<div class="application article clearfix" id="description">
<p class="printTableText" lang="en">Patent Form No. 5 *10054987942* <br><br>
NEW ZEALAND <br><br>
Patents Act 1953 5 6 3 9 7 4 <br><br>
COMPLETE SPECIFICATION <br><br>
TITLE: AN IMPROVED LOUVRED ROOFING SYSTEM AND COMPONENTS <br><br>
intellectual property office of n.z. <br><br>
4 - DEC 2007 <br><br>
.R EC El ven <br><br>
We Stratco (Australia) Pty Limited, of 125 Cavan Road, Gepps Cross, South Australia, 5094, Australia, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: <br><br>
4003q <br><br>
2 <br><br>
An Improved Louvred Roofing System and Components <br><br>
Related Applications <br><br>
5 This application is related to Australian provisional patent application 2006906802 filed on 5 December 2006, the contents of which are taken as being incorporated herein by this reference. <br><br>
Field of the Invention <br><br>
10 <br><br>
The present invention relates to an improved louvred roofing system and components thereof. The roofing system has particular, but not exclusive, application as an outdoor roof. <br><br>
15 Background of the Invention <br><br>
Different louvred roofing systems have been developed to date. Some of such systems include rotatable louvres that can be rotated to a closed position to form a roof that prevents sunlight and rain (in most weather conditions) from 20 passing between the louvres. Movement of the louvres is controlled, for example, by a control rod that may be moved manually by a user or upon activation of a motor drive. <br><br>
The systems developed to date have suffered from a number of disadvantages. 25 For example, they can be quite noisy when the louvres are rotated. Noise during rotation is more prevalent as the louvres wear through use. Additionally, movement of the louvres is often not accomplished in a smooth fashion. This can give the user the impression that the louvre system is of a poor or inferior quality. <br><br>
30 <br><br>
The louvred roofing systems currently available are quite complex to install and often necessitate the use of specialised installers. This increases the cost of such systems to a purchaser. <br><br>
3 <br><br>
The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general 5 knowledge as at the priority date of this application. <br><br>
The present invention seeks to provide an improved louvred roofing system and the components thereof. <br><br>
10 Summary of the Invention <br><br>
According to a first aspect of the invention there is provided a louvred roofing system including a plurality of rotatable louvres that can be rotated between a closed and an open position, a first supporting member and a second 15 supporting member, each louvre including a blade having first and second ends, each of the first and second ends having a shaft extending therefrom that is arranged to be located within a respective aperture formed in an adjacent one of the supporting members so that the blade can be rotated about a rotation axis extending longitudinally of the blade and wherein the shaft of the first end 20 of the blade is arranged to receive a biasing means so that in use the biasing means biases the first end of the blade away from the adjacent supporting member. <br><br>
Preferably, the shaft of the first end can be translated axially in the aperture in 25 the adjacent supporting member. <br><br>
Preferably, the aperture in each supporting member is formed by a bush mounted on the respective supporting member. The bush is preferably made from a plastics material to prevent undue wear of the shaft as it rotates and to 30 minimise any noise generated by the shaft rotating within the bush. <br><br>
Preferably, a spacer is arranged to be received on the shaft of the second end. <br><br>
4 <br><br>
Preferably, when the louvres are in the closed position they form a roof that prevents sunlight and rain (in most weather conditions) from passing between the louvres. When the louvres are in an open position, sunlight and air can pass through gaps formed between the louvres. <br><br>
5 Preferably, the louvred roofing system further includes a louvre control rod arranged to be connected to each of the rotatable louvres so that movement of the control rod causes the louvres to rotate about the rotation axis. <br><br>
The control rod may be operated manually or may be driven by a motor drive. <br><br>
10 <br><br>
Preferably, the second end of each of the louvres is arranged to be connected to the control rod. To this end, the second end preferably includes a bore arranged to receive a pin that extends outwardly of the control rod. The pin may be a snap-in bush, the shank of which passes through an aperture in the 15 control rod before being engaged in the bore in the second end of the blade. The pin or snap-in bush is preferably made of a plastics material. <br><br>
In some situations, it may be desirable for the first end of the blade to be connected to a second control rod. Preferably, the two control rods are 20 operated in unison by a motor drive to rotate the louvres. <br><br>
Preferably, when the louvred roofing system has a control rod driven by a motor, a weather sensor may be included. The weather sensor is arranged to signal the motor to rotate the louvres to a required position when adverse 25 weather is detected. For example, when rain is detected the louvres may be rotated to the closed position. However, when high winds are detected the louvre may be rotated to the open position. <br><br>
According to a second aspect of the present invention there is provided a louvre 30 including an elongate body having first and second ends, each of the first and second ends having a shaft extending therefrom that is arranged to be located within an aperture formed in an adjacent supporting member so that the louvre can be rotated about an axis extending longitudinally of the body and wherein <br><br>
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the shaft of the first end can be translated axially in the aperture and includes a biasing means mounted thereon so that in use the biasing means biases the body away from the adjacent supporting member. <br><br>
Preferably, a recessed portion is located around the shaft of the first end. The recessed portion is arranged so that at least an end portion of the biasing means located on the shaft can be received in the recessed portion. This enables the biasing means to be compressed into the recessed portion during installation of a louvre between the supporting members. <br><br>
Preferably, the aperture in each supporting member is formed by a bush mounted on the respective supporting member. The bush is preferably made from a plastics material to prevent undue wear of the shaft as it rotates and to minimise any noise generated by the shaft rotating within the bush. <br><br>
Preferably, the shaft of the second end is arranged to receive a spacer. The spacer is arranged to space the second end a required distance from the adjacent supporting member. In accordance with a particularly preferred embodiment of the invention, the biasing means (spring) and the spacer are selected and configured so that the gap formed between the first end of the body and the adjacent supporting member is substantially the same as the gap formed between the second end of the body and the adjacent supporting member. It is desirable to have the respective gaps substantially identical and to minimise those gaps. <br><br>
Preferably, the louvre has a composite construction including a first end cap, a second end cap, a core, an upper panel and a lower panel. Each of the first and second end caps preferably includes a body from which the shaft of the respective end of the blade extends. <br><br>
The core is preferably made from a foam material and is arranged to be located between the upper and lower panels. The upper and lower panels are preferably made from metal, such as powder-coated or pre-painted steel. <br><br>
-6- <br><br>
Preferably, a first end of each of the upper and lower panels is arranged to be secured to the body of the first end cap and a second end of each of the upper and lower panels is arranged to be secured to the body of the second end cap. <br><br>
5 According to a third aspect of the present invention there is provided a louvre end cap including a body arranged to be engaged with a louvre blade, said body having a shaft extending therefrom that is arranged to be located within an aperture in an adjacent supporting member so that said shaft can rotate and be translated within the aperture and wherein a biasing means is mounted on the 10 shaft so that in use the biasing means biases the body away from the supporting member. <br><br>
In one embodiment of the invention, a recessed portion is located on the body around the shaft, the recessed portion being arranged so that at least an end 15 portion of the biasing means located on the shaft can be received in the recessed portion. <br><br>
In another embodiment of the invention, rather than locating the recessed portion on the body of the end cap, the recessed portion is located on the 20 supporting member. In such an arrangement, the recessed portion may be formed in a bush arranged to be located in an aperture formed in the supporting member. <br><br>
A louvred roofing system according to the first aspect of the present invention may include a motor end cap arranged for attachment to a motor drive for the louvred roofing system, said motor end cap including means for engaging with said motor drive so that activation of said motor drive causes rotational movement of said motor end cap, a shaft arranged to rotate within an aperture formed in the first supporting member so that said shaft can rotate within said aperture when said motor drive is activated to rotate said end cap and engagement means for engaging said end cap with a control rod arranged for connection to at least some of said plurality of louvers whereby rotation of the shaft within said aperture results in a translation of said control rod and rotation of said louvres. <br><br>
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The invention further includes a structure incorporating a louvred roofing system, a kit of parts for constructing a louvred roofing system or a structure incorporating a louvred roofing system and a method of assembling the like. <br><br>
5 <br><br>
Description of the Drawings <br><br>
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: <br><br>
10 <br><br>
Figure 1 is a perspective view of a corner portion of a structure including a louvred roofing system in accordance with an embodiment of the invention; <br><br>
Figure 2 is a perspective view from the motor end of various louvre blades of 15 the roofing system shown in Figure 1; <br><br>
Figure 3 is a partial cross sectional view showing a louvre (with the blade shortened for illustrative purposes) connected between first and second supporting members; <br><br>
20 <br><br>
Figure 4 is a perspective view illustrating a first end of one of the louvre blades shown in Figure 1 located within a bush fitted to a first supporting member; <br><br>
Figure 5 is an assembly view of a louvre in accordance with an embodiment of 25 the invention. The blade of the louvre is shown shortened for illustrative purposes; <br><br>
Figure 6 is an assembly view of the first end of the louvre shown in Figure 5, the view showing the composite construction of the blade; <br><br>
30 <br><br>
Figure 7 illustrates a bush being fitted to a supporting member; <br><br>
8 <br><br>
Figure 8 illustrates a louvre being connected to a control rod using a snap-in bush; <br><br>
Figure 9 is an end view showing a drive arrangement used in the louvred 5 roofing system illustrated in Figure 1; and <br><br>
Figure 10 is an assembly view of a part of the drive arrangement shown in Figure 9. <br><br>
10 Detailed Description of the Preferred Embodiments <br><br>
A roofing system 10 in accordance with an embodiment of the present invention will hereafter be described. To facilitate that description, reference will be made to a roofing system 10 mounted on a free standing structure, such as a pergola. 15 It should be appreciated that the present invention may be used in a number of different applications and is not intended to be limited to use on free standing structures. For example, the invention also has application on verandas and privacy screens. <br><br>
20 The free standing structure includes four uprights (not illustrated) that support an upper rectangular frame made from four elongate beams 12. Mounted on top of the elongate beams 12 is a rectangular frame made from four elongate supporting members 14. As described in more detail below, a plurality of louvres 16 are arranged to be connected between a pair of the supporting 25 members 14. It will be understood that four elongate supporting members 14 are not required as louvres 16 are only connected between two of them. However, the inclusion of four such supporting members 14 provides more aesthetic appeal. <br><br>
30 The louvres 16 are connected together by a control rod 18. The control rod 18 is provided so that the louvres 16 can be rotated in unison. The control rod 18 is arranged so that a user may select to retain the louvres 16 in any desired position between and including a closed position and an open position. <br><br>
-9- <br><br>
Figure 3 shows a louvre 16 connected between first and second supporting members 14a, 14b. As illustrated, the first and second supporting members 14a, 14b are of different cross-sectional configuration. However, it is envisaged that they may adopt the same cross-sectional configuration. <br><br>
5 <br><br>
For clarity reasons, the louvre 16 shown in Figure 3 is shortened and the control rod 18 is not depicted. A length of internal guttering 20 is shown mounted to each of the beams 12. Typically, the guttering 20 and supporting members 14 would be connected to the beams 12 by threaded connectors (not illustrated). <br><br>
10 <br><br>
The louvre 16 may adopt a variety of different forms. For example in may be a simple blade with a shaft extending from either end. However, in accordance with a preferred embodiment, the louvre 16 adopts a form particularly suitable for use with veranda and patio products provided by the present applicant. <br><br>
15 Accordingly, each louvre 16 includes first and second end caps 22a, 22b which are connected to an elongate body which is hereinafter referred to as a blade 25 (Figure 6). End caps 22a, 22b as illustrated are identical in their construction and are preferably cast aluminium. However, the end caps 22a, 22b may be made from other materials, for example a plastics material. <br><br>
20 <br><br>
As best shown in Figure 6, the blade 25 adopts a composite construction including a core 27, an upper panel 28 and a lower panel 30. The core 27 is made from a length of foam material, for example polystyrene, and is arranged to be located between the upper and lower panels 28, 30. The upper and lower <br><br>
25 panels 28, 30 are, in this embodiment, made from powder-coated profiled steel. The core 27 is glued to each of the upper and lower panels 28, 30. Additionally, the longitudinal edges of the upper and lower panels 28, 30 that abut are glued together. <br><br>
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A first end 28a, 30a of each of the upper and lower panels 28, 30 is arranged to be secured to the first end cap 22a and a second end 28b, 30b of each of the upper and lower panels 28, 30 is arranged to be secured to the second end cap <br><br>
10 <br><br>
22b. Typically, a threaded fastener or rivet is used to secure each end of the upper and lower panels 28, 30 to the first and second end caps 22a, 22b. <br><br>
Each of the end caps 22 includes a body 24 having a shaft 26 extending from 5 one side. The shaft 26 is arranged to be located within a complimentary shaped aperture in an adjacent supporting member 14 so that the shaft 26 can rotate within the aperture. The aperture may be a simple hole formed in the adjacent supporting member 14. However, as depicted in Figure 7, the aperture is formed by a nylon bush 32 that press fits into a square hole formed 10 in the supporting member 14. The bush 32 has a circular shaped bore 32a for receiving the shaft 26 and a square shaped outer surface. The square shaped outer surface prevents the bush 32 from being inadvertently rotated within the aperture in the supporting member 14 when the shaft 26 is rotated. The use of a nylon bush 32 helps to minimise any noise during rotation of the louvre 16 and 15 also helps to reduce wear of the shaft 26. <br><br>
As best shown in Figures 3 and 7, the bush 32 extends within the supporting member 14 and is arranged so that the shaft 26 can translate axially within the bush 32 when a side ways force is applied to the end cap 22. To this end, the 20 bush 32 may be sized to allow the necessary axial translation or may be open ended so that the leading end of the shaft 26 passes out of the inner end of the bore 32a of the bush 32 when the side ways force is applied. This "translation" of the shaft 26 within the bush 32 will be explained in more detail below. <br><br>
25 A recessed portion 34 (Figures 6 and 8) is formed in the body 24 around the shaft 26. The recessed portion 34 is arranged so that an end portion of a biasing means (a spring 36) or a spacer 38, located on the shaft 26 can be received therein. The function of the spring 36 and the spacer 38 will be explained subsequently. <br><br>
30 <br><br>
Prior to mounting a louvre 16 between opposed first and second supporting members 14a, 14b, a spring bush 36a is pushed into one end of the spring 36. The spring 36 with spring bush 36a fitted is then located over the shaft 26 of the <br><br>
11 <br><br>
first end cap 22a of the louvre 16. As best shown in Figure 4, the first end cap 22a is then positioned so that the leading end of the shaft 26 is located in one of the bushes 32 fitted to the first supporting member 14a. The shaft 26 is pushed into the bore 32a of the bush 32 and translated axially therealong against the 5 bias of the spring 36. The spring 36 is compressed between the outer face of the bush 32 and the floor of the recessed portion 34. Side ways force in the direction of the arrows shown in Figure 4 is then continued to be applied until the shaft 26 on the second end cap 22b of the louvre 16 can be aligned with the bush 32 on the second supporting member 14b. That second bush 32 will be 10 co-linear with the bush 32 in which the first end of the louvre 16 is located. <br><br>
Before aligning the shaft 26 of the second end cap 22b in the bush 32, a spacer 38 is located over the shaft 26. The spacer 38 is preferably made from Acetal (polyoxymethylene - POM). <br><br>
15 <br><br>
Once the second end cap 22b is properly aligned with the bush 32 into which it is to be located, the sideways force is released so that the spring 36 on the first end cap 22a biases the louvre 16 away from the first supporting member 14a, thus driving the shaft 26 of the second end cap 22b into the bore 32a of its 20 respective bush 32. It will be appreciated that this movement of the louvre 16 occurs because the shaft 26 of the first end cap 22a translates axially within its bush 32 under the action of the bias of the spring 36. It will of course be understood that sufficient length of the shaft 26 extending from each of the first and second end caps 22a, 22b will be retained in their respective bushes 32 so 25 that the louvre 16 is properly retained between the first and second supporting members 14a, 14b. To this end, it is envisaged that in a domestic roofing application, a minimum of 25mm, but preferably at least 30mm, of each shaft 26 will be maintained within its respective bush 32. <br><br>
30 The spacer 38 serves to locate the second end cap 22b at a required distance away from the second supporting member 14b. Preferably, the spacer 38 is sized so that the gap between the second end cap 22b and the second <br><br>
12 <br><br>
supporting member 14b is substantially the same as the gap between the first end cap 22a and the first supporting member 14a. <br><br>
The outer face of the bush 32 prevents the end of the spacer 38 from rubbing 5 against the face of the second supporting member 14b. In a similar manner, the outer face of the spring bush 36a prevents the metal spring 36 from rubbing against the outer face of the bush 32 in the first supporting member 14a. The spring bush 36a is preferably made from Acetal (polyoxymethylene - POM). <br><br>
10 It will of course be appreciated that when constructing the roofing system 10 the proper spacing of the first and second supporting members 14a, 14b will be determined by factors such as the length of the louvre 16, the length of the shafts 26, the nature of the spring 36, the length of shaft 26 required to be located within the bush 32 and the amount the shaft 26 of the first end cap 22 15 can translate axially within the bush 32. <br><br>
It will also be appreciated that a plurality of louvres 16 will be mounted between the first and second supporting members 14a, 14b. To this end a plurality of bushes 32 will be mounted along each supporting member 14a, 14b. The 20 bushes 32 are spaced a sufficient distance apart to enable the louvres 16 to rotate between the open and the closed position. When the louvres 16 are in the open position, sunlight and air can pass through gaps formed between adjacent louvres 16. When the louvres 16 are in the closed position, they form a roof that prevents sunlight and rain (in most weather conditions) from passing 25 between adjacent louvres 16. <br><br>
As mentioned above and as illustrated in Figures 1, 2 and 10, the louvres 16 are connected together by a control rod 18. Each louvre 16 is connected to the control rod 18 by a plastics pin or plastics snap-in bush 40. The shank of the 30 snap-in bush 40 passes through an aperture 18a in the control rod 18 before engaging in a bore 24a formed in the body 24 of the end cap 22. The use of such a plastics pin or bush 40 to connect each louvre 16 to the control rod 18 <br><br>
- 13- <br><br>
minimises wear to the connected parts and minimises the likelihood of any noise being generated during rotation. <br><br>
In the described embodiment, the second end cap 22b of each louvre 16 is 5 connected to the control rod 18. The control rod 18 may be moved manually by the user using a simple mechanical lever or alternatively may be driven by an electronic motor. <br><br>
Figures 9 and 10 illustrate a drive arrangement 50 including a motor 52 having 10 a drive shaft 54. The drive shaft 54 engages with a complimentary socket (not visible) of the motor end cap 56 so that rotation of the drive shaft 54 causes movement of the end cap 56. The motor end cap 56 also has a shaft 58. The shaft 58 locates within a bush 32 in the adjacent supporting member 14 in the same manner as the shafts 26 of the first and second end caps 22a, 22b. The 15 motor end cap 56 is also connected via aperture 56a to the control rod 18 using a shoulder bolt 60 and a lock nut 62. Other connection methods are envisaged. <br><br>
The end of the control rod 18 to which the motor end cap 56 is attached includes a recessed portion 18b. The recessed portion 18b is provided to 20 prevent interference between the control rod 18 and the adjacent supporting member 14. The configuration of the recessed portion 18b may vary depending on the configuration of the adjacent supporting member 14 or other parts located thereby. <br><br>
25 When the motor 52 is activated the drive shaft 54 rotates causing rotation of the motor end cap 56 and hence rotation of the shaft 58 within its bush 32. As the motor end cap 56 is rigidly connected to the control rod 18 by the shoulder bolt 60 and lock nut 62, rotational movement of the motor end cap 56 causes <br><br>
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33 Si m 39p| louvres 16 connected to the control rod 18. Hence the louvres 16 can be <br><br>
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The motor end cap 56 is preferably made of cast aluminium and is arranged to fit flush with the motor 52 so as to prevent water entry. <br><br>
5 The controller (not shown) that activates the motor 52 preferably includes a weather sensor (not illustrated). The weather sensor is preferably arranged to signal the controller to rotate the louvres 16 to the closed position when rain is detected and to rotate the louvres 16 to the open position when high winds are detected. <br><br>
10 <br><br>
The embodiment of the invention described above includes a recessed portion 34 formed in the body 24 of the end cap 22 to receive an end portion of the spring 36. It has been found that it is desirable to include such a recessed portion 34 so that the spring 36 can be compressed into that recessed portion <br><br>
15 34 when the louvre 16 is being installed between first and second supporting members 14a, 14b. Without such a recessed portion 34 it can be difficult to compress the spring 36 sufficiently to enable the shaft 26 on the second end cap 22b to be located in the aligned bush 32 on the second supporting member 14b. This problem can be overcome by increasing the length of the shaft 26 <br><br>
20 and the spacer 38 but this will result in an increased gap between each of the first and second end caps 22a, 22b and the adjacent supporting member 14a, 14b. For aesthetic and functional reasons (e.g. water proofing) it is desirable to minimise those gaps. <br><br>
25 It is recognised that instead of including the recessed portion 34 in the end cap 22 of the louvre 16 it may be possible to include an appropriate recessed portion in the supporting member 14 or in the bush 32. For example, the bush 32 could be modified to include a recessed portion to receive an end portion of the spring 36. <br><br>
30 <br><br>
Alternatively, by altering the bias of the spring 36 or the form of the biasing means used it may be possible to eliminate the need for the recessed portion 34. It should be appreciated however that the spring bias needs to be such that <br><br>
-15- <br><br>
in use it will serve to bias the first end (first end cap 22a) of the louvre 16 away from the first supporting member 14a so that the louvre 16 is maintained in a proper position between the first and second supporting members 14a, 14b. If the bias of the spring is too low, it will allow the louvre 16 to translate axially 5 within the bushes 32 and hence the louvre 16 will "slop" back and forth between the first and second supporting members 14a, 14b. This is particularly undesirable. <br><br>
It is recognised that a leaf spring arrangement could be used to replace the coil 10 spring 36 and thus the end caps 22 would not need to include the recessed portion 34 about the shaft 16. <br><br>
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The described embodiment includes first and second end caps 22a, 22b that are identical. The use of identical end caps 22a, 22b on either end of the blade 25 is advantageous for manufacturing reasons. However, it is envisaged that non-identical end caps 22a, 22b could be used. For example, the second end cap 22b could be moulded with a step in the shaft 26. That step providing the same functionality as the spacer 38. The second end cap 22b could also be formed without a recessed portion 34 about the shaft 16. <br><br>
In the described embodiment, the louvres 16 are connected between two of the supporting members 14 that form a frame mounted on beams 12. However, it is envisaged that in other embodiments, instead of having both supporting members 14 and beams 12, the louvres 16 may be connected to the beams 12. <br><br>
It is also recognised that in some situations it may be desirable to replace the spacer 38 with another spring 36. Similarly, it may also be desirable to have both ends of the louvres 16 connected to respective control rods 18. Such may be necessary when the louvres are over a certain length or in high wind areas. <br><br>
It is envisaged that when the louvres 16 are in a closed position, the underside of the louvres 16 (i.e. the side visible from below) would have an appearance similar to other roofing products provided by the present applicant. <br><br>
16 <br><br>
Embodiments of the present invention are advantageous because: <br><br>
1. The louvres are quickly and easily connected to the supporting members and to the control rod. This means that a specialist installer is not <br><br>
5 required. <br><br>
2. The louvres are positioned and maintained evenly between the supporting members due to the use of the spring and the spacer. <br><br>
3. The louvres do not move axially during use because of the spring bias and the spacer. <br><br>
10 4. The gap between the end of each blade and the adjacent supporting member is minimised and thus the louvres have increased visual appeal. <br><br>
5. The use of plastic bushes and pins reduces wear to moving parts and reduces noise generated during rotation thus ensuring smooth and quiet operation. <br><br>
15 6. The first and second end caps of each louvre are identical in construction reducing manufacturing costs. <br><br>
7. The components of the system are made of weather resistant material ensuring a long service life. <br><br>
20 The embodiments have been described by way of example only and modifications within the spirit and scope of the invention are envisaged. <br><br>
The following claims refer to a louvred "roofing" system. It is to be understood that the term "roofing" should be interpreted broadly and includes within its 25 scope arrangements wherein the louvres are used, for example, to form a roof, a screen, a panel or a wall. <br><br></p>
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