NZ539212A - Panel clip for roofing assembled upwardly through elongate base plate - Google Patents

Abstract

A panel clip is inserted upwardly through an elongate base plate which can be indexed to an adjacent such plate end to end across the fall of a roof. The clip fits to the channel of a roofing panel but allows for relative sliding.

Description

NEW ZEALAND PATENTS ACT, 1953 No: 539212/539694 Date: 1 April 2005/27 April 2005 COMPLETE SPECIFICATION PANEL CLIP AND PANEL CLIP ASSEMBLIES We, FLETCHER BUILDING HOLDINGS LIMITED, a company duly incorporated under the laws of New Zealand of 810 Great South Road, Penrose, Auckland, New Zealand, 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: 0 5 APR 2007 The present invention relates to roofing and more particularly to components, subassemblies and related procedures and methodologies for clip fitting panels typified by metal 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.

With the advent of the DIMONDEK 630 onsite manufacturing of panels, extremely 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 panel of up to 65.5 metres long have been made.

With longer metal roofing panels, particularly if made of aluminium but also even if 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 an aspect the invention is a moulded panel retainer moulded of a plastics material or a plastics including material to define (i) a lower region for association with a base plate or rail connected to or to be connected to a structure to be clad by the panel; and (ii) an upper region to captively but slideably engage a complementary channel form of a panel to be retained thereby, wherein the upper region includes at least one downwardly facing shoulder to overlie and retain, at least in part, an underlying constriction of such a complementary channel form, and wherein the silhouette or footprint ("footprint") of the upper region, when viewed towards the lower region, differs from, or is at least in part less laterally extensive than, said lower region.

Preferably the lower region is defined at least in part by a peripheral plateau.

Preferably there are two downwardly facing shoulders. ^ ^ ^ Preferably the two downwardly facing shoulders are on opposing sides of the upper region.

Preferably the two downwardly facing shoulders are off set from each other.

Preferably there is a ramp linking an upper end of the upper region to each of the downwardly facing shoulders.

Preferably the moulding has locating lugs.

Preferably the moulding has at least one resilient arm extending diagonally downwards towards the lower region.

Preferably the or each resilient arm co-acts with the peripheral plateau for association with the base plate or rail.

Preferably there are two arms.

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

Preferably the plastic material is glass fibre filled nylon or nylon blend.

In another aspect the invention is a moulded panel retainer moulded of a plastics material or a plastics including material to define (iii) a lower region, and (iv) an upper region, wherein the upper region includes at least one ramp or curve to downwardly facing shoulder, and wherein the silhouette or footprint ("footprint") of the upper region, when viewed towards the lower region, differs from, or is at least in part less laterally extensive than, said lower region and has some asymmetry.

Preferably the moulded panel retainer is substantially as herein described with reference to any one or more of the accompanying drawings. 0 5 APR Z007 In another aspect the invention is a base plate for use with the moulding as described, the base plate anchorable to at least one purlin or other sub-structure of a to be clad roof, the base plate having a plurality of openings for association with the mouldings.

Preferably each opening is sized such that most of said moulding may be projected through but further upward projection is restricted by the peripheral plateau of the moulding.

Preferably the openings are spaced.

Preferably the base plate is anchorable by screw-fastening to the or each purlin or other sub-structure of a to be clad roof through punched holes.

Preferably the base plate is a metal rail.

Preferably the rail is profiled in transverse section.

Preferably the base plate is substantially as herein described with reference to any one or more of the accompanying drawings.

In another aspect the invention in combination, a retainer, and a base plate to receive therethrough in part, overlie in part and retain said lower region of the retainer.

Preferably an asymmetric opening of the base plate can retain as a flange at least part of the retainer otherwise fully insertable through such an opening.

Preferably the retainer is click fit retainable in the base plate.

In another aspect the invention is an assembly for use with like assemblies for clip fitting roofing panels or a roofing panel, the assembly comprising or including an elongate base plate anchorable to at least one purlin or other substructure of a to be clad roof, the elongate base plate having therealong at least two spaced openings, and having an adaption whereby it can be indexed end to end, or end with end, to a like base plate in order to provide some modularity of relationship of the openings of one base plate to those of the other, and 05 APR 2007 a plurality of upstanding moulded plastic members, each located upwardly through a said opening of a base plate, wherein each plastic member is adapted to clip fit engage and retain a channel of a said roofing panel yet to allow the roofing panel to slide relative thereto if and when required.

Preferably the plastic members are constantly spaced on the base plate.

Preferably the base plate is a metal rail.

Preferably the rail is profiled in transverse section.

Preferably the plastic member is made of glass fibre filled nylon or nylon blend.

Preferably the adaption is an opening.

Preferably the end to end or end with end indexing of like base plates is achieved by plastic member projecting through aligned openings.

Preferably the base plate is anchorable by screws, the screws located such that they are disposed within ribs of the roofing panel and will not interfere with the roofing panel.

Preferably each plastic member has lugs that locate each opening of the base plate such that said plastic member projects through the opening in a single orientation.

Preferably the plastic member has 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.

Preferably the plastic member defines a peripheral plateau in its lower region above which the upper region (of less lateral extent) projects to define at least one retention shoulder facing towards the lower region.

Preferably there are two retention shoulders on the plastic member.

Preferably the retention shoulders are associated with ramps whereby there can be a clip fit interengagement into the channel of a complementary panel.

Preferably there is at least one resilient arm provided to retain the plastic member to the base plate after projection through the opening. 05 APR 2007 Preferably there are two resilient arms.

Preferably an assembly of the base plate(s) is(are) substantially as described and the moulded items substantially as described.

Preferably the assembly is substantially as herein described with reference to any one of more of the accompanying drawings.

In another aspect the invention is a roofing assembly comprising or including: a plurality of upstanding plastic members, each spaced from another across the fall of the roof and fixed directly or indirectly to purlins or other substructure of a to be clad roof, at least one panel formed from sheet material having a plurality of spaced ridges complementary to the plastic members, wherein each plastic member is adapted to clip fit engage and retain a ridge of the panel, yet allow the panel to slide relative thereto in the roof fall direction.

Preferably the plastic members are spaced by a base plate.

Preferably the sheet material is metal.

Preferably the plastic member includes at least one retention shoulder in an upper region for engaging the panel.

Preferably there are two retention shoulders on the plastic member.

Preferably the retention shoulders are associated with ramps whereby there can be a clip fit interengagement into the ridge of the panel.

Preferably each plastic member has been retained by a said base plate prior to fitment of the base plate relative to another and prior to fitment of the base plate to a support structure to be clad by such a panel.

Preferably asymmetry of each plastic member in an opening of the base plate has ensured appropriate alignment of the plastic member to the base plate.

Preferably each plastic member has been clip fitted into an opening of a said base plate. 0 5 APR 2007 Preferably an opening of a said base plate has received a plastic member received by an opening of another said base plate.

In another aspect the invention is a roofing assembly comprising or including a pre-assembly of a base plate having a plurality of plastic members engaged to and spaced by the base plate, the pre-assembly anchorable to a purlin or other sub-structure of a to be clad roof, and a roofing panel formed from sheet material, adapted to engage the pre-assembly.

The invention is a roofing assembly which is of an assembly substantially as previously described, and a roofing panel formed from sheet material, adapted to engage the assembly.

Preferably the roofing assembly is substantially as herein described with reference to any one of more of the accompanying drawings.

In another aspect the invention is a method of cladding a roof, comprising the steps of: projecting a plurality of spaced apart upstanding plastic members through openings in a plurality of base plates, the plastic members retainable to the base plate, anchoring the plurality of base plates to at least one purlin or other sub-structure of the roof, engaging a preformed roofing panel with the upstanding plastic members, wherein an upper portion of the plastic member is engaged within a channel under the crest of a ridge of the roofing panel.

Preferably the preformed roofing panel is clip fitted onto the upstanding plastic members.

Preferably the preformed roofing panel is slid endwise to engage the upstanding plastic members. of: In another aspect the invention is a method of cladding a roof, comprising the steps 0 5 APR 2007 (v) projecting a plurality of upstanding plastic members through openings in a base plate, (vi) snap fitting the plastic members to the openings to prevent the plastic members from dislodging, (vii) anchoring the assembly of the plastic members and the base plate to at least one purlin or other sub-structure of the roof, (viii) repeating steps (i) to (iii) if necessary across the roof, and (ix) clip fitting a preformed roofing panel to the upstanding plastic members.

Preferably the plastic members are snap fitted to the openings by resilient arms extending from the plastic members.

Preferably the resilient arms provide interference fit with the openings to prevent dislodgement.

In another aspect the invention is a method of cladding a roof, comprising the steps of: anchoring a pre-assembly to at least one purlin or other sub-structure of the roof, engaging a roofing panel to the pre-assembly, wherein the pre-assembly comprises or includes a plurality of upstanding plastic members snap fitted and projecting through a base plate.

Preferably the roofing panel is engaged to the upstanding plastic members.

Preferably the roofing panel is clip fitted to the upstanding plastic members.

Preferably the plastic members are spaced by the base plate.

Preferably the method of cladding is performed substantially as herein described with reference to any one or more of the accompanying drawings.

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 0 5 APR 2007 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 (A) the ridge to ridge spacing of the panel and (B) 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"), 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.

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 form of a like retention assembly thereby to ensure modular spacing between all adjacent retention forms.

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.

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 (e.g. roll formed steel or aluminium roofing panel. 0 5 APR 2007 The present invention also consists in a retention formation adapted to fit within the underside of a ridge formation of a panel formed 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 (e.g. 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 (e.g. 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.

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.

In another aspect the present invention consists in an assembly having an anchorable member adapted for engagement to at least one purlin or other substructure 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.

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 (e.g. 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. 05 APR 200/ 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.

Preferably there are a plurality of such retention formations.

In another aspect the invention is a use of apparatus of the present invention.

In yet a further aspect the invention is the use of plastic mouldings 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 "(s)" following a noun means the plural and singular forms of that noun.

As used herein "clip" and "clip fit" includes componentry and assemblies of any push together interengagement where one member can be forced to be retained against easy 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 hand 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 0 5 APR 2007 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 1 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 (i.e. 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, Figure 6 is a corresponding view to that of Figure 5 but in the mode as shown in Figure 2, 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, 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 10, 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 roofing panel position thereover, it being 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, (e.g. 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 15, Figure 17 is a perspective view of the arrangements of Figures 15 and 16, 05 APR 2007 Figure 18 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 20, Figure 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.

Preferred forms are exemplified for roof cladding but the invention is equally applicable to walls, floors and the like and to formwork (e.g. 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 thereby ensuring the distance between 5 and 6, 6 and 7, 7/5A and 6A, 6A and 7A (where the A suggests formations of a different assembly but one mated and indexed thereto) is kept. Such an arrangement allows appropriate clip fitting of modularly spaced channels defined by ridges of long run roofing of a kind, for example, having the ridge/complementary channel in profile shown in Figure 3 in cross section (i.e. normal to the ridge axis).

In Figure 3 is shown retention shoulders 8 below the ramp regions 9 overlying a waisted region 10 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 1 is zinc 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 forms 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. 0 5 APR 2007 Also shown is the enlarged bottom portion 13 of the moulded 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 1 or lapped base members 1 and 15.

The mode of installation involves fixing a series of the base/retention form assemblies across the fall of the roof and a timely press fitting of roofing panels thereon preferably analogously to the manner in which the aforesaid DIMONDEK™ 630™ operates.

The DIMONDEK™ 630™ system by way of example has a ridge to ridge distance of 253mm and with the ridges being 62mm wide its modular spacing (ridge axis to ridge axis) is 315mm.

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 sheet and the clip. This movement can result in a hole being worn through the sheet, particularly if the roof metal is aluminum. Also, the roof sheet is roll-formed on site in long lengths (we have run 65 m, and can run up to 100 m) and these lengths compound the thermal movement. The roof metal can be of any appropriate thickness (e.g. 0.55mm or 0.75mm). 2. 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 0 5 APR 2007 thickness of the plastic, and the type of plastic is designed for loads up to 7 kN, and temperatures up to 100°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 fitted on such retention members is a short transverse section (simply as an example) of a roll formed roofing sheet profile 20.

The preferred retention member 19 of this embodiment is preferably as depicted in 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 like.

Persons skilled in the art will appreciate that a variety of different options of the present invention exist. 0 5 APR 2007

Claims (15)

WHAT WE CLAIM IS:

1. An assembly for use with like assemblies for clip fitting roofing panels or a roofing panel, the assembly comprising or including an elongate base plate anchorable to at least one purlin or other substructure of a to be clad roof, the elongate base plate having therealong at least two spaced openings, and having an adaption whereby it can be indexed end to end, or end with end, to a like base plate across the fall of the roof in order to provide some modularity of relationship of the openings of one base plate to those of the other, and a plurality of upstanding moulded plastic members, each located upwardly through a said opening of a base plate, subsequent to upward passage in part through a said opening, wherein each plastic member is adapted to clip fit engage and retain a channel of a said roofing panel yet to allow the roofing panel to slide relative thereto if and when required.

2. An assembly of claim 1 wherein the plastic members are constantly spaced on the base plate.

3. An assembly of claim 1 or 2 wherein the base plate is a metal rail.

4. An assembly of claim 3 wherein the rail is profiled in transverse section.

5. An assembly of any one of claims 1 to 4 wherein the plastic member is made of glass fibre filled nylon or nylon blend.

6. An assembly of any one of claims 1 to 5 wherein the adaption is an opening.

7. An assembly of any one of claims 1 to 6 wherein the end to end or end with end indexing of like base plates is achieved by plastic member projecting through aligned openings.

8. An assembly of any one of claims 1 to 7 wherein the base plate is anchorable by screws, the screws located such that they are disposed within ribs of the roofing panel and will not interfere with the roofing panel. Intellectual Property Office of N.2. 12 FEB 2008 RECEIVED -17-

9. An assembly of any one of claims 1 to 8 wherein each plastic member has lugs that locate each opening of the base plate such that said plastic member projects through the opening in a single orientation.

10. An assembly of any one of claims 1 to 9 wherein the plastic member has 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.

11. An assembly of claim 10 wherein the plastic member defines a peripheral plateau in its lower region above which the upper region (of less lateral extent) projects to define at least one retention shoulder facing towards the lower region.

12. An assembly of claim 11 wherein there are two retention shoulders on the plastic member.

13. An assembly of any one of claims 10 to 12 wherein the retention shoulders are associated with ramps whereby there can be a clip fit interengagement into the channel of a complementary panel.

14. An assembly of any one of claims 1 to 13 wherein there is at least one resilient arm provided to retain the plastic member to the base plate after projection through the opening.

15. An assembly of claim 14 wherein there are two resilient arms. DATED THIS (Z^ DAY OF ^06? AJ ?w/i J PER JWyfaJ-- AUENTS fOK TMI APPLICANT 12 FEBM