EP4343073A1

EP4343073A1 - Roof panel

Info

Publication number: EP4343073A1
Application number: EP22196457.0A
Authority: EP
Inventors: Tuomo Huopana
Original assignee: Rautaruukki Oyj
Current assignee: Rautaruukki Oyj
Priority date: 2022-09-20
Filing date: 2022-09-20
Publication date: 2024-03-27

Abstract

A roof panel (100), comprising a male locking profile (1) and a female locking profile (2). The male locking profile (1) comprises two male extensions (6) extending to an upper side (UP) of the roof panel and a channel (7) between the male extensions (6). The channel (7) has a bottom (8) connecting the male extensions and an open top (9). The bottom (8) provides an attachment surface configured to receive fasteners (10). he female locking profile (2) comprises two female extensions (11) extending to the upper side (UP) of the roof panel, said female extensions (11) creating a female groove (12) therebetween. The female groove (12) has a closed top (13) connecting the female extensions, and an open bottom (14). The female groove (12) is compatible with the male locking profile (1) for engaging therewith for creating a tongue- and-groove joint (15) locking two adjacent roof panels to each other.

Description

BACKGROUND

The invention relates to roof panels for standing seam roofs.
Standing seam roofs constructed from standing seam roof panels are widely used. However, the known standing seam roof panels have shown to contain some disadvantages.

BRIEF DESCRIPTION

Viewed from a first aspect, there can be provided a roof panel, comprising

a male locking profile arranged on a first edge of the panel,
a female locking profile arranged on a second edge, opposite to the first edge of the panel,
a panel zone between the locking profiles, wherein
the male locking profile comprises
- -- two male extensions extending to an upper side of the roof panel, and
- -- a channel between the male extensions, wherein
- -- the channel has a bottom connecting the male extensions and an open top,
- -- the bottom providing an attachment surface configured to receive fasteners for attaching the roof panel to a building structure beneath said roof panel, and
- -- the open top being open to the upper side of the roof panel, wherein
the female locking profile comprises
- -- two female extensions extending to the upper side of the roof panel,
- -- said female extensions creating a female groove therebetween,
- -- the female groove having a closed top connecting the female extensions and an open bottom, wherein
- -- the open bottom being open to an underside of the roof panel, and wherein
the female groove being compatible with the male locking profile for engaging therewith for creating a tongue-and-groove joint locking two adjacent roof panels to each other.

Thereby a roof panel having many advantages may be achieved. Type and design of fasteners can be selected freely, since they lie in a tunnel created by the male locking and the female locking profile away from sight and without contacting the next roof panel. Further, said tunnel is created simply by putting the male and the female locking profiles together without any sealing caps or other separate elements. Still further, the tongue-and-groove joint created by the male and the female locking profiles may provide an extremely stiff tongue-and-groove joint.
The roof panel is characterised by what is stated in the independent claim. Some other embodiments are characterised by what is stated in the other claims. Inventive embodiments are also disclosed in the specification and drawings of this patent application. The inventive content of the patent application may also be defined in other ways than defined in the following claims. The inventive content may also be formed of several separate inventions, especially if the invention is examined in the light of expressed or implicit sub-tasks or in view of obtained benefits or benefit groups. Some of the definitions contained in the following claims may then be unnecessary in view of the separate inventive ideas. Features of the different embodiments of the invention may, within the scope of the basic inventive idea, be applied to other embodiments.
Various embodiments of the first aspect may comprise at least one feature from the following paragraphs:
In one embodiment, the male locking profile, the female locking profile and the panel zone are all constructed from a same sheet of material.
An advantage is that the structure is simple to manufacture and there is no seams or joints that may leak or initiate corrosion.
In one embodiment, the roof panel is constructed from a single sheet of material, preferably bent from a single metal sheet.
An advantage is that the structure is simple, durable and seamless.
In one embodiment, the locking profiles are parallelly directed.
An advantage is that a rectangular roof side is simple to cover with the roof panels.
In one embodiment, the panel zone is substantially even on the upper side of the panel.
An advantage is that amount of used material may be decreased.
In one embodiment, the panel zone comprises at least one rib or furrow on the upper side of the panel.
An advantage is that the stiffness of the roof panel may be increased, and the architectural image of the roof trimmed.
In one embodiment, the cross-sectional profile of the female locking profile is constructed from straight sections bent into a stepwise curvature.
An advantage is that precise locking shapes that keep the locking profiles firmly attached may be provided.
In one embodiment, the cross-sectional profile of the female locking profile constructed from straight sections bent into a stepwise curvature comprises a bend in range of 90°- 130° in each of the two female extensions.
An advantage is that firmness of the tongue-and-groove joint may be optimized.
In one embodiment, the cross-sectional profile of the female locking profile comprises a circular arch.
An advantage is that forming of circular arch instead of rather sharp bending decreases amount of local work hardening of the material that alters material properties locally. Thus, properties of the locking profile are more homogenous, which may lead to an even more firm locking of the locking profiles.
In one embodiment, the cross-sectional profile of the female locking profile is constructed from the circular arch.
An advantage is that an even more firm locking of the locking profiles may be achieved.
In one embodiment, the female extensions, or the male extensions, preferably both said extensions, have symmetrical profiles.
An advantage is that a symmetrical bending of the locking profile(s) may be assisted, and thus easier installation process of the roof achieved.
In one embodiment, the cross-sectional profile of the male locking profile is constructed from straight sections bent into a stepwise curvature.
An advantage is that precise locking shapes that keep the locking profiles firmly attached may be provided.
In one embodiment, the cross-sectional profile of the male locking profile constructed from straight sections bent into a stepwise curvature comprises a bend in range of 90°- 130° in each of the two male extensions.
An advantage is that firmness of the tongue-and-groove joint may be optimized.
In one embodiment, the cross-sectional profile of the male locking profile comprises a circular arch.
An advantage is that even more firm locking of the locking profiles may be achieved.
In one embodiment, the bottom is arranged on a same level as the upper side of the panel zone.
An advantage is that an even roof surface without toothing may be achieved.
In one embodiment, at least one end of the panel zone extends past the ends of the locking profiles and creates an extension strip bendable to the underside or the upper side of the roof panel, the extension strip being optionally provided with weak point(s) or weak line(s) for helping the bending thereof.
An advantage is that a protective element may be provided in the transverse direction of the roof panel, on upper side or underside thereof.
In one embodiment, at least one end of the female locking profile comprises an extension flap that is arrangeable to close said at least one end of the female locking profile.
An advantage is that the inner side of the tongue-and-groove joint may be shielded against the elements.

BRIEF DESCRIPTION OF FIGURES

Some embodiments illustrating the present disclosure are described in more detail in the attached drawings, in which

Figure 1 is a schematic perspective view of a roof panel seen from upper side thereof,
Figure 2 is a schematic view of a roof panel seem from end thereof,
Figure 3a is a schematic view of a female locking profile,
Figure 3b is a schematic view of a male locking profile,
Figure 4 is a schematic view of another female locking profile, and
Figure 5 is a schematic view of a part of another roof panel.

In the figures, some embodiments are shown simplified for the sake of clarity. Similar parts are marked with the same reference numbers in the figures.

DETAILED DESCRIPTION

Figure 1 is a schematic perspective view of a roof panel seen from upper side thereof, and Figure 2 is a schematic view of the roof panel seem from end thereof. The roof panel 100 is for use in standing roofs, primarily in residential buildings, such as detached houses.
The roof panel 100 comprises a male locking profile 1 that is arranged on a first 3 edge of the panel shown on left in Figure 1, and a female locking profile 2 that is arranged on a second 4 edge, opposite to the first edge of the panel 100. Typically, the length of the locking profiles 1, 2 corresponds to the length L of the roof panel.
A panel zone 5 is arranged between the locking profiles 1, 2. Typically, the panel zone 5 creates most of the width W of the roof panel.
In an embodiment, the length L of the roof panel is selected so that it covers all the length of a roof side, for instance from a ridge to eaves. In an embodiment, the length L of the roof panel is essentially shorter than the roof side, and the said length is covered by at least two roof panels.
In an embodiment, the width W of the roof panel is in range of 400 mm - 1100 mm, such as 450 mm - 550 mm.
In an embodiment, the height of the locking profiles 1, 2 measured from the panel zone 5 is in range of 15 mm - 50 mm, preferably 25 mm - 35 mm.
In an embodiment, the width of the locking profiles 1, 2 is in range of 20 mm - 70 mm, preferably 25 mm - 60 mm, more preferably 30 mm - 50 mm.
In one embodiment, such as shown in Figure 1, the locking profiles 1, 2 are parallelly directed. In other words, the panel zone 5 has a constant width. However, this is not always necessary: e.g. roof panels for round roofs or for roundish details of roofs may have a panel zone that tapers towards one end of the panel.
In one embodiment, the panel zone 5 is substantially even on the upper side UP of the panel. In another embodiment, the panel zone 5 comprises at least one rib or furrow 16 on the upper side UP of the panel, typically arranged in lengthwise direction of the panel. Said rib or furrow 16 may have a functional purpose, e.g. stiffening the panel, or just an aesthetical purpose.
In one embodiment, such as shown in Figure 1, the male locking profile 1, the female locking profile 2 and the panel zone 5 are all constructed from a same sheet of material.
In one embodiment, the roof panel 100 is constructed from a single sheet of material. The sheet of material may be a single layer sheet or a multi-layer sheet. The sheet of material may be coated e.g. with paint, plastic film etc.
In one embodiment, the sheet of material comprises metal, such as steel.
In one embodiment, the thickness of the sheet of material is 1 mm or less, for instance in range of 0.5 - 0.6 mm. The thickness may be even less than 0.5 mm, but at least some roofing standards prescribe 0.5 mm as the minimum thickness of roof panels.
In one embodiment, the roof panel 100 is shaped to its shape by bending or squaring method or roll forming.
The male locking profile 1 comprises two male extensions 6 (best shown in Figure 3b) that extend to the upper side UP of the roof panel. Between the two male extensions 6 there is a channel 7. The channel 7 has a bottom 8 that connects said two male extensions. The channel 7 has additionally an open top 9 that is open to the upper side UP of the roof panel.
The bottom 8 is preferably even and it provides an attachment surface for attaching the roof panel 100 to a building structure (not shown) beneath said roof panel by fasteners 10. The fastener 10 may be e.g. a screw or a nail. In one embodiment, the bottom 8 is provided with fixing apertures 21 through which the fastener 10 may be attached to the building structure. The fixing apertures 21 shown in Figure 1 have an oblong shape; however, other shapes are possible, such as round.
In one embodiment, such as shown in Figure 2, the bottom 8 is arranged on a same level as the upper side of the panel zone 5.
The female locking profile 2 that is arranged on the second edge 4 of the roof panel comprises two female extensions 11 (best shown in Figures 3a and 4) that extend to the upper side UP of the roof panel.
The female extensions 11 create a female groove 12 therebetween. Said female groove 12 has a closed top 13 that connects the two female extensions together, and an open bottom 14. The open bottom 14 is open to an underside UN - opposite to the upper side UP - of the roof panel 100.
The female groove 12 is compatible with the male locking profile 1 in such an extent that said male locking profile 1 can be secured in said female groove 12 for creating a tongue-and-groove joint 15 that locks two adjacent roof panels 100 to each other. There is no need for using fasteners, such as screws, or glue etc. in the tongue-and-groove joint 15.
The structure of at least one of the male locking profile 1 and the female locking profile 2 is elastically flexible so that the male extensions 6 can be pressed or forced through the open bottom 14 of the female locking profile into the female groove 12, and then elastic forces press the locking profiles against each other. Said flexibility is preferably based on the properties of the sheet of material.
Following creating the tongue-and-groove joint 15 where two roof panels join to each other, the fasteners 10 are inside a "tunnel" created by the closed top 13 of the female locking profile and the male extensions 6 of the male locking profile. Said "tunnel" creates an airway through which air can flow. This flow flushes contacting points of the bottom 8 and the fasteners 10, reduces dampness and thus reduces risk of corrosion between the bottom and the fasteners.
The locking profiles 1, 2 attached to each other may serve as an attachment point to various fasteners, brackets, clamps 22 etc. by means of which roof safety products or other products may be coupled to a roof. The roof safety product may be e.g. a snow guard, roof ladders and bridges. The roof safety products may be installed with a crimped connection, which is allowed by the shape of the locking profile. Crimped connection does not need any holes to be drilled thus avoiding any addition of leakage points to the roof panel. Other products may be e.g. a solar panel.
Figure 3a is a schematic view of a female locking profile, and Figure 3b is a schematic view of a male locking profile.
In one embodiment, the female locking profile 2 is constructed from straight sections that are bent into a stepwise curvature. In other words, the cross-sectional profile XF of the female locking profile comprises straight sections that creates a stepwise curvature. This stepwise curvature comprises a locking shape 23 in a form of at least one bend, shown in Figure 3a. The locking shape 23 provides a laterally projecting part in the cross-sectional profile XF into which the male locking profile 1 can lock with its corresponding lateral male locking shape 24, shown in Figure 3b.
In one embodiment, the bend is in range of 90°- 130°.
In one embodiment, one of the female extensions 11 comprises the locking shape 23, but another female extension is devoid thereof. In one embodiment, the female extensions 11 have symmetrical profiles. In one embodiment, each of the two female extensions 11 comprises the locking shape.
In one embodiment, the male locking profile 1 is constructed from straight sections that are bent into a stepwise curvature, i.e. the cross-sectional profile XM of the male locking profile comprises straight sections that creates a stepwise curvature, such as shown in figure 3b. This stepwise curvature comprises a male locking shape 24 in a form of at least one bend. This shape provides a laterally projecting part in the cross-sectional profile XM that can lock with its corresponding lateral female locking shape 23, for instance as shown in Figure 3a.
In one embodiment, the bend is in range of 90°- 130°.
In one embodiment, one of the male extensions 6 comprises the male locking shape 24, but another male extension is devoid thereof. In one embodiment, the male extensions 6 have symmetrical profiles. In one embodiment, each of the two male extensions 6 comprises the male locking shape. The embodiments shown in Figures 3a and 3b have five straight sections in their cross-sectional profiles. However, the number of the straight sections may be less or more than five.
In one embodiment, the female locking profile 2 additionally comprises at least one outwardly directed guiding surface 25. The embodiment shown in Figure 3a comprises guiding surfaces 25 on both sides of the profile. These surfaces help with fitting the male locking profile 1 in the female locking profile 2.
Figure 4 is a schematic view of another female locking profile. In one embodiment, the cross-sectional profile of the locking profile comprises a circular arch. This kind of locking profile may be the male locking profile 1 or female locking profile 2, or they both.
Figure 4 is showing an embodiment of the female locking profile 2 where the cross-sectional profile XF is completely constructed from an arch. Said arch has a constant radius, but this is not always necessary. In other words, the arch may also comprise a section having different radius than another section of said arch.
In one embodiment, the cross-sectional profile of the locking profile comprises at least one arched section and at least one straight section. In one embodiment, the cross-sectional profile of the locking profile comprises alternating arched and straight sections.
In one embodiment, such as shown in Figures 1 and 2, the cross-sectional profile XF of female locking profile has a same profile as the male locking profile 1. However, this is not necessary. The profiles may differ much, as long as they can engage for creating the tongue-and-groove joint 15. For example, a female locking profile having an arched profile may engage with a male locking profile constructed from straight sections bent into a stepwise curvature.
Figure 5 is a schematic view of another roof panel. In an embodiment, at least one end 17 of the panel zone extends past the ends of the locking profiles and creates an extension strip 18. In an embodiment, both ends of the panel zone are provided with the extension strip 18.
This extension strip 18 can be bend towards the underside UN or the upper side UP of the roof panel 100, and then left in a bend position. The extension strip 18 may then provide shielding or screening sometimes needed at the end of the roof panel when the roof panel end is installed at the ridge of the roof. The extension strip 18 allows for ventilation of roof structure underneath the roof panel 100 and blocks e.g. leaves and rain to enter the roof structure from the gap between the roof panel and the ridge of the roof.
In an embodiment, the extension strip 18 comprises weak point (s) or weak line(s) 19 that help(s) the bending thereof to desired position. In an embodiment, there are multiple lines weakened by the weak point(s) or weak line(s) 19 so that multiple bends can be made easily in the extension strip. The extension strip 18 may also comprise openings to allow air to reach the roof structure beneath the roof panel 100 for ventilation purposes.
The dimensions of the extension strip depend on e.g. heights of the locking profiles and the width of the panel zone.
It is to be noted, that the extension strip 18 does not necessitate presence of the male locking profile 1 and the female locking profile 2 described in this description. In other words, the extension strip 18 may be present in roof panels that comprises alternative locking profiles.
In an embodiment, at least one end of the female locking profile 2 comprises an extension flap 20 that can be bent to close said end of the female locking profile 2. The extension flap 20 is preferably of the same sheet of material as the female locking profile.
In Figure 5 the extension flap 20 has been bent on the open end of the female locking profile.
The invention is not limited solely to the embodiments described above, but instead many variations are possible within the scope of the inventive concept defined by the claims below. Within the scope of the inventive concept the attributes of different embodiments and applications can be used in conjunction with or replace the attributes of another embodiment or application.
The drawings and the related description are only intended to illustrate the idea of the invention. The invention may vary in detail within the scope of the inventive idea defined in the following claims.

REFERENCE SYMBOLS

1: male locking profile
2: female locking profile
3: first edge
4: second edge
5: panel zone
6: male extension
7: channel
8: bottom
9: open top
10: fastener
11: female extension
12: female groove
13: closed top
14: open bottom
15: tongue-and-groove joint
16: rib or furrow
17: end of panel
18: extension strip
19: weak point or weak line
20: extension flap
21: fixing aperture
22: fastener for roof safety products
23: female locking shape
24: male locking shape
25: guiding surface

100: roof panel

L: length of panel
UN: underside
UP: upper side
W: width of panel
XF: cross-sectional profile of female locking profile
XM: cross-sectional profile of male locking

Claims

A roof panel (100), comprising
- a male locking profile (1) arranged on a first (3) edge of the panel,

- a female locking profile (2) arranged on a second (4) edge, opposite to the first edge of the panel,

- a panel zone (5) between the locking profiles (1, 2), wherein

- the male locking profile (1) comprises
-- two male extensions (6) extending to an upper side (UP) of the roof panel, and

-- a channel (7) between the male extensions (6), wherein

-- the channel (7) has a bottom (8) connecting the male extensions and an open top (9),

-- the bottom (8) providing an attachment surface configured to receive fasteners (10) for attaching the roof panel (100) to a building structure beneath said roof panel, and

-- the open top (9) being open to the upper side (UP) of the roof panel, wherein

- the female locking profile (2) comprises
-- two female extensions (11) extending to the upper side (UP) of the roof panel,

-- said female extensions (11) creating a female groove (12) therebetween,

-- the female groove (12) having a closed top (13) connecting the female extensions and an open bottom (14), wherein

-- the open bottom (14) being open to an underside (UN) of the roof panel, and wherein

- the female groove (12) being compatible with the male locking profile (1) for engaging therewith for creating a tongue-and-groove joint (15) locking two adjacent roof panels to each other.
The roof panel as claimed in claim 1, wherein
- the male locking profile (1), the female locking profile (2) and the panel zone (5) are all constructed from a same sheet of material.
The roof panel as claimed in any of the preceding claims, wherein
- the roof panel (100) is constructed from a single sheet of material, such as a single metal sheet.
The roof panel as claimed in any of the preceding claims, wherein
- the locking profiles (1, 2) are parallelly directed.
The roof panel as claimed in any of the preceding claims, wherein
- the panel zone (5) is substantially even on the upper side (UP) of the panel.
The roof panel as claimed in any of claims 1 - 4, wherein
- the panel zone (5) comprises at least one rib or furrow (16) on the upper side (UP) of the panel.
The roof panel as claimed in any of the preceding claims, wherein
- the cross-sectional profile (XF) of the female locking profile is constructed from straight sections bent into a stepwise curvature.
The roof panel as claimed in claim 7, wherein
- each of the two female extensions (11) comprises a bend in range of 90°- 130°.
The roof panel as claimed in any of claims 1 - 8, wherein
- the cross-sectional profile (XF) of the female locking profile comprises a circular arch.
The roof panel as claimed in any of the preceding claims, wherein
- the female extensions (11) have symmetrical profiles.
The roof panel as claimed in any of the preceding claims, wherein
- the cross-sectional profile (XM) of the male locking profile is constructed from straight sections bent into a stepwise curvature, preferably comprising a bend in range of 90°- 130° in each of the two male extensions (11).
The roof panel as claimed in any of the preceding claims, wherein
- the cross-sectional profile (XM) of the male locking profile comprises a circular arch.
The roof panel as claimed in any of the preceding claims, wherein
- the bottom (8) is arranged on a same level as the upper side of the panel zone (5).
The roof panel as claimed in any of the preceding claims, wherein
- at least one end (17) of the panel zone extends past the ends of the locking profiles and creates an extension strip (18) bendable to the underside (UN) or the upper side (UP) of the roof panel, the extension strip (18) being optionally provided with weak point(s) or weak line(s) (19) for helping the bending thereof.
The roof panel as claimed in any of the preceding claims, wherein
- at least one end of the female locking profile (2) comprises an extension flap (20) that is arrangeable to close said at least one end of the female locking profile (2).