Information
-
Patent Grant
-
6460309
-
Patent Number
6,460,309
-
Date Filed
Thursday, January 20, 200024 years ago
-
Date Issued
Tuesday, October 8, 200222 years ago
-
Inventors
-
-
Examiners
- Friedman; Carl D.
- Slack; Naoko
Agents
- Pieper; David B.
- Waddey & Patterson
-
CPC
-
US Classifications
Field of Search
US
- 052 7291
- 052 901
- 052 200
- 052 2202
- 052 395
- 052 465
- 052 469
- 052 555
- 052 640
- 052 DIG 17
- 052 2201
- 052 7304
- 052 7312
- 052 7321
- 052 198
- 052 74506
-
International Classifications
-
Abstract
A roofing apparatus for forming round, square, and oval rooms utilizing channel beams and interlocking roof panels. A system and method for utilizing vinyl as a construction material for forming roofing system is taught along with the use of connecting spiders, connection blocks, and insulated and sheathed vinyl panels. The system teaches the use of a non-thermally conductive I-beam for forming a roof system for improved insulation and long-term longevity of building structures.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to roofing systems for buildings and sunroom additions to homes. More particularly, this invention pertains to a method and apparatus for constructing a roof from an extruded material for improved thermal characteristics and stability.
FIG. 1
of the drawings shows a prior art profile of a metal I-beam
10
. The design utilizes a top planar member
12
, a vertical planar member
14
, and a bottom planar member
16
. While the metal I-beam
10
design is well recognized in standard construction techniques and assemblies, This design is limited in its functionality and effective utilization of materials.
Prior art disclosures are found in a multitude of U.S. Pat. Nos. including 2,947,040 issued to Schultz on Aug. 2, 1960; 3,055,461 issued to Ridder on Sep. 25, 1962; 3,096,861 issued to Frick et al. on Jul. 9, 1963; 3,340,657 issued to Thomas on Sep. 12, 1967; 3,345,794 issued to Proud on Oct. 10, 1967; 3,562,992 issued to Kinsey on Feb. 16, 1971; 3,733,756 issued to Butler on May 22, 1973; 3,760,544 issued to Hawes et al. on Sep. 25, 1973; 3,805,470 issued to Brown on Apr. 23, 1974; 3,848,387 issued to Hafner on Nov. 19, 1974; 3,952,461 issued to Kinsey on Apr. 27, 1976; 3,978,629 issued to Echols, Sr. on Sep. 7, 1976; 4,040,219 issued to Budich on Aug. 9, 1977; 4,057,941 issued to Schwartz on Nov. 15, 1977; 4,069,627 issued to Pegg on Jan. 24, 1978; 4,110,942 issued to Slocomb, Jr. on Sep. 5, 1978; 4,167,838 issued to Metheny on Sep. 18, 1979; 4,583,333 issued to Minter on Apr. 22, 1986; 4,594,828 issued to Taylor on Jun. 17, 1986; 4,601,139 issued to Esposito on Jul. 22, 1986; 4,724,646 issued to Meyers on Feb. 16, 1988; 4,745,723 issued to Esposito on May 24, 1988; 4,765,102 issued to Kuchem on Aug. 23, 1988; 4,773,193 issued to Biebuyck et al. on Sep. 27, 1988; 4,796,395 issued to Israel on Jan. 10, 1989; 4,884,376 issued to DeBlock et al. on Dec. 5, 1989; 4,903,455 issued to Veazey on Feb. 27, 1990; 4,918,882 issued to Funk on Apr. 24, 1990; 5,003,733 issued to Strobl, Jr. et al. on Apr. 2, 1991; 5,007,215 issued to Minter on Apr. 16, 1991; 5,046,791 issued to Kooiman on Sep. 10, 1991; 5,090,164 issued to Mische on Feb. 25, 1992; 5,125,207 issued to Strobl, Jr. et al. on Jun. 30, 1992; 5,197,253 issued to Johnson on Mar. 30, 1993; 5,293,728 issued to Christopher et al. on Mar. 15, 1994; 5,325,647 issued to Forry et al. on Jul. 5, 1994; 5,363,615 issued to Christopher et al. on Nov. 15, 1994; 5,394,664 issued to Nowell on Mar. 7, 1995; 5,555,681 issued to Cawthon on Sep. 17, 1996; 5,560,155 issued to Back on Oct. 1, 1996; 5,568,707 issued to Ishikawa et al. on Oct. 29, 1996; 5,608,997 issued to Mahowich on Mar. 11, 1997; 5,771,640 issued to Back on Jun. 30, 1998; 5,783,286 issued to DiNicola on Jul. 21, 1998; 5,792,529 issued to May on Aug. 11, 1998; Design Patent Des. 327,744 issued to Francis on Jul. 7, 1992; and Swiss Patent No. 459 516. These patents are hereby incorporated by reference.
A representative number of these patents will be reviewed in the following discussion:
U.S. Pat. No. 3,760,544 issued to Hawes et al. on Sep. 25, 1973, discloses a SEALING GASKET WITH ELONGATED INTERNAL STIFFENER. This specification is directed towards an extruded plastic gasket which is constructed with a full length of strip or insert of a different material in the gasket. This inner material is utilized to strengthen the portion of the gasket in which it is located and reduce any creeping or other movement of the gasket after it has been installed.
U.S. Pat. No. 3,952,461 issued to Kinsey on Apr. 27, 1976, discloses MULTI-LAYER WALLS FOR FRAMELESS BUILDINGS FORMED FROM EXTRUDED ALUMINUM OR PLASTIC INTERLOCKING WALL ELEMENTS.
FIG. 20
of this application describes the use of a sub-comb having upwardly facing, angularly disposed surfaces for engaging and supporting the upper ends of the metallic roof rafters. As noted by the remainder of the specification, the specification is directed towards a multi-layer wall structure which utilizes so extruded wall elements to interlock and form a frameless multi-story building complex.
U.S. Pat. No. 4,601,139 issued to Esposito on Jul. 22, 1986, discloses a METHOD AND FRAMEWORK FOR A GREENHOUSE OR THE LIKE INCLUDING A REVERSIBLE GABLE ADAPTER. As noted in
FIG. 8
of the drawings, wedge-shaped adapters is utilized to join vertical bars with sloped bars. This adapter is inserted into a chamber using the prong of the adapter.
U.S. Pat. No. 5,046,791 issued to Kooiman on Sep. 10, 1991, discloses an Extrusion Frame and Components Therefor. This specification is directed towards the framing of cabinetry and the like which utilizes a connecting element for joining extrusion frame components.
U.S. Pat. No. 5,325,647 issued to Forry et al. on Jul. 5, 1994, discloses a Composite Ceiling Grid. This specification is directed towards ceiling grid runners and the associated method of assembly which utilizes metal reinforced thermal plastic compounds. This system utilizes the metal in strategically positioned areas to maximize the strength ratio of the plastic.
U.S. Pat. No. 5,555,681 issued to Cawthon on Sep. 17, 1996, discloses a Modular Building System. This specification is directed towards the construction of various light structures. An octagonal cap is described which may be separated to serve as an Apex for a quarter-end structure for a shed like addition. As shown in
FIG. 13
of the drawings, a roof ridge member may be used to form the roof ridge or crest of a gabled structure.
U.S. Pat. No. 5,792,529 issued to May on Aug. 11, 1998, discloses a Reinforced Plastic Extrusion. This specification describes the use of three different extrusions in order to form a single configuration with increased components strength and stiffness. Thus, the desired profile is extruded which allows for the strategic placement within a profile to obtain optimum strength and stiffness.
Prior art aluminum roofing systems for additions or sunrooms are well known. These sunrooms pose certain problems during their life. Aluminum works as an excellent heat conductor as evidenced by its use in a variety of heat dissipation applications. However, this high thermal conductivity causes several problems in roofing systems. Aluminum roofing systems transfer cold from the outside of a structure to the interior environment. This heat transfer can lead to condensation on the interior roof of the structure, and the transfer of interior heat to the outside environment results in thermal inefficiencies. In addition, aluminum structures are rigid and may dent, scratch, or be punctured due to contact with normal everyday items such as lawn mower, foot traffic, or wind blown debris. Thus, the present art of aluminum roof construction has several disadvantages. can lead to condensation on the interior roof of the structure, and the transfer of interior heat to the outside environment results in thermal inefficiencies. In addition, aluminum structures are rigid and may dent, scratch, or be punctured due to contact with normal everyday items such as lawn mower, foot traffic, or wind blown debris. Thus, the present art of aluminum roof construction has several disadvantages.
Thus, the prior art patents teach limited structures which pose problems for temperature variations, normal wear and tear associated with buildings, and long term stability. What is needed, then, is an improved method and apparatus for constructing buildings with increased efficiency.
SUMMARY OF THE INVENTION
The present invention is directed towards a vinyl roofing system utilizing beams to inter-connect roof panels with a roof cap for providing a roof structure. The system may utilize a connecting spider for forming rounded roofing systems, and an upper and lower roof cap for connecting the roofing system together. The system may utilize channel beams with top and bottom plates with a plurality of vertical members to form a center aperture. This center aperture may be utilized with a beam filler, and may also be utilized as a raceway for electrical, water, or other connections within the structure. A further embodiment of the present invention utilizes channel V-beams to form a rounded roofing system for efficient roofing construction and methods. These beams may utilize end caps for completing the structural appearance and integrity of the building.
Different connecting blocks and means are taught for connecting the various rafters together. Different panels including vinyl sheathing panels, insulated and polycarbonate panels, as well as polycarbonate panels are taught in the present invention which may utilize fascia caps for protecting the ends of the panels, or the sheathing may wrap over edges to cover adjacent surfaces of the roofing panels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
shows a prior art I-beam profile.
FIG. 2
of the drawings shows a channel I-beam.
FIG. 3
of the drawings shows a channel I-beam with a filler insert.
FIG. 4
of the drawings shows a pointed channel V-beam.
FIG. 5
of the drawings shows a pointed channel V-beam with filler insert.
FIG. 6
of the drawings shows a flat top channel V-beam.
FIG. 7
of the drawings shows a flat top channel V-beam with filler insert.
FIG. 8
of the drawings shows a channel T-beam.
FIG. 9
of the drawings shows a pointed channel arrow beam.
FIG. 10
of the drawings shows a flat top channel arrow beam
FIGS. 11-19
of the drawings shows various configurations for end caps for the different profile configurations of the beams.
FIG. 20
of the drawings shows the interconnection of two channel T-beams for extended thickness insulated roof panels with the channel beams.
FIG. 21
of the drawings shows the interconnection of a flat top channel V-beam with insulated panels.
FIG. 22
shows a straight wall stud rafter-stud channel connecting block.
FIG. 23
shows a curved wall stud rafter-stud channel connecting block.
FIGS. 24 and 25
of the drawings show the interconnection of the rafter-stud channel connecting block with the wall and the rafter.
FIGS. 26-28
of the drawings show the rafter-rafter channel connecting block.
FIGS. 29-32
of the drawings show the multiple rafter spider connecting block.
FIG. 33
of the drawings shows a circular roof with insulated panels.
FIG. 33
a
of the drawings shows the connecting cap apparatus.
FIG. 34
of the drawings shows a circular roof with poly-carbonate panels.
FIG. 35
of the drawings shows a circular insulated wall and stud configuration.
FIGS. 36-44
of the drawings show an oval room configuration.
FIGS. 45-47
of the drawings show an embossed roof panel configuration.
FIG. 48
of the drawings shows a partial oval room configuration.
FIGS. 49-51
of the drawings show a shed and gable roof configurations for the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed towards a new apparatus and method for building and roof construction utilizing individual members which are interconnected to form the desired structure. Each of these members will be described in detail, and then the combination of the members to form structures will also be described for the varying embodiments.
While the I-beam
10
profile of
FIG. 1
may be used for certain positions in building structures, a typical I-beam is limited in application due to its basic structure. Thus, the preferred embodiment of this invention utilizes a different configuration for the beams that are used in constructing a roofing apparatus.
FIGS. 2 and 3
show one preferred embodiment of the channel beam apparatus as utilized in the present invention. This channel beam apparatus
20
is a channel I-beam
21
which includes a top structure
22
, a plurality of vertical members
25
engaging the top structure
22
, and a bottom structure
28
engaging the plurality of vertical members
25
. The plurality of vertical members
25
is shown as separate vertical members
24
and
26
. It is also envisioned that the plurality of vertical members
25
could include more than two vertical members for constructing various configurations of the channels beams
20
. Each of the vertical members
24
and
26
is inwardly disposed from the outer edges of the top structure
22
to form a central aperture
30
.
The channel beam
20
is preferably constructed from an extruded vinyl with degradation inhibitors for weather and sunlight, including ultraviolet light exposure. Vinyl compositions are well known for outdoor exposures and thus, will not be described in further detail.
The top structure
22
and bottom structure
28
may be formed as a flat planar structure
23
as shown in
FIGS. 2 and 3
, or may be formed in a more complex configuration as shown in
FIGS. 4 through 10
. The more complex configurations for the top structure
22
and bottom structure
28
utilize wings
40
that may be directly connected to each other as shown in
FIGS. 4 and 5
, or may utilize a connection to an aperture base
42
as shown in
FIGS. 6 and 7
. These wings
40
are angled in a wing angle
44
to form the general shape of a pointed or flat bottom upper V for the top structure
22
and a pointed or flat bottom lower V for the bottom structure
28
. These angles
44
maybe formed so that the wing angle
44
allows for forming a central roof rafter, curved wall studs, finishing edges for panels, or a curved roof structure. One preferred embodiment utilizes a wing angle
44
of 135 degrees. This allows for the formation of curved buildings with 45 degree angling between each panel around the curve. The drawings show a steep wing angle
44
to emphasize the wing angle
44
for illustrative purposes.
The open space between the plurality of vertical members
25
forms a central aperture
30
. The plurality of vertical members
25
is generally formed as parallel planar structures
24
and
26
between the top structure
22
and bottom structure
28
, although it is envisioned that deviations from the parallel planar construction could be utilized for varying embodiments of the channel beams
20
.
The central aperture
30
may be utilized as a utility run for installing electrical cables, water pipes, gas lines, or other connections as required in the construction process. A beam filler
32
may be placed within the central aperture
30
to add strength, insulation properties for use as a connecting base for screws, or for other purposes. The preferred beam filler
32
is a compressed wood product with laminated wood layers which adds strength and insulation properties to the channel beam
22
as well as providing a solid base for screw installation.
Each of the various configurations of the beam elements, including the top structure
22
, plurality of vertical members
25
, and bottom structure
28
form different types of beams.
FIG. 4
shows a pointed channel V-beam configuration
48
. The pointed channel V-beam
48
utilizes a plurality of vertical members
25
, a pointed V top structure
22
, and pointed V bottom structure
28
.
FIG. 5
shows the pointed channel V-beam
48
with a filler
32
in the central aperture
30
.
FIG. 6
shows the channel flat bottom V-beam
50
. The flat bottom channel V-beam
50
utilizes a plurality of vertical members
25
, a flat bottom V top structure
22
, and flat bottom V bottom structure
28
.
FIG. 7
shows the flat bottom channel V-beam
50
with a filler
32
in the central aperture
30
.
FIG. 8
of the drawings shows another possible configuration of a channel beam
20
as a channel T-beam
52
. The channel T-beam
52
utilizes a plurality of vertical members
25
, a planar bottom structure
28
, and a planar top structure
22
. The channel T-beam
52
may be formed by machine the lower wings
40
from the channel I-beam
20
. This allows for one extrusion to be made and then machined when necessary for installation. The machining of the wings
40
from the other styles of the channel beams may also be performed to obtain different shapes as called for in the construction process.
FIG. 9
shows a pointed channel arrow-beam
54
which utilizes a plurality of vertical members
25
, a pointed V top structure
22
, and wingless pointed V bottom structure
28
.
FIG. 10
shows the channel flat bottom V-arrow-beam
56
. The flat bottom V channel arrow-beam
56
utilizes a plurality of vertical members
25
, a a flat bottom V top structure
22
, and an aperture base
42
bottom structure
28
.
FIGS. 11 through 19
show various configurations of end caps
60
for covering the center aperture
30
and covering the end of the various configurations of the channel beams
20
. These end caps
60
are also known as retainer caps
60
. As shown in
FIG. 11
, the retainer caps
60
may be attached to the filler
32
in the center aperture
30
through the use of screws
62
which pass through attachment holes
64
in the end caps. Alternative methods for attachment, including clip-on-caps, friction-engagement caps, and glue or adhevisely held caps are also envisioned.
FIG. 11
shows a simple center aperture cover
60
designed only to cover the aperture
30
itself.
FIG. 12
shows a complete end cover
60
for the channel I-Beams
20
shown in
FIGS. 2 and 3
. The end cap
60
shown in
FIG. 13
may be used to cover the end of a channel T-beam
52
as shown in FIG.
8
.
FIG. 14
shows the end cover
60
for the center aperture of any of the pointed V style of beams.
FIGS. 15 through 17
show additional embodiments that may be utilized for covering additional portions of the pointed V style of beams.
FIGS. 18 and 19
show curved end caps
60
that may be used for covering the angled end where the adjoining roof panels form an angle on a circular or oval style of room construction. These end caps
60
fit the angle formed on the end of the roof rafters necessary to form the curved roof line at the wall stud top plate.
FIG. 20
of the drawings shows the interconnection of two channel T-beams
52
for extended thickness insulated roof panels
102
with the channel T-beams
52
. A first channel T-beam
52
is placed on top of the insulated panels
102
and a filler
32
is inserted into the aperture
30
of the first channel T-beam
52
. A second channel T-beam
52
is placed under the insulated panels
102
. The first and second channel T-beams
52
are then joined by screws
53
which are driven through the second channel T-beam
52
and into the filler
32
in the first channel T-beam
52
. This connection method allows for varying sizes of roofing materials to be utilized by changing the length of screw
53
that is used to connect the first and second channel T-beams. For a finished look, a screw cap
55
may be placed over the head of the screw
53
. The construction of the insulated panels is discussed infra.
FIG. 21
of the drawings shows the interconnection of a flat top channel V-beam
50
with insulated panels
102
. The panels
102
may be held in place by screws driven through the wings
40
of the beam
50
, friction, adhesive, or the physical shape of the surrounding building structure.
FIG. 22
shows a straight wall stud rafter-stud channel connecting block
70
, and
FIG. 23
shows a curved wall stud rafter-stud channel connecting block
71
. These blocks are used to connect the roof rafters to the wall studs and their associated top plate.
FIGS. 24 and 25
show the connection of a straight rafter-stud channel connecting block
70
to a roof rafter
72
and wall stud top plate
74
. The straight channel connecting block
70
utilizes a base
76
which is screwed into center aperture
30
of the wall stud top plate
74
. The embodiment shown utilizes screws
80
as an attachment means for connecting the connecting block
70
to the wall stud top plate
74
. A pointed V-plane top or a flat bottom V-plane top plate can be utilized for the connecting block to connect to the wall stud top plate
74
and the rafter
72
. The top
78
of the connecting block
70
mates inside the center aperture
30
of the roof rafter
72
profile. The connecting block
70
may also be attached with screws
80
.
The connecting block
70
is shown in one preferred embodiment as utilizing a top
78
with a pitch angle
79
for connection to the pitch angle of the roof rafter
72
. The top
78
profile is designed to slip into the center aperture
30
of the rafter
72
and use burrs or other frictional means for retaining the connection. A simple slot in the bottom of the roof rafter allows the rafter to overhang if an end opening for the center aperture is not available. A similar style of insert connection may be used for connection to the wall stud top plate or even a direct connection into a wall stud. Another alternative embodiment could use attachment arms that can be crimped to engage the wings
40
of the wall stud top plate
74
or the roof rafter
72
. By utilizing the frictional engagement or the crimp engagement, no additional connectors would be necessary for connecting the stud top plate
74
to the rafter
72
with the rafter-stud block
70
.
FIGS. 26 through 28
show the rafter channel connecting block
84
and the method for connecting rafters
72
together. The rafter channel connecting block
84
is inserted into each of the rafters
72
and secured with screws
80
. As previously noted for the rafter-stud connecting block
70
, the rafter-rafter connecting block
84
may also utilize a frictional or bur style of arrangement for connecting rafters
72
together. The use of adhesive is also anticipated for this connection.
FIGS. 29 through 32
show the use of a multiple rafter spider connecting block
90
that is utilized to construct round roofing systems. This spider block
90
utilizes legs
92
that are inserted and secured into the center aperture
30
of the channel beams
20
. These legs
92
may also be placed next to the vertical member
25
for constructing a round roofing system.
FIG. 29
shows the use of the spider block
90
for connecting two rafters
72
together like a rafter-rafter connector
84
. Note the angle-cut end
96
of the second rafter
72
. This angle cut end is utilized when multiple rafters
72
are to be connected to the spider block
90
to form a rounded roof. As shown in
FIG. 30
, the angle cut ends
96
allow for multiple rafters
72
to be connected to a single spider block
90
to allow for the rounded roofs.
FIGS. 31 and 32
show the connection of eight rafters
72
to a spider connecting block
90
for the formation of a round roof for a structure such as a gazebo.
This circular or rounded roofing apparatus
100
utilizes the connecting spider
90
and multiple channel beams
72
which are connected to the spider
90
and supported by the spider arms
92
. The connecting spider includes a spider body
94
and can use any number of spider arms
92
to connect the channel beams
20
to the spider body
94
. The preferred embodiment as shown utilizes eight spider arms
92
so that a gazebo style structure with eight roofing panels may be constructed. Note that the number of spider arms
92
will dictate the panel to panel angle across the roofing panels and thus, the wing angle of the channel beam
20
. In addition, the pitch angle of the spider arms to the spider body will control the pitch angle of the roof once constructed. Thus, the number of spider arms
92
, their location around the spider body
94
, and the pitch angle of the spider arms
92
to the spider body
94
will control the style of roof to be built.
The rounded roofing apparatus
100
shown in
FIG. 33
is shown with pointed channel V-beams
48
. It is also envisioned that other channel beams
20
such as I-beams, or channel I-beams, could be utilized for this construction. However, the preferred embodiment will utilize pointed channel V-beams
48
.
As shown in
FIG. 33
, the rounded roofing apparatus
100
utilizes pointed channel V-beams
48
and each pointed channel V-beam
48
supports at least two roof panels
102
. The wing angle
44
of each pointed channel V-beam
48
is associated with the roof curve angle between two roof panels
102
. As illustrated, this configuration will utilizes eight roof panels
102
, so the wing angle
44
will equal to forty-five degrees. Obviously, the pitch angle can be any angle. The pitch angle is usually chosen for aesthetic reasons, and may be influenced by local building codes or weather conditions. Each pointed-channel V-beam
48
that is connected to the spider
90
utilizes an angle-cut end
96
for the roof pitch angle, and the sides of the pointed channel V-beams
48
are adapted for the roof curve angle. Note that a large spider connecting block
90
would allow for the rafters
72
to be cut only for the pitch angle. Furthermore, if the spider connecting arms
92
were of sufficient length, then the rafters
72
would not need to be cut for the pitch angle. Thus, a standard square end cut channel beam
20
could be utilized as a rafter
72
with any of the top structures
22
or bottom structures
28
to form a roofing system. However, the preferred embodiment utilizes the small connecting spider
90
and the angle-cut ends
96
as illustrated.
FIG. 33
shows the circular roof
100
utilizing pointed channel V-beams
48
and panels
101
shown as insulated panels
102
which are held in place by the end caps
60
. The end caps are removed for illustrative purposes on the right side of the drawing. The pointed channel V-beams
48
are connected by a spider block
90
(not shown) and the connection to the spider block
90
is covered and secured by a roof connecting cap apparatus
104
. This roof cap apparatus may be used for both round rooms and oval room construction. This roof connecting cap apparatus
104
includes an upper roof cap
106
and a lower roof cap
108
. The lower roof cap
108
is adjustably connected to the upper roof cap
106
to clamp the spider
90
and rafter
72
assembly together and to finish off the inside look of the roof apparatus
100
.
As shown in
FIG. 33
a
of the drawings, the lower roof cap
108
and upper roof cap
106
form a clamping system for holding the roof rafters
72
and connecting spider
90
together as a unitary assembly. It is envisioned that connecting cap apparatus
104
could be designed to eliminate the spider connecting block
90
and only utilize the roof connecting cap assembly
104
, but the preferred embodiment utilizes the spider connecting block
90
for additional strength. The lower roof cap
108
is connected to the upper roof cap
106
by a threaded connecting bolt
110
. Alternative means for connection, including welding, clamping, fictional engagement, and mating connectors are also envisioned for this connection. The roof connecting cap apparatus
104
may also include an electrical connection through the lower roof cap
108
for an internal electrical fixture.
FIG. 34
of the drawings shows a circular style roof
100
with panels
101
shown as ploy-carbonate panels
110
. These poly-carbonate panels
110
may be clear to allow for the utilization of the roof apparatus
100
for a sun room or greenhouse. These thinner panels
110
may be held in place by a quarter round sealing bead
112
as shown in the drawings, or it is also envisioned that bead wings
40
could be molded with the vertical members
25
of the channel beam
20
. Thus, the roofing apparatus may include a channel beam
20
with a roof panel
101
interlocked with the channel beam
20
.
Different styles of panels
101
may be utilized in the roofing apparatus, including the insulated panels
102
and poly-carbonate panels
110
previously described, or alternatives such as glass panels and sheathing panels including both aluminum and polyvinyl-chloride. These panels
101
may be light permeable to allow for skylights, sunrooms, or green house construction, or the panels
101
may include insulated panels
102
for thermal efficiency. A mixture of panels
101
may be used for varying the different effects of each style of roof.
The preferred insulated panel
102
is constructed from poly-vinyl chloride sheathing
114
with polystyrene
116
adhesively laminated to provide insulation for the insulated panel
102
. The panel edges
118
may be covered with a fascia cap
122
, or the sheathing
114
may wrap around the edges
118
of the panel
102
so that the sheathing
114
continuously covers two adjoining surfaces of the panel
102
. Further adaptations may be made to the various styles of panels
101
by including a faux shingle appearance as shown in FIG.
45
.
FIG. 35
shows the construction of a circular room configuration
120
with insulated walls
122
formed from insulated panels
102
and pointed channel V-beams
48
. The preferred embodiment seals the panel to wall connection with silicon adhesive although any suitable adhesive may be used.
FIGS. 36-44
show the oval room configuration
130
. In this embodiment, an oval roof apparatus
130
is constructed from eight panels
101
. These panels
101
include two side panels
132
and six end panels
134
. The roof panel angle
136
is forty five degrees, and any pitch may be utilized for the roofing apparatus as previously discussed.
An oval room utilizes a spider connecting block
90
at each end of the oval room to form a rounded end for each end of the oval room. Then a connecting rafter
72
will be utilized between the two spider blocks
90
to form the center of the oval room. Fascia caps
120
are shown mounted on the edges of the roof panels
101
, and retainer caps
60
are shown on the ends of the channel beams
20
. As shown in
FIG. 38
of the drawings, two spider connecting blocks
90
are utilized to construct an oval room. Each spider connecting block
90
utilizes five arms
92
, four arms to form the rounded roof for each end, and one arm to support the central rafter header
138
.
FIG. 39
shows an isometric view of the oval room
130
frame construction. Note that the central rafter header
138
has not been used in this embodiment of the design, and that the roof connecting cap apparatus
104
is not shown. Clear panels
101
have been drawn in for both the roof and side wall structure.
FIGS. 40 and 41
show the upper roof cap
104
for this embodiment, and
FIGS. 42-44
show the various roof panel
101
configurations used for the construction. This embodiment has utilized both angled and rectangular side panels
101
to illustrate another style or embodiment for the roofing system. As shown by
FIGS. 42-44
, an oval room uses three different roof panel shapes and a round room uses only one roof panel shape.
FIGS. 45 and 47
show the roof panel
101
with embossing
140
with a shingle pattern formed into the vinyl.
FIG. 46
shows two inverted panels
101
connected with a C-channel
142
.
FIG. 48
shows a partial oval room configuration
150
. The channel beams
20
on each end have been modified to form channel C-beams
142
for flush mounting with the walls
152
. The underlying walls
154
have been shown using conventional frame style construction.
FIGS. 49 and 50
show the use of channel beams
20
with flat insulated sheathing panels
102
for the construction of a shed style roofing system
160
, and
FIG. 51
shows the end view of the gable style construction
170
.
Thus, although there have been described particular embodiments of the present invention of a new and useful Vinyl I-beam Roofing System and Method, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
Claims
- 1. A roofing apparatus, comprising:an aperture channel beam; and a roof panel interlocked with said aperture channel beam.
- 2. The roofing apparatus of claim 1, wherein said roof panel includes sheathing.
- 3. The roofing apparatus of claim 2, wherein said sheathing includes polyvinyl-chloride.
- 4. The roofing apparatus of claim 2, wherein said sheathing is light permeable.
- 5. The roofing apparatus of claim 2, wherein said sheathing includes poly-carbonate.
- 6. The roofing apparatus of claim 1, Therein said roof panel includes an insulated panel.
- 7. The roofing apparatus of claim 6, wherein said insulated panel includes sheathing adhesively laminated to insulation.
- 8. The roofing apparatus of claim 7, wherein said insulation includes polystyrene.
- 9. The roofing apparatus of claim 1, wherein said roof panel includes a fascia cap.
- 10. A rounded roofing apparatus, comprising:a connecting spider; and multiple aperture channel beams connectively supported by said spider.
- 11. The rounded roofing apparatus of claim 10, whereinsaid connecting spider includes a spider body with multiple spider arms for connectively engaging said channel beams.
- 12. The rounded roofing apparatus of claim 10, whereinsaid multiple channel beams are V-beams.
- 13. The rounded roofing apparatus of claim 10, whereineach V-beam supports at least two roof panels; and each V-beam has a wing angle associated with the roof curve angle between two roof panels.
- 14. The rounded roofing apparatus of claim 10 whereineach beam is adapted for the roof pitch angle.
- 15. The rounded roofing apparatus of claim 10, whereineach beam is adapted for the roof curve angle.
- 16. An aperture channel beam apparatus, comprising:a top structure; a plurality of vertical members engaging said top structure; and a bottom structure engaging said plurality of vertical members, wherein said plurality of vertical members are inwardly disposed from the outer edges of the top structure to form a central aperture, and wherein said channel beam is a V-beam, said top structure is an upper V and said bottom structure is a lower V.
- 17. A covered-aperture channel beam apparatus, comprising:an aperture channel beam apparatus, including a top structure, a plurality of vertical members engaging said top structure, and a bottom structure engaging said plurality of vertical members, wherein said plurality of vertical members are inwardly disposed from the outer edges of the top structure to form a channel beam aperture; and a retainer cap for covering the channel beam aperture.
US Referenced Citations (56)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2177436 |
Jul 1986 |
GB |