the first coupling portion and the second coupling portion, such that relative movement between the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes is inhibited.

One of the first and second coupling portions may form a male portion, and the other of the first and second coupling portion may form a female portion. The male portion and the female portion may have complementary profiles. Step (b) may comprise: receiving the male portion in the female portion such that the structural frame member and the batten are coupled to each other.

The first coupling portion may comprise a rib. The second coupling portion may define a complimentary recess. Step (b) may comprise: receiving the rib in said complimentary recess to inter-engage the first coupling portion and the second coupling portion such that the structural frame member and the batten are coupled to each other.

The recess may be a groove or channel.

The first coupling portion may comprise two opposed ribs at least partially defining a cavity forming a female portion. The second coupling portion may comprise a male portion. The female portion and the male portion may have complimentary profiles. Step (b) may comprise: receiving the male portion in the female portion, such that the structural frame member and the batten are coupled to each other.

Step (b) may comprise: translating the first coupling portion and the second coupling portion together in a direction parallel to both the first longitudinal axis and the second longitudinal axis to inter-engage the first coupling portion and the second coupling portion.

Step (b) may comprise: translating the first coupling portion and the second coupling portion together in a direction transverse to both the first longitudinal axis and the second longitudinal axis to inter-engage the first coupling portion and the second coupling portion.

The batten may be formed as a single solid block of material for receiving a mechanical fixing, such as a nail or screw, therein.

The batten may comprise a mounting face extending across a transverse width of the batten for mounting a roof component, such as a fascia board or roofing sheet, thereto. The mounting face may be on an opposite side of the batten to the second coupling portion.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are now disclosed by way of example only with reference to the drawings, in which: Figure 1 is an isometric view of a lightweight roof construction according to an embodiment; Figure 2 is an isometric view of the lightweight roof construction of Figure 1 with outer roof components omitted; Figure 3A is a profile view of a structural frame member and a batten according to an 25 embodiment; Figure 3B is a magnified view of Figure 3A; Figure 4 is a profile view of another structural frame member and a batten according to an embodiment; Figure 5 is a profile view of a further structural frame member and two battens according to an embodiment; Figure 6 is a profile view of a further structural frame member and two battens according to an embodiment; and Figure 7 is a profile view of a further structural frame member and a batten according to an embodiment.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Figure 1 shows a lightweight roof construction 10 including a structural frame 12 and outer roof components 14. In the illustrated embodiment, the outer roof components 14 include a fascia board 14a and a roofing sheet 14b. The outer roof components 14 may be formed from any suitable material, such as engineered wood material (e.g. plywood) or uPVC sheets for example. The structural frame 12 is configured to sit upon and extend between walls of a structure (not shown), such as a conservatory for example. By "outer roof components", it is intended to mean non-glazing components of the lightweight roof construction 10 that are located outside of a volume defined by the structural frame 12 and the walls of the structure upon which the structural frame 12 sits.

A plurality of elongate battens 16 are coupled to the structural frame 12, as will be discussed in more detail in the following. The roof components 14 are mounted to the battens 16 via one or more mechanical fixing components 18, such as nails or screws, passing through the roof components 14 and received in the battens 16.

By "batten", it is intended to mean a strip of material, which is suitable for receiving one or more mechanical fixing components 18 in order to provide a fixing point for the outer roof components 14.

Although not shown in Figure 1, the lightweight roof construction 10 may include: a plurality of the fascia boards 14a; a plurality of the roofing sheets 14b; a waterproof membrane arranged to cover an outer surface of the one or more roofing sheets 14b; a plurality of lightweight roof tiles (e.g. formed from a plastics material or a metallic material) arranged to provide an outermost layer of the lightweight roof construction 10; thermal insulation material (e.g. expanded polystyrene) secured to the structural frame 12 and located internally with respect to the outer roof components 14; one or more sheets of plasterboard arranged to provide an innermost layer of the lightweight roof construction 10; and/or one or more glazing elements, such as roof lights or skylights.

Figure 2 shows the lightweight roof construction 10 of Figure 1 with the outer roof components 14 omitted. The structural frame 12 is formed from a plurality of connected elongate structural frame members 20. In the illustrated embodiment, the structural frame members 20 include a common rafter beam 20a, an eaves beam 20b, and a ridge beam 20c. Each batten 16 is coupled to one of the structural frame members 20.

In alternative embodiments (not shown), the structural frame 12 may include any suitable structural frame member 20, such as a hip rafter beam 20d (see Figure 6) and/or a jack rafter beam (not shown), for example.

In the illustrated embodiment, the structural frame members 20 are formed from an aluminium alloy, which helps to ensure that the structural frame members 20 are lightweight whilst having sufficient strength to support the outer roof components 14. In alternative embodiments (not shown), the structural frame members 20 may be formed from any suitable material, such as a metallic material other than aluminium.

In the illustrated embodiment, each batten 16 is formed from a polyvinyl chloride (PVC) material, such as PVC foam or unplasticized polyvinyl chloride (uPVC) In alternative embodiments (not shown), the battens 16 may be formed from any suitable material, such as a plastics material other than PVC (e.g. nylon), or a non-plastics material (e.g. wood). Advantageously, forming the batten 16 from a plastics material, such as PVC, helps to ensure that the batten is low-cost, lightweight, thermally insulative and not affected by corrosion or degradation, which can occur in other materials such as wood for example.

In the illustrated embodiment, each batten 16 is formed as a solid block of PVC foam material, which is suitable for receiving a mechanical fixing 18, such as a nail or screw, therein. By "solid block of material", it is intended to mean that each batten 16 is free from substantial internal cavities form by extrusion dies as opposed to small (sub millimetre) discrete pores in the foam. Advantageously, forming each batten 16 as a solid block of material may help to ensure that mechanical fixings 18 received in the batten 16 are strongly secured to the batten 16. In other embodiments (not shown), the battens may have voids, e.g. by being extruded with voids, if a secure fixing can be achieved.

Each structural frame member 20 has a first longitudinal axis along which its predominantly extends. Each batten 16 has a second longitudinal axis along which it predominantly extends.

In the illustrated embodiment, each structural frame member 20 has a constant profile along the first longitudinal axis thereof. Similarly, each batten 16 has a constant profile along the second longitudinal axis thereof. Typically, both the structural frame member 20 and the batten 16 may be formed by an extrusion process. In alternative embodiments (not shown), each structural frame member 20 and/or each batten 16 may have a non-constant profile along its respective longitudinal axis.

Figure 3A shows a profile view of one of the structural frame members 20, in particular the rafter beam 20a, coupled to one of the battens 16. In the view shown in Figure 3A, the first longitudinal axis of the structural frame member 20 and the second longitudinal axis of the batten 16 are aligned and normal to the page. Figure 3B is a magnified view of a section of Figure 3A.

With reference to Figures 3A and 3B, the structural frame member 20 includes a structural portion 22 and a first coupling portion 24. The structural portion 22 connects to other structural frame members 20 to form the structural frame 12. The batten 16 includes a second coupling portion 26.

The structural portion 22 includes an inner channel 23 and a pair of outer channels 25. The inner channel 23 has a profile shaped to receive a head of a bolt (not shown) for connecting the rafter beam 20a to the ridge beam 20c. Each outer channel 25 has a profile shaped to receive a connecting member (not shown), such as a cleat for example, for connecting the rafter beam 20a to the eaves beam 20b.

The first coupling portion 24 and the second coupling portion 26 are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, an inter-engagement between the first coupling portion 24 and the second coupling portion 26 couples the structural frame member 20 and the batten 16 to each other, such that relative movement between the structural frame member 20 and the batten 16 along a direction transverse to both the first and second longitudinal axes is inhibited. Advantageously, this enables the structural frame member 20 and the batten 16 to be coupled to each other without requiring additional mechanical fixings, such as nails or screws.

The first coupling portion 24 is arranged on an outer face of the structural frame member 20. The structural frame member 20 is configured such that said outer face forms an outer face of the structural frame 12, in use, as shown in Figure 2. As such, outer roof components 14 can be mounted to the outer face of the structural frame member 20 via the batten 16 as shown in Figure 1.

With reference to Figure 3B, the first coupling portion 24 includes two opposed ribs 28.

The second coupling portion 26 includes two corresponding complimentary recesses 30. Each rib 28 is configured to be receivable in the corresponding complimentary recess 30 to inter-engage the first coupling portion 24 and the second coupling portion 26, for coupling the structural frame member 20 and the batten 16 to each other.

In the illustrated embodiment, the recesses 30 are shaped to form grooves or channels in the batten 16. In alternative embodiments (not shown), one or both recesses 30 may have any suitable shape.

The recesses 30 in the batten 16 are arranged such that the batten 16 projects outwardly from the ribs 28 (i.e. in a direction away from the structural frame member 20), when the batten 16 is coupled to the structural frame member 20. As such, when the batten 16 is formed from a thermally insulative material, such as a PVC material for example, the batten 16 acts as a thermal break between the structural frame member 20 and the outer roof component 14 mounted to the batten 16.

The first coupling portion 24 further includes two opposed walls 32 and a base 34. Each rib 28 projects from one of said walls 32. The walls 32, the base 34 and the ribs 28 define a cavity 36 forming a female portion. In the illustrated embodiment, the female portion 36 has a substantially rectangular profile.

The second coupling portion 26 comprises a male portion 38. The male portion 38 is partially defined by the recesses 30. In the illustrated embodiment, the male portion 38 has a substantially rectangular profile.

The female portion 36 and the male portion 38 have complimentary profiles such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion 38 is receivable in the female portion 36, for coupling the structural frame member 20 and the batten 16 to each other.

In the illustrated embodiment, the walls 32 of the first coupling portion 24 are substantially parallel. Advantageously, this helps to ensure a stronger inter-engagement with the male portion 38, which has a substantially rectangular profile. In alternative embodiments (not shown), the walls 32 may not be parallel, and instead may be oriented towards or away from each other.

In the illustrated embodiment, the structural section 22 includes two opposed substantially parallel side walls 33. Each of the walls 32 extends from, and is parallel to, one of the side walls 33. Advantageously, such a configuration enables blocks of thermally insulative material to fit snugly against outer surfaces of the walls 32 and the side walls 33, which helps to reduce heat losses through the lightweight roof construction 10 via convection.

In the illustrated embodiment, each rib 28 projects substantially perpendicularly from the corresponding wall 32. Advantageously, this helps to reduce the profile of the first coupling portion 24 whilst enabling a strong coupling between the structural frame member 20 and the batten 16. In alternative embodiments (not shown), each rib 28 may project from the corresponding wall 32 at any suitable angle.

In the illustrated embodiment, the ribs 28 project from their corresponding walls 32 in a common plane. Again, this helps to reduce the profile of the first coupling portion 24. In alternative embodiments (not shown), the ribs 32 may project in different, for example offset, planes.

In the illustrated embodiment, the first coupling portion 24 and the second coupling portion 26 are both symmetric. Advantageously, this may help to simplify manufacture of the structural frame member 20 and the batten 16. In alternative embodiments (not shown), the first coupling portion 24 and/or the second coupling portion 26 may not be symmetric.

The first coupling portion 24 and the second coupling portion 26 are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, the first coupling portion 24 and the second coupling portion 26 interengage via translation of the first coupling portion 24 and the second coupling portion 26 together in a direction parallel to both the first longitudinal axis and the second longitudinal axis. To enable this in the illustrated embodiment, the female portion 36 has at least one open longitudinal end through which the male portion 38 can be received.

The batten 16 includes a mounting face 40 extending across a transverse width W of the batten 16 (indicated by a double arrowed line in Figure 3B) for mounting a roof component 14 thereto. The mounting face 40 is on an opposite side of the batten 16 to the second coupling portion 26.

The mounting face 40 includes a substantially planar surface 42 for receiving the roof component 14 thereon. In alternative embodiments (not shown), the mounting face 40 may have any suitable surface.

In the illustrated embodiment, the substantially planar surface 42 extends across the transverse width W of the batten 16. Moreover, the substantially planar surface 42 forms one side of a substantially rectangular profile of the batten 16.

In alternative embodiments (not shown), the substantially planar surface 42 may not extend across the transverse width W of the batten 16. For example, the substantially planar surface 42 may be defined on one or more castellations on the mounting face 40.

With further reference to Figure 1, when constructing the lightweight roof construction 10, the corresponding roof component 14 is mounted to the mounting face 40 of the batten 16 via one or more mechanical fixing components 18, such as nails or screws, passing through the roof component 14 and received in the batten 16 via the mounting face 40.

The batten 16 may have a transverse width W greater than or equal to 20mm. In exemplary embodiments, the batten 16 may have a transverse width W in the range of 20mm to 50mm, preferably in the range of 25mm to 45mm, more preferably in the range of 30 to 40mm. For example, the batten 16 may have a transverse width W of approximately 35mm. Such transverse widths W are sufficient to enable two mechanical fixing components 18 to be received in the batten 16 side-by-side along the transverse width W, which may be required if two roof components 14 are mounted to the batten 16 for example.

The batten 16 may have a depth D (indicated by a double arrowed line in Figure 3B) greater than or equal to lOmm. In exemplary embodiments, the batten 16 may have a depth in the range of lOmm to 30mm, preferably in the range of 15 to 25mm. For example, the batten 16 may have a depth D of approximately 19mm. Such depths D are sufficient to enable a strong connection between the batten 16 and a mechanical fixing component 18 received in the batten 16 via the mounting face 40.

In the following, a method of coupling the structural frame member 20 and the batten 16 to each other will be described.

In a first step, the structural frame member 20 and the batten 16 are arranged such that the first longitudinal axis and the second longitudinal axis are aligned.

In the illustrated embodiment, a longitudinal end of the structural frame member 20 is arranged adjacent a longitudinal end of the batten 16, such that the male portion 38 of the second coupling portion 26 is receivable through an open end of the female portion 36 of the first coupling portion 24.

In a subsequent step, the first coupling portion 24 and the second coupling portion 26 are inter-engaged such that relative movement between the structural frame member 20 and the batten 16 along a direction transverse to both the first and second longitudinal axes is inhibited.

In the illustrated embodiment, the first coupling portion 24 and the second coupling portion 26 are translated together in a direction parallel to both the first longitudinal axis and the second longitudinal axis to inter-engage the first coupling portion 24 and the second coupling portion 26.

As the first coupling portion 24 and the second coupling portion 26 are translated together, the male portion 38 is received in the female portion 36. Moreover, the ribs 28 are received in the complimentary recesses 30 to inter-engage the first coupling portion 24 and the second coupling portion 26 such that the structural frame member 20 and the batten 16 are coupled to each other.

Figure 4 shows a profile view of the eaves beam 20b coupled to one of the battens 16. In the view shown in Figure 4, the first longitudinal axis of the eaves beam 20b and the second longitudinal axis of the batten 16 are aligned and normal to the page. The eaves beam 20b includes a structural portion 22' and a first coupling portion 24'. The first coupling portion 24' is the same as the first coupling portion 24, with the only difference being that the first coupling portion 24 of Figures 3A and 3B extends outward from the structural portion 22, whereas the first coupling portion 24' of Figure 4 is partially enclosed by the structural portion 22'.

The structural portion 22' includes a cavity 44 for receiving a soffit (not shown) therein. The soffit is arranged to be located outside of the walls of the structure on which the structural frame 12 sits. One or more lighting elements (e.g. light bulbs or LEDs) may be mounted to the soffit.

The structural portion 22' includes a first channel 23', which has a profile shaped to receive a head of a bolt (not shown) for connecting the eaves beam 20b to the rafter beam 20a.

The structural portion 22' includes a second channel 46 to receive a suitable corner fixing (not shown) to secure the eaves beam 20b to another eaves beam (not shown) that meets it at an angle.

Figure 5 shows a profile view of the ridge beam 20c coupled to two of the battens 16. In the view shown in Figure 5, the first longitudinal axis of the ridge beam 20c and the second longitudinal axis of each batten 16 are parallel and normal to the page. The ridge beam 20c includes a structural portion 22" and two first coupling portions 24.

The two first coupling portions 24 of the ridge beam 20c are arranged such that the mounting faces 40 of the battens 16 coupled to said first coupling portions 24 are oriented at a non-zero angle with respect to each other, for enabling two roofing panels 14b, each mounted to one of the battens 16, to form a ridge of the lightweight roof construction 10.

The structural portion 22" includes two channels 25'. Each channel 25' has a profile shaped to receive a connecting member (not shown), such as a cleat for example, for connecting the ridge beam 20c to another structural frame member 20, such as a hip rafter beam for

example.

Figure 6 shows a profile view of a hip rafter beam 20d coupled to two of the battens 16. The hip rafter beam 20d is configured to be connected between the ridge beam 20c and the eaves beam 20b.

In the view shown in Figure 6, the first longitudinal axis of the hip rafter beam 20d and the second longitudinal axis of each batten 16 are parallel and normal to the page. The hip rafter beam 20d includes a structural portion 22-and two first coupling portions 24.

The two first coupling portions 24 of the hip rafter beam 20d are arranged such that the mounting faces 40 of the battens 16 coupled to said first coupling portions 24 are oriented at a non-zero angle with respect to each other, for enabling two roofing panels 14b, each mounted to one of the battens 16, to form a hip of the lightweight roof construction 10.

The structural portion 22-includes an inner channel 23" and a pair of outer channels 25". The inner channel 23" has a profile shaped to receive a head of a bolt (not shown) for connecting the hip rafter beam 20d to the ridge beam 20c via a suitable connector. Each outer channel 25" has a profile shaped to receive a connecting member (not shown), such as a cleat for example, for connecting the hip rafter beam 20d to the eaves beam 20b or a jack rafter beam (not shown).

Figure 7 shows a partial profile view of an alternative embodiment of an elongate structural frame member 120 and an elongate batten 116. Features in common with the structural frame member 20 and the batten 16 of Figures 1 to 6 are denoted with common reference numerals and their description shall not be repeated for brevity. In the view shown in Figure 7, a first longitudinal axis of the structural frame member 120 and a second longitudinal axis of the batten 116 are aligned and normal to the page.

The structural frame member 120 includes a first coupling portion 124 and the batten 116 includes a second coupling portion 126. The first coupling portion 124 and the second coupling portion 126 are configured such that they inter-engage via translation of the first coupling portion 124 and the second coupling portion 126 together in a direction transverse to both the first longitudinal axis and the second longitudinal axis (i.e. along a vertical axis in Figure 7).

The first coupling portion 124 includes a female portion 136 defined by the walls 32, the base 34 and two opposed ribs 128. The second coupling portion includes a male portion 138 partially defined by two complimentary recesses 130. The female portion 136 and the male portion 138 are configured such that the male portion 138 is receivable in the female portion 136 via translation of the first coupling portion 124 and the second coupling portion 126 together in a direction transverse to both the first longitudinal axis and the second longitudinal axis, for coupling the structural frame 120 and the batten 116 to each other.

In this embodiment the ribs 128 and complementary recesses 130 are angled, with a triangular profile 160b to facilitate resilient deformation of the of the batten 116 and subsequent secure snap fit engagement. To further facilitate assembly, leading edges 160a of the batten 116 are chamfered.

In alternative embodiments (not shown), the ribs 128 may have any suitable profile to facilitate a snap fit.

In the foregoing description, the first coupling portion 24, 24', 124 includes two ribs 28, 128 and the second coupling portion 26, 126 includes two complimentary recesses 30, 130. In alternative embodiments (not shown), the first coupling portion 24, 24', 124 may include only one rib and the second coupling portion 26, 126 may include only one complimentary recess. In such embodiments, the rib and the recess may have profiles configured to inhibit relative movement between the structural frame member 20, 120 and the batten 16, 116 along any direction transverse to both the first and second longitudinal axes. For example, the rib and the recess may have complimentary hook-shaped or L-shaped profiles.

In the foregoing description, the first coupling portion 24, 124 forms a female portion 36, 136 and the second coupling portion 26, 126 forms a male portion 38, 138. In alternative embodiments (not shown), the first coupling portion 24, 124 may form a male portion and the second coupling portion 26, 126 may form a female portion, the male portion and female portion having complementary profiles, such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion is receivable in the female portion, for coupling the structural frame member 20, 120 and the batten 16, 116 to each other.

Claims

CLAIMS1. A kit of parts for a lightweight roof construction comprising: an elongate structural frame member having a first longitudinal axis, and comprising a first coupling portion; and an elongate batten having a second longitudinal axis, and comprising a second coupling portion, wherein the first coupling portion and the second coupling portion are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, an inter-engagement between the first coupling portion and the second coupling portion couples the structural frame member and the batten to each other, such that relative movement between the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes is inhibited.
2. The kit of parts of claim 1, wherein the first coupling portion is arranged on an outer face of the structural frame member, the structural frame member configured such that said outer face forms an outer face of a structural frame for a lightweight roof construction, in use.
3. The kit of parts of claims 1 or 2, wherein the batten is formed from a plastics material, such as polyvinyl chloride (PVC), for example, unplasticized polyvinyl chloride (uPVC); optionally, wherein the structural frame member is formed from a metallic material, such as aluminium.
4. The kit of parts of any preceding claim, wherein one of the first and second coupling portions forms a male portion, and the other of the first and second coupling portion forms a female portion, and wherein the male portion and female portion have complementary profiles, such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion is receivable in the female portion, for coupling the structural frame member and the batten to each other.
5. The kit of parts of any preceding claim, wherein the first coupling portion comprises a rib, and the second coupling portion defines a complimentary recess, wherein the rib is configured to be receivable in said complimentary recess to inter-engage the first coupling portion and the second coupling portion, for coupling the structural frame member and the batten to each other; optionally, wherein the recess is a groove or channel.
6. The kit of parts of claim 5, wherein the first coupling portion comprises two opposed ribs at least partially defining a cavity forming a female portion, wherein the second coupling portion comprises a male portion, the female portion and the male portion having complimentary profiles such that when the first longitudinal axis and the second longitudinal axis are aligned, the male portion is receivable in the female portion, for coupling the structural frame member and the batten to each other.
7. The kit of parts of claim 6, wherein the first coupling portion comprises two opposed substantially parallel walls, wherein each rib projects from one of said walls, wherein the walls and the ribs at least partially define the cavity forming the female portion; optionally, where each rib projects substantially perpendicularly from the corresponding wall, for example, wherein the two ribs project in a common plane.
8. The kit of parts of any preceding claim, wherein the first coupling portion and the second coupling portion are configured such that, when the first longitudinal axis and the second longitudinal axis are aligned, the first and second coupling portions inter-engage via translation of the first coupling portion and the second coupling portion together in a direction parallel to both the first longitudinal axis and the second longitudinal axis.
9. The kit of parts of any preceding claim, wherein the structural frame member is one of: an eaves beam; a rafter beam; or a ridge beam, and/or wherein the batten is formed as a solid block of material for receiving a mechanical fixing, such as a nail or screw, therein.
10. The kit of parts of any preceding claim, wherein the batten comprises a mounting face extending across a transverse width of the batten for mounting a roof component, such as a fascia board or roofing sheet, thereto, the mounting face on an opposite side of the batten to the second coupling portion.
11. The kit of parts of claim 10, wherein the mounting face comprises a substantially planar surface for receiving the roof component thereon; optionally, wherein said planar surface extends across the transverse width of the batten, for example, wherein the batten has a substantially rectangular profile.
12. A lightweight roof construction comprising: the structural frame member and the batten of the kit of parts of claims 10 or 11; and a roof component, such as a fascia board or roofing sheet, wherein the structural frame member and the batten are coupled to each other via inter-engagement between the first coupling portion and the second coupling portion, and wherein the roof component is mounted to the mounting face of the batten via one or more mechanical fixing components, such as nails or screws, passing through the roof component and received in the batten.
13. An elongate structural frame member for a lightweight roof construction, the structural frame member having a first longitudinal axis and comprising: a coupling portion configured for coupling the structural frame member to an elongate batten having a second longitudinal axis via inter-engagement between the coupling portion and the batten when the first and second longitudinal axes are aligned, such that relative movement between the structural frame member and the batten along a direction transverse to the longitudinal axes is inhibited, wherein the coupling portion is arranged on an outer face of the structural frame member, the structural frame member configured such that said outer face forms an outer face of a structural frame for a lightweight roof construction, in use, wherein the coupling portion comprises two opposed substantially parallel walls and two opposed ribs, each rib projecting from one of said walls, wherein the walls and ribs at least partially define a cavity forming a female portion, wherein the female portion is configured such that when the first longitudinal axis and the second longitudinal axis are aligned, a male portion of the batten is receivable in the female portion, for coupling the structural frame member and the batten to each other; optionally, wherein the structural frame member is formed from a metallic material, such as aluminium.
14. The elongate structural frame member of claim 13, wherein the structural frame member comprises a constant profile along the first longitudinal axis, and/or wherein the structural frame member is one of: an eaves beam; a rafter beam; or a ridge beam.
15. A method of coupling an elongate structural frame member for a lightweight roof construction having a first longitudinal axis and an elongate batten having a second longitudinal axis to each other, the structural frame member comprising a first coupling portion and the batten comprising a second coupling portion, the method comprising the steps of: (a) arranging the structural frame member and the batten such that the first longitudinal axis and the second longitudinal axis are aligned; and (b) inter-engaging the first coupling portion and the second coupling portion, such that relative movement between the structural frame member and the batten along a direction transverse to both the first and second longitudinal axes is inhibited.
16. The method of claim 15, wherein the first coupling portion is arranged on an outer face of the structural frame member, the structural frame member configured such that said outer face forms an outer face of a structural frame for a lightweight roof construction, in use.
17. The method of claims 15 or 16, wherein the batten is formed from a plastics material, such as polyvinyl chloride (PVC), for example, unplasticized polyvinyl chloride (uPVC); optionally, wherein the structural frame member is formed from a metallic material, such as aluminium.
18. The method of any one of claims 15 to 17, wherein one of the first and second coupling portions forms a male portion, and the other of the first and second coupling portion forms a female portion, the male portion and the female portion having complementary profiles, wherein step (b) comprises: receiving the male portion in the female portion such that the structural frame member and the batten are coupled to each other.
19. The method of any one of claims 15 to 18, wherein the first coupling portion comprises a rib, and the second coupling portion defines a complimentary recess, wherein step (b) comprises: receiving the rib in said complimentary recess to inter-engage the first coupling portion and the second coupling portion such that the structural frame member and the batten are coupled to each other; optionally, wherein the recess is a groove or channel.
20. The method of claim 19, wherein the first coupling portion comprises two opposed ribs at least partially defining a cavity forming a female portion, wherein the second coupling portion comprises a male portion, the female portion and the male portion having complimentary profiles, wherein step (b) comprises: receiving the male portion in the female portion, such that the structural frame member and the batten are coupled to each other.
21. The method of claim 20, wherein the first coupling portion comprises two opposed substantially parallel walls, wherein each rib projects from one of said walls, wherein the walls and the ribs at least partially define the cavity forming the female portion; optionally, where each rib projects substantially perpendicularly from the corresponding wall, for example, wherein the two ribs project in a common plane.
22. The method of any one of claims 15 to 21, wherein step (b) comprises: translating the first coupling portion and the second coupling portion together in a direction parallel to both the first longitudinal axis and the second longitudinal axis to inter-engage the first coupling portion and the second coupling portion.
23. The method of any one of claims 15 to 22, wherein the structural frame member is one of: an eaves beam; a rafter beam; or a ridge beam, and/or wherein the batten is formed as a single solid block of material for receiving a mechanical fixing, such as a nail or screw, therein.
24. The method of any preceding claim, wherein the batten comprises a mounting face extending across a transverse width of the batten for mounting a roof component, such as a fascia board or roofing sheet, thereto, the mounting face on an opposite side of the batten to the second coupling portion.
25. The method of claim 24, wherein the mounting face comprises a substantially planar surface for receiving the roof component thereon; optionally, wherein said planar surface extends across the transverse width of the batten, for example, wherein the batten has a substantially rectangular profile.