WO2007141616A1

WO2007141616A1 - Roof construction comprising elongate cover elements having longitudinal cavities

Info

Publication number: WO2007141616A1
Application number: PCT/IB2007/001450
Authority: WO
Inventors: Pieter Martin Henderson
Original assignee: Pieter Martin Henderson
Priority date: 2006-06-06
Filing date: 2007-06-01
Publication date: 2007-12-13
Also published as: WO2007141616A8

Abstract

An elongate roof cover element (1) is provided of the type having longitudinally extending edges suitable for overlapping edge formations (2, 3) of like contiguous elements to provide a weather resistant joint between the roof cover elements. The roof cover element is in the form of an extrusion, typically of a plastics material compounded with fibrous material. The cross- sectional shape of the element defines a plurality of longitudinally extending cavities (4, 5) configured such that the roof cover element is self-supporting over a predetermined span and is suitable for use in the absence of a conventional roof cover supporting framework. The longitudinally extending cavities preferably extend laterally over substantially the entire width of the roof cover element with the exception of the edge formations (2, 3). The height of the cavities preferably alternates to form a generally corrugated outer surface.

Description

ROOF CONSTRUCTION COMPRISING ELONGATE COVER ELEMENTS HAVING LONGITUDINAL CAVITIES

5 FIELD OF THE INVENTION

This invention relates to a roof construction that may be used for the construction of an elevated roof, in particular, but by no means exclusively, a roof of a low-cost building such as low-cost housing and industrial buildings 0 as well as other roofs such as those of carports, lean-tos and the like. The invention also relates to prefabricated components for use in the construction of such roofs.

BACKGROUND TO THE INVENTION 5

The construction of the roofs of buildings and other structures is typically relatively complex and a reasonable amount of skill is required in order to construct such a roof. Usually, a roof construction comprises a supporting framework of one form or another, typically made of wooden beams and, if 0 appropriate, rafters, to which a roof covering such as elongate sheets of corrugated iron or aluminium of many different configurations, including inverted box rolled (IBR) sections and other such arrangements, or alternatively tiles of one form or another, is secured, often with a series of battens interposed between the roof covering and frame. A substantial 5 amount of time and a reasonable amount of skill are necessary to construct such a roof properly.

The frame, particularly in the instance in which a pitched roof (mono-pitch or double pitch) is being constructed, typically comprises a series of laterally 0 spaced trusses that include rafters, tie-beams, king posts and various braces wherein the trusses are usually interconnected by means of a series of parallel battens secured to them and to which the roof covering is secured. Typically the trusses are prefabricated at a factory and transported to the construction site for installation in the manner indicated.

This is a costly procedure; often necessitates puncturing the roof covering in order to secure it to the supporting frame with consequent potential for leaks to develop; and does not provide any aesthetically acceptable internal finish, whatsoever. Generally a separate ceiling needs to be installed that also involves the construction of a separate frame often including one or two series of parallel battens, or the securing of ceiling panels or elongate cover elements directly to the underside of components of the frame such as tie beams, rafters and the like.

OBJECT OF THE INVENTION

It is an object of this invention to provide a roof construction and components thereof whereby the erection of a roof is simplified and facilitated, at least to some extent.

SUMMARY OF THE INVENTION

In accordance with a first aspect of this invention there is provided an elongate roof cover element having longitudinally extending edges rendering it suitable for use in the construction of a roof cover that is defined by a plurality of such roof cover elements extending in parallel relationship relative to each other with overlapping edge regions providing a weather resistant joint between adjacent roof cover elements, the roof cover element being characterised in that it assumes the form of an extrusion having a cross- sectional shape that defines a plurality of longitudinally extending cavities configured such that the roof cover element is self-supporting over a predetermined span and is adapted to be secured in an operative position in the absence of a conventional roof cover supporting framework. Further features of this aspect of the invention provide for the roof cover element to be extruded from a suitable plastics material such as polypropylene compounded with fibrous material such as subdivided wood and organic fibrous material; for the longitudinally extending cavities within the building element to extend laterally over substantially the entire width of the roof cover element with the exception of edge formations that are adapted to cooperate with a cooperant edge of a contiguous similar roof cover element in overlapping relationship in the operative position; for a plurality of the cavities to have a generally squat configuration relative to the width of the roof cover element whilst interposed cavities that are strength enhancing cavities have a shape that extends beyond the height of the squat cavities to provide an operatively outer surface of generally corrugated shape; and for the strength enhancing cavities be of generally triangular shape in cross-section with the wall defining the base of the triangle being generally coplanar with walls defining the corresponding sides of the squat cavities.

Still further features of the invention provide for the operatively inner surface of the roof cover element to have an assembly flange extending along each lateral edge thereof such that, when the edges of two adjacent roof cover elements are overlapped in an installed relationship, the adjacent assembly flanges can be fastened together; for the assembly flanges to be provided with a series of perforations or other formations spaced apart along the length thereof for receiving fasteners in the form of screws, bolts, clips or latches; and for the operatively inner face of the roof cover element to have a plurality of longitudinally extending integral, laterally spaced parallel support flanges configured to support cooperating flanges provided on an inner cover element that may operatively be used to form a ceiling.

In accordance with a second aspect of the invention there is provided an inner cover element for cooperation with the roof element as defined above wherein the inner cover element is pre-fitted with a utility item selected from an electric light fitting, and ventilation or air conditioning vents.

It will be understood that it is the intention that each roof cover element is preferably dimensioned to extend over substantially the entire length of a roof span so that no joins are necessary in the length of a span.

In accordance with a third aspect of this invention there is provided a roof construction comprising a plurality of roof cover elements as defined above located with their longitudinal edges in overlapping relationship and wherein pairs of adjacent assembly flanges are fastened together and wherein roof ties attaching the roof construction to a supporting structure are secured to the assembly flanges or support flanges, or both.

In accordance with a fourth aspect of this invention there is provided a roof construction comprising a plurality of roof cover elements as defined above located with their longitudinal edges in overlapping relationship and wherein pairs of adjacent assembly flanges are fastened together and wherein the roof construction includes two inclined roof sections forming a pitched roof construction and a tie-beam interconnecting the roof sections has each end thereof secured to the assembly flanges or support flanges, or both, at predetermined positions along the length thereof.

In order that the above and other features of the invention may be more fully understood one embodiment of roof cover element according to the invention and its use in one application on a basic house having a pitched roof with a gabled end will now be described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:-

Figure 1 is a schematic end elevation of a building having a pitched roof constructed utilizing roof cover elements according to the invention;

Figure 2 is a cross-section taken through a single roof cover element according to the invention showing, in exploded relationship relative thereto, co-operating cover elements;

Figure 2a is an enlargement of one half of the width of the cover element illustrated in Figure 2;

Figure 3 is an exploded end elevation showing two roof cover elements and cooperating cover elements about to be connected in side-by-side relationship;

Figure 4 is an oblique projection showing the roof cover elements illustrated in Figure 3 fully interconnected;

Figure 5 is an end view showing the lateral end regions of a roof construction according to the invention in relation to spaced lateral walls of an associated building;

Figure 6 is an underneath oblique projection of a short length of cover element having a ventilation vent therein; and,

Figure 7 is similar to Figure 6 illustrates a preassembled light fitting on a cover element. DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

In the embodiment of the invention illustrated in the drawings, an elongate roof cover element (1) assumes the form of an extrusion having a cross- sectional shape that defines a plurality of longitudinally extending cavities configured such that the roof cover element is self-supporting over a predetermined span and is adapted to be secured in an operative position in the absence of a conventional roof cover supporting framework, as envisaged by the invention.

In this embodiment of the invention the roof cover element is extruded from a suitable plastics material such as polypropylene compounded with fibrous material such as subdivided wood and organic fibrous material, and the thickness of the walls defining the various cavities is preferably of the order of about 4 to 10 millimetres, and preferably around about 5 or 6 millimetres.

The width of the roof cover element is preferably made to conform with building norms and, typically, where a building module of 900 millimetres in width is employed, the roof cover element could be an effective 450 millimetres wide excluding the additional width required for the overlap between adjacent roof cover elements in the installed position.

The longitudinally extending cavities are juxtaposed in a single row thereof so as extend over substantially the entire width of the roof cover element with the exception of edge formations (2, 3) that are adapted to cooperate with each other in overlapping relationship in the operative position as will be further described below.

The plurality of the cavities includes a plurality of squat cavities (4) that are of a generally squat configuration relative to the width of the roof cover element and a pair of interposed strength enhancing cavities (5) that extend operatively upwards well beyond the thickness of the squat cavities (in this embodiment of the invention their height is about three times that of the squat cavities) to provide an operatively outer surface of generally corrugated shape. In this embodiment of the invention the strength enhancing cavities are of generally triangular shape with the wall defining the base (6) of the triangle being generally coplanar with walls defining the corresponding sides (7) of the squat cavities to provide a flat inner surface to the roof cover element.

Reverting now to the longitudinally extending edge formations (2, 3), the one edge formation (2) has substantially the outer shape of the triangular cross- sectioned strength enhancing cavities so that, in outer appearance, it is substantially indistinguishable therefrom. The outer side of this edge formation forms an overhang that operatively receives, underneath it, an opposite edge formation (3) that assumes the form of an upwardly and outwardly inclined tongue. The edge formations are configured such that the tongue is obscured, in the operative position, so that the overhang provides a continuous corrugated outer shape to the composite roof that results from the assembly of a series of laterally assembled roof cover elements.

Extending along each lateral edge of the roof cover element is an inwardly directed assembly flange (8) configured such that, when the edges of two adjacent roof cover elements are overlapped in an installed relationship, the two juxtaposed assembly flanges can be fastened together, typically using bolts (9). The assembly flanges are accordingly provided with a series of perforations (10) spaced apart along the length thereof for receiving the aforesaid bolts.

The operatively inner face of the roof cover element also has a plurality of longitudinally extending integral, laterally spaced parallel support flanges (11) configured to cooperate with cooperant flanges (12) on an extruded inner cover element (13) that may operatively be clipped into place to be used to form a ceiling or support for items that can be housed in the resultant enclosures that are indicated by numeral (14) in Figure 4. Clipping is achieved utilising ridges (15) and recesses (16) formed in the cooperating flanges during the extrusion processes.

In this embodiment of the invention the inner cover elements are made to cover one half of the width of a roof cover element so that two juxtaposed inner cover elements are required to cover the inside surface of one roof cover element. As indicated above, such inner cover element may be pre- fitted with a utility item selected from an electric light fitting, as illustrated in Figure 7 or a ventilation or air conditioning vent, as illustrated in Figure 6. It will be understood that the resultant longitudinally extending enclosures (14) themselves may serve as ventilation ducting.

It is generally the intention that each roof cover element be cut to a length calculated to extend over substantially the entire roof span so that no joins are necessary in the length of a span. Thus, as illustrated in Figure 1 , a plurality of roof cover elements as described above may be located with their longitudinal edges in overlapping relationship and their assembly flanges fastened together to define two roof sections (17) meeting at an apex (18). A special apex moulding (not shown) may be employed to provide a water resistant apex to such pitched roof.

The roof sections may be supported on walls (19) of an associated building and roof ties (not shown) may attach the roof construction to the supporting structure by securing them to the assembly flanges or support flanges, or both.

In such a pitched roof arrangement, a tie-beam (20) may be connected to extend between the roof sections at an elevated position to tie them together and the required angle to each other and such a tie-beam may be secured to the assembly flanges. Indeed, it is one possibility according to the invention that an inverted length of roof cover element may be bolted to the roof cover elements of the roof sections described above to provide a tie-beam.

The presence of such tie-beams may, however, be obviated in the event that the gabled walls at the ends of the roof are sufficiently strong to support the weight of the roof. This will, in any event, depend to some extent on the size of the roof and the cross-sectional configuration of the roof cover element. In this regard, a separately manufactured gable section to the walls, typically in prefabricated form, is envisaged as being a practical alternative or addition to tie-beams.

Finally, in order to finish off the lateral edges of a pitched roof at the gable end thereof, and as shown Figure 5, one roof cover element can be cut longitudinally along the centreline so as to provide two half elements indicated by numerals (1a and 1b) in Figure 5 in order to finish off the lateral ends of the roof.

It will be understood that numerous variations may be made to the embodiment of the invention described above without departing from the scope hereof. Numerous configurations of roof cover element are possible within the scope of this invention all of which will be self-supporting and require no support frame installation.

It will be appreciated that installation of such a roof construction will be simple and may be carried out effectively and efficiently using only semiskilled labour. Also, the roof is inherently more heat insulating than a typical metal roof and, in addition, the various cavities or enclosures formed by the inner cover elements, or both, can be filled with heat insulating material such as a suitable foam. This is a most important aspect of the invention as, when compared to the most common existing roof element in the form of corrugated iron, the heat insulating characteristics are clearly vastly superior.

Claims

CLAIMS:

1. An elongate roof cover element (1 ) having longitudinally extending edges rendering it suitable for use in the construction of a roof cover

5 that is defined by a plurality of such roof cover elements extending in parallel relationship relative to each other with overlapping edge regions (2, 3) providing a weather resistant joint between adjacent roof cover elements, the roof cover element being characterised in that it assumes the form of an extrusion having a cross-sectional shape that 10 defines a plurality of longitudinally extending cavities (4, 5) configured such that the roof cover element is self-supporting over a predetermined span and is adapted to be secured in an operative position in the absence of a conventional roof cover supporting framework.

!5

2. An elongate roof cover element as claimed in claim 1 in which the roof cover element is extruded from a suitable plastics material compounded with fibrous material.

20 3. An elongate roof cover element as claimed in either one of claims 1 or 2 in which the longitudinally extending cavities within the building element extend laterally over substantially the entire width of the roof cover element with the exception of edge formations (2, 3) that are adapted to cooperate with a cooperant edge of a contiguous similar

25 roof cover element in overlapping relationship in the operative position.

4. An elongate roof cover element as claimed in any one of the preceding claims in which a plurality of the cavities (4) have a

30 generally squat configuration relative to the width of the roof cover element whilst interposed cavities (5) that are strength enhancing cavities have a shape that extends beyond the height of the squat cavities to provide an operatively outer surface of generally corrugated shape.

5. An elongate roof cover element as claimed in claim 4 in which the strength enhancing cavities are of generally triangular shape in cross- section with the wall (6) defining the base of the triangle being generally coplanar with walls (7) defining the corresponding sides of the squat cavities.

6. An elongate roof cover element as claimed in any one of the preceding claims in which the operatively inner surface of the roof cover element has an assembly flange (8) extending along each lateral edge thereof such that, when the edges of two adjacent roof cover elements are overlapped in an installed relationship, the adjacent assembly flanges can be fastened together.

7. An elongate roof cover element as claimed in any one of the preceding claims in which the operatively inner face of the roof cover element has a plurality of longitudinally extending integral, laterally spaced parallel support flanges (11) configured to support cooperating flanges (12) provided on an inner cover element (13) that may optionally form a ceiling.

8. An elongate roof cover element as claimed in claim 7 in which one or more inner cover elements form, together with the roof cover element, longitudinally extending enclosures (14).

9. An elongate roof cover element as claimed in either one of claims 7 or 8 in which an inner cover element is pre-fitted with a utility item selected from an electric light fitting, and ventilation or air conditioning vents.

10. A roof construction comprising a plurality of roof cover elements as claimed in any one of the preceding claims located with their longitudinal edges in overlapping relationship and wherein pairs of adjacent assembly flanges are fastened together and roof ties attach the roof construction to a supporting structure.

11. A roof construction as claimed in claim 10 in which the roof construction includes two inclined roof sections (17) forming a pitched roof construction and a tie-beam (20) that interconnects the roof sections has each end thereof secured to the assembly flanges or support flanges, or both, at predetermined positions along the length thereof.

12. Inner cover elements particularly adapted for use in cooperation with elongate roof cover elements as claimed in any one of claims 1 to 9.