Patent Application
20250188744
This application claims priority to British patent application no. 2318710.7 filed on Dec. 7, 2023.
This disclosure relates to methods and devices for improving or facilitating the attachment of elongate elements extending transversely to one another, preferably the attachment of a smaller element across a larger fixed element, and especially but not exclusively the attachment of roofing battens onto roof support members such as rafters. It has particular application when the elements are wooden elements secured using nails. Another suitable use is in fencing, such as in securing cross-members to upright posts.
A conventional pitched roof has a set of longitudinally-spaced rafters, typically extending at an angle from eaves to ridge. The flat top support surfaces of the rafters all lie in a plane defining the support plane for the roof. Usually, the support surface of each rafter is 50 mm (2 inch) wide although some are 75 mm (3 inch) or even wider. A flexible layer (felt, underlay, membrane, sarking) lies on top of the rafters in most modern roofs, usually being fixed to the rafters by nails. An array of overlapping tiles or slates is supported on the rafters, held in position by multiple parallel horizontally-extending battens. The battens are secured to the rafters beneath by nailing at the intersections, nailing through the intervening flexible layer where this is present.
Conventional battens are rectangular-section wooden lengths, usually 25 mm (1 inch) deep and either 38 or 50 mm (1½ inch or 2 inch) wide, i.e., in the direction of the length of the rafters. Each batten is usually long enough to span across several rafters, but depending on the size and shape of the roof surface it is inevitably necessary to combine battens end-to-end to span the correct distances. The battens are not supported between the rafters and freely projecting cantilevered ends would seriously lack strength. So, batten joints are made by adjusting the lengths of adjacent battens so that their ends meet part-way across the top of a rafter. A nail is driven through the end of each batten and down into the rafter, usually at an angle towards the centre of the rafter. Where there is no batten joint and a batten simply crosses a rafter, only a single central nail is used. The usual fasteners used are 60 mm or 76 mm (2½ inch or 3 inch) round wire nails, but of course in principle other kinds of fasteners, such as screws, or other types or sizes of nails, can be used.
Apart from purlins, which are widely spaced and beneath the flexible layer, the battens are the only horizontally-extending elements of the structure and it is normal that people working on the roof use them to support their weight when moving around the working site. When a worker—who may be carrying a heavy load—puts their foot on a batten end at a joint, the single-nail attachment of the batten end onto half the width of the rafter is liable to come adrift because the batten has no portion extending on the other side of the rafter to help support it. If the nail comes adrift the batten end usually bends and breaks and the batten must be replaced. The breaking of a batten on which someone is standing presents a significant danger, and if the broken batten end drops far enough, either it or the worker's foot may go through the flexible underlayer if one is present.
A related situation may arise in a roof valley, where two roof planes meet at an angle less than 180°. A rafter (valley blade) extending up the valley line—or more usually, a valley board above a valley blade—is a termination boundary for the battens of each roof plane. The end of each batten is cut at an angle to lie close up against the side of the valley board, and a fastener is driven sideways through the end of the batten, (e.g., substantially diagonally or approximately perpendicularly) into the side face of the valley board. Here again workers may carelessly tread on the battens, and since there is very little vertical support for a projecting batten end it is likely to break and puncture any flexible layer e.g., felt beneath.
The present disclosure is directed towards a batten support (e.g., a plate) which is provided at the end of a batten, to help transfer or distribute load on the batten to an adjacent roof support member and/or other batten, thereby reducing the demand on a nail or other fastener holding the batten in place and helping to avoid or reduce the problems described above.
According to a first aspect there is provided a batten support (e.g., a batten support plate) which has a base portion shaped to lie on or against a roof support member (e.g., a timber, rafter, or valley board). The base portion is configured to be secured to the roof support member by a fastener (e.g., a nail) passing through the base portion into the roof support member. The batten support also has a ledge portion (e.g. at least one ledge portion) projecting at an angle (e.g., substantially perpendicular, or perpendicular, and/or substantially upwardly) relative to the base portion, to lie against a lateral surface (as distinct from an end surface) of the batten, thereby supporting it.
According to a second aspect there is provided a method of forming (e.g., constructing) a roof structure, the roof structure when formed comprises at least one batten, at least one roof support member and a batten support (e.g., a batten support plate) as described above in relation to the first aspect. The method comprises:
Advantageously the batten support comprises the ledge portion and base portion as mutually angled portions of a single plate. Since the roof support member surfaces and batten surfaces are substantially flat, the base portion and ledge portion of the batten support are also desirably flat, or present a flat support locus even if interrupted. The base portion may define a support surface for direct contact with the at least one batten.
The first and/or second aspects may include the following optional features in any combination unless the context demands otherwise.
An exemplary arrangement of the batten support for use on a rafter may comprise or consist of an L-section plate (or plate comprising an L-section portion), with a flat base plate and a substantially perpendicular (e.g., substantially upright when in use) side plate constituting the ledge portion. These elements may have substantially the same length (i.e., in the length direction of the batten in use). In a preferred method the batten support plate is positioned with its base portion lying on the rafter top surface, the ledge portion running substantially horizontally (e.g., in a lateral direction of the rafter) and to either side of the rafter centre line so as to support the ends of one or both battens at the joint.
The ledge portion may be configured to support at the lateral surface of least one, or each, of the battens over a length of at least 25 mm, more preferably at least 35 mm or at least 40 or 45 mm. The ledge portion may be configured (e.g., dimensioned) to support the ends of both battens at the joint. The batten support may be configured (e.g., dimensioned and/or arranged) to project (e.g., in a substantially horizontal direction) out beyond the edge of the top of the rafter; this may depend on the width of the rafter.
The batten support may comprise a second ledge portion projecting at an angle (e.g., substantially perpendicular, or perpendicular) relative to the base portion. The second ledge portion may be arranged at a side of the base portion opposite to the ledge portion. Thus, the ledge portion may be referred to as a first ledge portion.
The batten support plate may comprise a channel form, or U-section, defined by the first and second ledge portions and the base portion. The first and second ledge portions may be parallel upper and lower support ledges, or ledge portions, (e.g. substantially perpendicular plate flanges) between which the batten ends fit closely. This enables load on a batten end, e.g., if a person treads on it, to be transferred more effectively not only to the rafter through surfaces other than the securing fastener but also to the end of an adjacent batten, thereby taking advantage of the strength of that batten and also of any additional fastener which may be securing the other batten end to the rafter. Such a batten support plate in channel form may be simple and symmetrical for convenience of use.
The height of the ledge portion(s) may not be more than the thickness of the batten used, which may be 25 mm. Thus, the height of the ledge portion(s) may be 20 mm or less, more preferably 15 mm or less: higher ledge flanges confer little additional strength because the strength will arise primarily from the plate strength at the angle (e.g., the angle formed between the ledge portion and the base portion) unless some discrete bracing formation is provided. Such bracing formations are not preferred because of the additional expense and complexity associated with them.
The batten support may be formed of a material which is stiff enough to provide useful support. For example, the batten support may define a metal plate (e.g., steel plate or aluminium plate). Alternatively tough polymeric materials may be used. The thickness can be minimised to reduce weight and cost and so that the batten ends are not supported higher off the rafters than at other rafters (i.e., where batten supports are not present). In practice plate thickness of 1.5 mm or less, preferably 1.0 mm or less, usually 0.5 mm or more, is satisfactory. At these thicknesses, especially at 1 mm or less, fasteners such as nails—which are preferred—can usually be driven directly through the plate without pre-formed openings being needed, at least not at full size.
Considering the attachment of the plate to the rafter, a preliminary fastener such as a nail or screw may be used to fix the support plate in position in the rafter before the batten ends are positioned. At least one of the base portion and the ledge portion(s) (e.g. the first and/or second ledge portion) may comprise a pre-formed opening for receiving the preliminary fastener. The pre-formed opening(s)—preferably not an elongate slot—may be provided centrally in the base portion and/or centrally in the ledge portion(s). The plate may be patterned or marked to indicate the centre for this purpose. The batten ends are laid on the support plate.
Preferably a respective fastener (e.g., a nail) is driven through each batten end. With a channel-section plate and/or a preliminary plate attachment fastener, each batten end can derive support from the plate even if a fastener for that batten end does not itself directly engage the plate. It is acceptable to provide clearance openings in the base portion to ease passage of fasteners. The exact position of openings is not usually visible to the worker (e.g., since it may be obscured by the batten). So, a substantial opening may be provided, such as one or more elongate clearance openings or slots (i.e., at least as wide as, and longer than, the fastener thickness). The elongate clearance opening(s) may have a longitudinal dimension parallel to the ledge portion(s) (e.g. parallel to the first and/or second ledge portion).
In an exemplary arrangement (such as described above) the fasteners can be driven through the plate material and this direct engagement with the plate provides additional support. If a fastener is driven through the batten ends and through into the rafter directly through the plate material, substantial support is achieved even if no preliminary plate fastener is put in place.
Alternatively, one or more open window regions may be provided in the batten support so that batten fasteners do not engage the batten support at all.
Additionally or alternatively the batten support may have one or more fastener-penetrable regions or zones which are not open but have an array of multiple small openings, e.g. in the nature of a gauze or mesh. The one or more fastener-penetrable regions may be formed in the base portion. In use, these openings are desirably smaller than the fastener thickness, i.e., so that there is necessary deformation of the plate material when a fastener—preferably a nail—is driven through. This gives reliable grip and positioning. The openings may be formed integrally in the material of the plate e.g., by pressing or stamping, laser cutting or water cutting. Less conveniently they may be provided by a mesh or gauze element fixed to occupy a corresponding window opening in the plate. The array option—typically plural or multiple rows and columns in a regular array—is preferable to slots or fastener-sized holes in that the array can be essentially non-selective as to position of the fastener. This is a decisive advantage when the plate region is obscured by the workpiece (typically the batten), and also even at visible regions for fast work, especially with a nail gun. It is also much better when a fastener such as a nail may not be driven perpendicular to the plate, such as through a batten end lying against a valley board or valley plate. The array is easy to drive a fastener through at any position in the region but still gives strength of mechanical engagement with the fastener to locate the plate relative to the underlying support member (e.g., rafter). An array of openings (perforations) formed directly through the plate, e.g., stamped openings, is preferred. The array (its outline) may occupy at least 20%, at least 30%, at least 40% or at least 50% of the overall area of that plate portion, being a portion in one plane, in which it is formed.
In such an array the openings preferably have any one or more or all selected from the following preferable features. Maximum longitudinal and/or transverse dimensions: at least 0.5 or 1 mm, not more than 4 or 3 mm. One of the longitudinal and transverse dimensions is not more than twice the other, more preferably is about the same, e.g., round, square or other polygonal holes. Longitudinal and/or transverse spacing between openings, corresponding to width of plate material there: not more than 3 times, 2 times or 1.5 times the maximum longitudinal and/or transverse dimension of the openings, e.g., about the same. The total number of openings in an array forming a fastener-penetrable region (the plate may have 2 or more of these regions at separate places): at least 10, 20, 30 or 40. Openings regularly arranged, e.g., in plural (2, 3 or more) rows. Openings all the same shape and size.
It will be appreciated that when a channel-section support plate is used, it is preferably dimensioned to fit closely around the chosen batten(s), e.g., with a clearance of not more than 2 mm and preferably not more than 1 mm. Spacing between the upper and lower support ledges of about 40 mm or about 50 mm is therefore preferable in aspects of the present disclosure. At least one or each of the ledge portions may take a simple rectangular form. The corners of the ledge portion(s) are desirably rounded or chamfered for safe handling.
The length of the ledge portion(s) is desirably at least 50 mm, preferably at least 60 mm or at least 80 mm, to provide substantial engagement with both batten ends. In practice it is convenient to make the ledge and the base portion substantially the same length, and in the case of a channel-section device—which in any case is preferably symmetrical—the same applies to the second ledge portion or flange on the other side.
The ledge portion(s) may be an integral portion(s) of a sheet metal piece constituting the batten support plate. The shaped plate may readily be formed in one piece by a pressing operation. At the desired (e.g., small) thicknesses of the plate, some reinforcement of the support ledge(s) may be desirable. This may conveniently be provided by forming one or more slight indentations in the sheet metal at the angle between base and ledge portion (e.g. between the base portion and the first ledge portion and/or between the base portion and the second ledge portion, indented from the outside towards the inside of the angle so as to project slightly on the inside and reinforce against outward bending there. That is, each indentation projects between the base portion and the ledge portion. Preferably two or more such reinforcing indentations are provided along each angle of the plate base with a support ledge flange.
As mentioned, the ledge portions (e.g., the at least one ledge portion) are preferably simple continuous flanges, but it will be appreciated that any number of alternatively configured (e.g., shaped and sized) discontinuous projections may be regarded as falling within the scope of the term ledge or flange, since they will serve the same function albeit with less strength.
A further exemplary arrangement of the batten support comprising a pair of opposed ledge portions (e.g., flanges) relates to the tolerance associated with the gap between them. A reasonably close fit of the batten between the flanges is desired, to maximise support for the batten. However, battens are not precision items, and the exact dimensions vary. Also, the battens may expand if they are damp. It is important that the user can be confident that the batten will fit between the flanges of the batten support. In this respect, an exemplary arrangement of the batten support provides that one or both of the flanges is outwardly inclined (i.e., inclined outwardly relative to the perpendicular from the batten support plane (e.g., a plane parallel to the base portion of the batten support).
The one or more flanges may be configured to incline outwardly at least adjacent to its distal edge (i.e., at the part defining the ‘mouth’ of the channel). The one or more flanges may be configured to incline outwardly over most or all of its projection from the base portion (e.g., along its entire upstanding height, when in use). Accordingly, the one or more flanges may define a substantially planar flange which is inclined (e.g., at from 3° to 10°) to the perpendicular relative to the base portion.
This divergence provides a maximum lateral dimension at the mouth of the batten support, so that even slightly oversize battens can be easily inserted, while the convergence lower down provides closeness of fit for correctly-sized or slightly undersized battens. If a batten is slightly oversized, it can be pushed down into the batten support with slight deformation of the support flanges thereof, because these are formed of a deformable material (e.g., thin metal). A useful support effect is still achieved. The opposed support flanges may be symmetrically and/or identically configured relative to each other.
An alternative arrangement of the batten support (e.g., a batten support plate) may be configured for use where the end of a batten meets the side surface of a roof member (e.g., such as a valley board) end-on. The base portion may be configured to be fixed against the side surface of the support member, facing onto the end of the batten in use. The ledge portion(s) may be configured to project out from the base portion (e.g., in a substantially horizontal direction) such that in use the ledge portion (e.g. the first ledge portion) is arranged underneath the end of the batten to support it. Thus, the first ledge portion may be a support ledge. A fastener (such as a fastener passing also through the batten) can hold the batten support onto the roof support member. The end of the batten is then supported by the ledge portion (e.g. the first ledge portion) of the batten support as well as by the fastener.
An exemplary arrangement of the batten support has a Z-section (e.g., a square Z-section) defined by the first ledge portion, the second ledge portion, and the base portion. The second ledge portion may project form the base portion (e.g., may be bent relative to the base portion) in the opposite direction to the first ledge portion (e.g., the first and second ledge portions may extend in opposite but substantially parallel directions). Accordingly, the batten support may be configured such that when the base portion is arranged against the lateral surface of the support member, the second ledge portion may lie on top of the roof support member (e.g., valley board). Thus, the second ledge portion may be a top flange. Accordingly, the method may comprise arranging the base portion against the side surface of the roof support member such that the ledge portion (e.g. second ledge portion) contacts the upper surface of the roof support member. The method may further comprise passing the fastener through the ledge portion (e.g. the second ledge portion) before arranging the batten in place. Location and retention of the batten support on the roof support member may then be improved, or facilitated—in particular, if done before the batten is put in place—by one or more fasteners, passing through this top flange (or ledge portion) into the top of the roof support member, as well as, or instead of, a fastener through the base portion.
In the Z-section structure it is desired that it is formed by pressing from a single sheet. Again, the angles between the base portion and the flanges may be reinforced by the formation of one or more indents along the angles as discussed above.
Preferably a fastener-penetrable region having any of the above-listed structural options is provided in the base portion. Preferably a fastener-penetrable region having any of the above-listed options is provided on the top flange. The top flange and support ledge may have similar or identical form, e.g., both having a fastener-penetrable region, so that the plate can be used either way up (although generally no nailing is needed through the support flange)
A further exemplary arrangement may be dimensioned to receive the end of only a single batten e.g. on top of a rafter which is at a verge (next to a gable) or is a hip blade where roof planes meet convexly. This may be of a shorter length. On a hip blade the corresponding batten may terminate half-way across e.g., with a sloping end cut to allow for another batten from the adjacent roof plane. A single batten support plate with mutually angled ledge/channel portions to support both batten ends is an option for this.
A yet further exemplary arrangement, applicable with batten support plates of any of the aspects described herein, is that plural or multiple (2, 3 or more) plates are provided as respective portions of a multi-unit length, connected end-to-end through integral links or unions which can be broken, cut, or otherwise separated to obtain support plates (or support portions) for separate use. The connected support unit plates have their functional portions (base plate, ledge portions etc.) aligned in the multi-unit length so that it is also possible to use two or more of the connected unit plates together, as a plate of greater length. Such a multi-unit length may comprise e.g., five or more or ten or more separable unit plates.
The integral links or unions can be provided by pre-cutting along part of the boundary between adjacent unit plates, leaving one or more portions uncut. Preferably the, or each, union is adjacent an edge of the plate so as to be accessible to a cutter such as snips. First and second unions at opposite exposed edges provide a strong and stable connection that is also easily cut apart.
Such a multi-unit length may be formed in a process in which the pre-cuts are formed at the same stage as multiple openings are formed in a blank to constitute one or more fastener-penetrable regions for each of the unit plates, e.g., by pressing or stamping. The plate blanks can be bent to form the base portion and the ledge portion(s) (e.g. one or more flanges, support ledge, top flange etc.) angled generally perpendicularly (e.g., substantially perpendicularly) to one another, with the angles running along the length of the multi-unit article.
The disclosure includes the batten support themselves, methods of assembling a roof structure in which one or more such batten supports are used to support batten ends as described, and roof structures comprising such batten supports supporting the batten ends in relation to roof support members as described.
The exemplary arrangements above and herein are made with reference to a batten support, a batten and roof support member because that is a particularly preferred application, but it should be understood that the above described exemplary arrangements have wider application so that the disclosure is applicable also to an element support, a transverse element, and a support member in general terms. Preferably these are wooden elements, preferably secured by nails. The transverse element may be secured to the support member which is already a fixed structure. The transverse element may be cross-sectionally smaller than the support member at the connection location, e.g. less than 50% or less than 25% the cross-sectional area thereof. Another application of the present disclosure is in the field of fencing where the support elements may be posts and the transverse elements cross-pieces, bars, or rails.
Examples are now described with reference to the accompanying drawings, in which:
In usual practice a flexible layer such as a felt lies on top of the rafters and under the battens, held in position by independent nails into the rafters and also by the battens and by the nails that fasten the battens. This layer is not shown in the drawings so that the rafter can be seen.
In fact, a conventional (e.g. 3 inch) nail can readily be driven through 0.8 mm steel plate so that clearances such as slots 55 are optional. See
Note that the support ledges 152 of the
Look again at
Thus, by a simple means the end of a batten can be substantially reinforced against damage. Little or no extra work and few fasteners are required. It will be appreciated for example that the locating fastener 9 is optional, since the batten fasteners 3 will hold the arrangement in place and one batten end will support the other via the support plate. If one or both batten fasteners 3 engage the plate base 51 directly, there will be further support. Indeed, there is support even if one batten fastener is entirely forgotten or comes out.
The illustrated support plate 7—see
In use the batten end is cut to conform to the timber side surface 82 as before. The support plate 7 is positioned with a lower one of the support flanges 72 lying under the batten end to support it, and the upper one lying on top of the roof timber, e.g., valley board 8, as shown in
As a first refinement, at the angle 257 where each support flange 252 meets the base plate 251 small inward indentations (sometimes called ‘cleats’) are pressed integrally into the plate. As previously, the plate is preferably galvanised steel e.g., 0.8 mm thick. In the arrangement shown, each angle has two of these indentations 259. Because they project inwardly of the angle—perhaps as best seen in
A second refinement is that the side flanges 251 diverge outwardly relative to the perpendicular, as seen most clearly in
The manner of providing the fastener-penetrable region 9 with an array of small openings is not particularly limited, and any of the above proposals may be used with any of the types of batten support plate described herein, e.g., in combination with the specific features described in the earlier arrangements. Also, as mentioned above, the fastener-penetrable region 9 may be replaced by actual window openings, e.g., in the
Here each of the riser portion 271 and the top and bottom perpendicular flanges 272 of each unit plate 207 has a respective fastener-penetrable region 9 formed of a regular array of circular through-holes. The array 9 on the riser 271 facilitates possibly angled insertion of a nail through the batten end, in the
Pre-cut openings 201 in the form of elongate slots are formed along the boundaries between adjacent unit plates 207, in the same operation that forms the openings of the fastener arrays 9, and extend continuously from part-way across one flange 272, across the riser 271 and to part-way across the other flange 272, leaving link regions or unions 202 holding the plates together at the edges. In use, these unions can easily be cut with tinsnips to separate the unit plates for use. The option also exists to use the plates in combinations of two or more in special situations. Indeed, it is possible to lay a complete multi-unit length up along a rafter or valley board, e.g., in situations where the exact positions of the battens are not yet known or might vary, or simply for convenience.
The following numbered paragraphs (paras.) contain further statements of various aspects and embodiments of the present invention:
| Number | Date | Country | Kind |
|---|---|---|---|
| 2318710.7 | Dec 2023 | GB | national |
