AU2006200865A1 - Panel Clip And Panel Clip Assemblies - Google Patents

Description

01-MRR-2006 15:52 A J PRRK 64 9 3566990 o -1- 0 Regulation 3.2 t

AUSTRALIA

PATENTS ACT, 1990 0 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventors: Address for service in Australia: Invention Tidtle: FLETCHER BUILDING HOLDINGS LIMITED IAN KURT McCLEW, ANTHONY GEORGE RALLIS, RYK KLEYNHANS, DONALD GERARD CAMPBELL and PAUL FLEMING BUCKLEY A J PARK, Level 11, 60 Marcus Clarke Street, Canberra ACT 2601, Australia Panel Clip And Panel Clip Assemblies The following statement is a full description of this invention, including the best method of performing it known to us- COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAPR-2006 15:52 A J PARK 64 9 3566990 P.06 -2- The present invention relates to roofing and more particularly to components, subci assemblies and related procedures and methodologies for clip fitting panels typified by metal Ct roofing or other long run roofing panels.

Frequently metal roofing is held to the purlins or other substructure by a clipping mechanism. Such a clipping system for steel panels involves steel fittings adapted to be attached to the purlins inter alia by nailing and/or screwing and to clip fit engage in the underside of the ridges of the roofing panel.

VaO 0c' Wit the advent of the DIMONDEIC 630 onsite manufacturing of panels, extremely o long roofing panels can be manufactured so as to avoid a need for lapping of panels down the fall of a roof. Currently roofs with a pane] of up to 65.5 metres long have been made.

o With longer metal roofing panels, particularly if made of aluminium but also even if (N made, as has been conventional, from steel) there are thermal expansion difficulties which will cause movement of the panel on these retention clips. This gives rise to localised regions of wear that ultimately can damage the water tightness of the structure.

The present invention wishes to evolve a system whereby such wear is reduced and yet the integrity of the system will not be undermined.

It is therefore to such structures, systems, methods and componentry that the present invention is directed.

In another aspect the invention is a modular panel retention system for panels to be held on or by) a structure, the system comprising or including at least one retention member or assembly ("retention assembly") having, or each having, plural panel engagement forms upstanding from a base adapted to be retained (inter alia by fixing means) on or by a said structure, and at least one panel formed from sheet material and defining spaced ridge features ("ridge(s)") to its outside, wherein each engagement form is clip fit and/or endwise slidably engageable into the underside of' a ridge to retain the panel, and wherein at least a or the bearing surface(s) of each engagement form to bear on a fitted panel is non metal and adapted to allow sliding by the panel relative thereto on or parallel to the ridge axis.

Preferably both the ridge to ridge spacing of the panel and a ridge to the nearest ridge of a like panel to be mated thereto corresponds to the engagement fonn to engagement form spacing ("the modular spacing"), 364132_IDOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAR-2006 15153 A J PARK< 64 9 3566990 P.07 I-3- Preferably each retention assembly is indexable to a like retention assembly so as to maintain the modular spacing of the collective series of engagements forms.

Preferably each retention member -has a moulded plastics member for each retention form inserted through an elongate base or rail.

Preferably said insertion is through a metal base or rail.

Preferably said metal base has an opening or other facility for each retention form insertion and to prevent pull through.

IND Preferably said base or rail includes at or adjacent one end thereof an indexing opening or other facility to engage a base of a like retention assembly and/or about a retention N 10 form of a like retention assembly thereby to ensure modular spacing between all adjacent

IND

o retention forms.

c-I In another aspect the invention is a moulded plastics member having at least one ramp down to a retention shoulder at or near its upper extremity in its upper region and a larger extent when considered in plan of its lower region with respect to said upper region.

is The plastics member preferably defines a peripheral plateau in its lower region above which the upper region (of less lateral extent) projects to define at least one (and preferably two) retention shoulders facing towards the lower region.

Preferably the retention shoulder(s) is associated with a ramp(s) whereby there can be a clip fit interengagernent into the channel of a panel roll formed steel or aluminium.

roofing panel.

The present invention also consists in a retention formation adapted to fit within the underside of a ridge formation of a panel fanned from a sheet material wherein the retention formation is of a plastics material on which the panel is adapted to slide when affected by thermal expansion.

Preferably the plastics material is selected from a range of nylon based materials.

However any long life lubricating or slippery plastics material can be used as a moulding or facings for the retention formation.

In another aspect the present invention relates to a fabricated assembly for attachment to a building envelope or structure purlins and/or roofing framing components, wall components, etc.) said fabricated member having a component of a first material adapted to be fixed by appropriate fixing means screws, nails, or the like) and at least one formation as aforesaid upstanding therefrom of a second material, said second 5841 32. J.iOC COMS ID Na:SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAR-2006 15:53 A J PRK 64 9 3566990 P.08 -4- O material being of a plastics material adapted to have a panel engaged therewith and to slide responsive to thermal expansion/contraction thereon.

The present invention in another aspect is directed to a gang of clips formed as a unitary member or as a fabricated assembly adapted to be supported by the purlins and/or other sub-frame members of a building or other structure yet to provide clips modularly spaced each adapted to be engageable within a channel underlying a longitudinal ridge of a panel to be retained at least in part thereby.

I, In another aspect the present invention consists in an assembly having 0 San anchorable member adapted for engagement to at least one purlin or other sub- C-i 10 structure of a to be cladded roof, and Sat least one plastics member retainable by the anchorable member that projects, or C that each project, upwardly therefrom and are adapted to clip fit engage and retain (at least in part) a roofing panel having a complementary ridge defined channel accessible by the plastics member from below the crest of the ridge.

The plastics member preferably defines a peripheral plateau in its lower region above which the upper region (of less lateral extent) projects to define at least one (and preferably two) retention shoulders facing towards the lower region.

Preferably the retention shoulder(s) is associated with a ramp(s) whereby there can be a clip fit interengagement into the channel of a panel roll formed steel or aluminium roofing panel.

In yet a further aspect the present invention consists in, in combination, a said assembly and a complementary panel.

Preferably said complementary panel is a roofing panel e.g. a long run roofing panel.

Preferably said roofing panel is of a metal e.g. steel, aluminium, or other.

Preferably said plastics member is insertable through a base plate or rail of metal fixable by screws, etc to thereby be anchored.

In yet a further aspect the present invention consists in, whether fabricated or a unitary member, a base or rail adapted to be fitted by any appropriate means (whether reliant on fixing means or otherwise) to the envelope or other structure of a building (for example, purlins and/or roofing framing components, wall components, etc.) and upstanding from the base, at least one moulded plastics retention formation adapted to be received by a complementary panel formed from a sheet material.

584132_ DOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAR--2006 15:53 A J PARK 64 9 3566990 P.09 INO Preferably there are a plurality of such retention formations, In another aspect the invention is a use of apparatus of the present invention.

ci In yet a further aspect the invention is the use of plastic mnouldings in a retention system for long run steel or aluminium cladding.

In another aspect the invention is a method of cladding as hereindescribed.

As used herein "and/or" means "and" or "or".

As used herein following a noun means the plural and singular forms of that 00 nloun.

As used herein "clip" and "~clip fit" includes componentry and assemblies of any push VaO 10 together interengagement where one member can be forced to be retained against easy o removal by a resultant abutment or abutment potential.

As used herein "base plate" is not confined to a non profiled member.

Two preferred forms of the present invention will now be described.

Figure 1 is a plan view from above of a base plate of a first embodiment in accordance with the present invention e.g. of steel showing three locations for a retention formation and shown at the left hand end one such moulded plastics retention member inserted upwardly through an appropriate opening of the base plate or rail, Figure 2 is a perspective view of the retention form shown to the left band end of the base plate or rail and moulded retention formation assembly of Figure 1, the retention form being indexed to a separate but like base plate to that of Figure 1 (albeit at the other end thereof), the opening of which surrounds the upstanding Moulded form to act as a clip fit retention member, Figure 3 shows in side elevation the interrelationship between parts of two different base plates and the retention member depicted in Figures I and 2, the moulded retention form having been clip fit engaged within a channel under the crest of a ridge of a complementary panel as shown, Figure 4 is an end elevational view of a retention member as depicted in the preceding drawings showing the enlarged lower part of the moulding a peripheral plateau) that prevents pull through of the base, Figure 5 is an enlarged view of the retention form and left hand end of the assembly as shown in Figure 1, 584132. L.DOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MPR-2006 15:54 A J PARK 64 9 3566990 -6- VaO o Figure 6 is a corresponding view to that of Figure 5 but in the mode as shown in c-I Figure 2, Ct Figure 7 is a top view solely of a metal rail as depicted in the Figure 1 partial assembly, Figure 8 is a section at D-D of the rail of Figure 7, Figure 9 is a section at E-E of the rail of Figure 7, ~fl Figure 10 is another view of the rail of Figure 7 showing the section for C-C, Figure 11 is a section at C-C with respect to the rail of Figure 0 Figure 12 is a side elevational view of two rails as in Figures 1, 7 and 10 with the members upstanding therethrough and a long run rooting paniel position thereover, it being 0N realized that other upstands of the plastics material would be provided along the expanse of.

the rails for support of the free edges shown once it each laps over or under or a complementary extremity of a like panel, Figure 13 is a plan view of the arrangement of Figure 12, the drawings showing only a short longitudinal expanse of the roofing panel, a long run roofing panel), Figure 14 is a perspective view of the arrangement of Figures 12 to 13, Figure 15 is a plan view of two rails of a second embodiment of the present invention each lapped one over the other at one end and showing upstanding therethrough two retention members of a different kind to that of the first embodiment, Figure 16 is a side elevation of the arrangement of Figure Figure 17 is a perspective view of the arrangements of Figures 15 and 16, Figure IS is a perspective view of a preferred retention member of preferably the second embodiment as shown in Figures 15 through 17 but not necessarily restricted for use with rails specifically of that kind, Figure 19 is a top view of the retention member of Figure 18, Figure 20 is a side view of the retention member of Figures 18 and 19, Figure 21 is a front view of the retention member of Figures 18 to flgure 22 is a perspective view of the arrangement of Figure 17 showing a short transverse section of roof cladding clip fitted to the retention members immerging through the rail, Figure 23 is a side elevation of the arrangement of Figure 22, and Figure 24 is a plan view of the arrangement of Figures 22 to 23.

584)32 IDOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MPR-2006 15:54 A J PARK 64 9 3566990 P.11 -7- VaO o Preferred forms are exemplified tbr roof cladding but the invention is equally 0 applicable to walls, floors and the like and to formwork for floors).

As shown in the Figures preferably there is a base plate or rail 1, having by way of example, three locations 2, 3 and 4 for a retention form as shown. A retention form 5 is shown through the left hand end with small end opening. Similarly such a form 5 (not shown) would be presented at the time of mounting the plate, if not earlier through the opening 6.

The opening 7 preferably is that which overlies a formation 5 of a like assembly NOc thereby ensuring the distance between 5 and 6, 6 and 7, 7/5A and 6A, 6A and 7A (where the 0 Ni 10 Such an arrangement allows appropriate clip fitting of modularly spaced channels defined by VaO o ridges of long run roofing of a kind, for example, having the ridge/complementary channel in ci profile shown in Figure 3 in cross section normal to the ridge axis).

In Figure 3 is shown retention shoulders 8 below the ramp regions 9 overlying a waisted rcgion I1) of the roofing panel 11. It can be seen that the plastics member underlies the crest 12 of the ridge formation.

Preferred materials for the base plate I is z-inc or zinc-aluminium. coated steel (although the base plate or rail can be a plastic or metal e.g. it could be manufactured from an extruded plastic or aluminium section) and for the retention fornms is a glass fibre filled nylon or nylon blend.

We envisage however a form for the base plate or rail as depicted which is best pressed from a coated steel strip.

Also shown is the enlarged bottom portion 13 of the muoulded plastics form 5 which Prevents pull through through an opening substantially of a same perimeter as shown as 6 and 7.

Whilst a skeletal (in part) form of the moulded member is shown, this is not essential.

Preferably however the moulded form includes sufficient deployed features such as lugs 14 to ensure accuracy of its location and a friction fit in the base member or rail I or lapped base members I and The mode of installation involves fixing a series of the base/retention form assemblies across the fail of the roof and a timely press fitting of roofing panels thereon preferably analogously to the manner in which the aforesaid DIMONDEKyM 630Th operates.

584132_.0C COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAR-2006 15:55 A J PARK 64 9 35G6990 P.12 I-8o The DIMONDEK Tm 630TM system by way of example has a ridge to ridge distance of CA 253mm and with the ridges being 62mm wide its modular spacing (ridge axis to ridge axis) is Ct 315mmn.

Features of interest further include: 1 The element of the clip that engages with the metal roofing is plastic so that the thermal expansion and contraction of the roof sheet will not result in wear between the roof In sheet and the clip. This movement can result in a hole being worn through the sheet, 0 o lengths (we have run 65 mn, and can run up to 100 in) and these lengths compound the thermal INO 10 movement. The roof metal can be of any appropriate thickness 0.55mm or 0.75mmn).

o2. Each plastic element is fitted through a hole in the metal carrier strip, and the plastic element has 6 small lugs that precisely locate the element in the hole. The metal carrier strip preferably is about 67mm wide.

3. The metal strip spaces the plastic elements exactly to the pitch of the roofing ribs, and each strip must therefore engage with the previous one in such a way that there is no tolerance that would cause a compounding alignment problem. This design solves the problem by the end of one clip lapping over the plastic element of the previous clip.

4. The rails are preferably screw-fastened to the purlins through punched holes, which are located such that the screw heads will not interfere with the metal roof bearing upon the metal strip element of the clip.

The metal strip preferably has a large radius formed along its edge to prevent a hard line showing through the pan of the roof sheet.

6. The plastic element engages with the roof in such a way that it is an interference fit that will resist upward load resulting from wind forces on the building. The shape and thickness of the plastic, and the type of plastic is designed for loads up to 7 kN, and temperatures up to 100 0

C

Figures 15 through 24 show a second embodiment having some changes to those already described by reference to Figures 1, 2 and 14. As can be seen in these drawings there are rails 16 and 17 shown in a lapping condition at the region 18. Retention members 19 are shown emerging through the lapping region 18 as well as through one of the openings of the rail 17 itself, Shown fined on such retention members is a short transverse section (simply as an example) of a roil formed roofing sheet profile 584132 J.DOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-MAR-2006 15:55 A J PARK 64 9 3566990 P. 13 -9- O The preferred retention member 19 of this embodiment is preferably as depicted in 0 Figures 18 through 21. There is provision whereby the regions 21 and 22 can allow tie down of those forms via openings 23 and 24 of, say, the rail 17 using appropriate coach bolts or the tlike.

Persons skilled in the art will appreciate that a variety of different options of the

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present invention exist.

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0 0 64132 I,DOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01

Claims (25)

1. 01-MAR-2006 15:55 A J PARK @1-PR-00615:5 PJ PRI<64 9 3566990 P.14 O CLAIMS: c-i1. A modular panel retention system for panels to be held on or by a structure, the ct system comprising or including, or including the use of, at least one retention member or assembly (hereafter "retention assembly") having, or each having, plural panel engagement forms upstanding from a base adapted to be retained on or by a said structure by fixing means), and at least one panel formed from sheet material and defining spaced ridge features INO ("ridge(s)") to its outside, 00 wherein each engagement form is clip fit and/or endwise slidably engageable into the Cl 10 underside of a ridge to retain the panel, O and wherein at least a or the bearing surface(s) of each engagement form to bear on a ci fitted panel is non metal and adapted to allow sliding by the panel relative thereto on or parallel to the ridge axis.
2. 2. A modular panel retention system of claim 1 wherein both the ridge to ridge spacing of the panel and a ridge to the nearest ridge of a like panel to be mated thereto corresponds to the engagement form to engagement form spacing ("the modular spacing").
3. 3. A modular panel retention system of claim 1 or 2 wherein each retention assembly is indexable to a like retention assembly so as to maintain the modular spacing of the collective series of engagements forms.
4. 4. A system of any one of the preceding claims wherein each retention member has a moulded plastics member for each retention form inserted through an elongate base or rail. A system of claim 4 wherein said insertion is through a metal base or rail.
5. 6. A system of claim 5 wherein said metal base or rail has an opening or other facility for each retention form insertion and to prevent pull through.
6. 7. A system of claim 4, 5 or 6 wherein said base or rail includes at or adjacent one end thereof an indexing opening or other facility to engage a base of a like retention assembly and/or about a retention form of a like retention assembly thereby to ensure modular spacing between all adjacent retention forms.
7. 8. Apparatus of a system of any one of the preceding claims.
8. 9. A moulded plastics member of or for a system of any one of claims I to 8 having at least one ramp down to a retention shoulder at or near its upper extremity in its upper region and a larger extent when considered in plan of its lower region with respect to said upper region. 564132_I.DOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006403-01 01-MAR-2006 15:55 A J PARK 01-IRR200 1555 J PRK64 9 3566990 I-Il o 10, A member of claim 9 that defines a peripheral plateau in its lower region above which 0 ci the upper region (of less lateral extent) projects to define at least one retention shoulders Ct facing towards the lower region.
9. 11. A member of claim 10 wherein there are two. retention shoulders.
10. 12. A member of claim 10 or I Ithe retention shoulder(s) is(are) associated with a ramp(s) whereby there can be a clip fit interengagement into the channel of a complementary panel.
11. 13. A retention formation adapted to fit within the underside of a ridge formation of a VaO 00 panel formed from a sheet material wherein the retention formation is of a plastics material o on which the panel is adapted to slide when affected by thernal expansion.
12. 14. A formation of claim 13 wherein the plastics material is selected from a range of nylon based materials. A fabricated assembly for attachment to a building envelope or structure (e.g. purlins; and/or roofing framing components, wall components, floor components, etc.) said fabricated member having a component of a first material adapted to be fixed by appropriate fixing means screws, nails, or the like) and at least one formation as aforesaid upstanding therefrom of a second material, said second material being of a plastics material adapted to have a panel engaged therewith and to slide responsive to thermal expansion/contraction thereon.
13. 16. A gang of clips formed as a unitary member or as a fabricated assembly adapted to be supported by the purlins and/or other sub-frame members of a building or other structure yet to provide clips modularly spaced each adapted to be engageable within a channel underlying a longitudinal ridge of a panei to be retained at least in part thereby.
14. 17. An assembly having an anchorable member adapted for engagement to at least one purlin or other sub- strucure of a to be cladded roof, and at least one plastics member retainable by the anchorable member that projects, or that each project, upwardly therefrom and are adapted to clip fit engage and retain (at least in part) a roofing panel having a complementary ridge defined channel accessible by the plastics member from below the crest of the ridge-
15. 18. An assembly of claim 17 wherein said plastics member defines a peripheral plateau in its lower region above which the upper region (of less lateral extent) projects to define at least one (and preferably two) retention shoulders facing towards the lower region. 584132 LDOC COMS ID No: SBMI-02830234 Received by IP Australia: Time 14:02 Date 2006-03-01 01-PAR-206 15156 A J PARK6 64 9 3586990 P. 16 -12- 8N)
16. 19. An assembly of claim 18 wherein the retention shoulder(s) is(are) associated with a ramp(s) whereby there can be a clip fit interengagement into the channel of a panel roll formed steel or aluminium roofing panel. In combination, an assembly of any one of claim 17 to 19 and a complementary pool.
17. 21. A combination of claim 20 wherein said complementary panel is a roofing panel. 22, A combination of claim 21 said roofing panel a long run metal panel. IN)
18. 23. A combination of any one of claims 20 to 22 wherein said plastics member is 0insertable through a base plate or rail of metal fixable by screws, etc to thereby be anchored.
19. 24. Apparatus, whether fabricated or a unitary member, comprising or including 24 Na base or rail adapted to be fitted by any appropriate means (whether reliant on fixing 0 means or otherwise) to the envelope or other structure of a building (for example, purlins and/or roofing framing components, wall components, etc.) and upstanding from the base, at least one moulded plastics retention formation adapted to be received by a complementary panel formed from a sheet material. Apparatus of claim 2 4 wherein there are a plurality of such retention formations.
20. 26. The use of apparatus of any one of the preceding claims.
21. 27. The use of plastic mouldings in a retention system for long run steel or aluminium cladding.
22. 28. A use of claim 27 substantially as herein described with reference to any one of the accompanying drawings.
23. 29. A method of cladding using a system of any one of claims 1 to 8. Apparatus substantially as hereinbefore described with reference to any one or more of the accompanying drawings.
24. 31. A method of cladding substantially as hereinbefore described with reference to any one or more of the accompanying drawings. 584132_LDOC COMS ID No: SBMI-0283023 4 Received by IP Australia: Time 14:02 Date
25. 2006-03-01