Patent Application
20070204525
This invention relates in general to construction of buildings and, more specifically, to construction of eaves for roofs on buildings.
Eaves are common on many types of buildings. Eaves extend the roof line some distance beyond the walls of the underlying building, ensuring that water run-off from the roof falls at least a nominal distance from the building's walls. Water that falls near the walls may, over time, damage the walls and/or base of the building. Additionally, eaves may fulfill an aesthetic function.
Eaves may be constructed of a single piece that is attached to the edge of the roof of a building. This type of construction is economical for the builder, but may lead to warping of the eave. This can lead to misalignment of building parts and consequent exposure of the interior of the building to the outside environment. To remedy this problem, eaves are often constructed of multiple pieces to reinforce the structure of the eave and thereby prevent warping.
Present methods in the art involve fastening these pieces to parts of an eave that are already attached to the building. This can be a difficult task, resulting in misalignment of the various pieces, increased construction time and reduced building quality. For instance, present methods may require attaching pieces to parts of the eave from the underside of the eave, necessitating operations such as hammering nails upward from underneath the eave.
These operations may strain the physical and technical abilities of manufacturers. In these scenarios it may not be possible to squarely insert fasteners, such as nails, into the eave pieces. Other parts of the building may obstruct the space required to properly operate fastening tools such as nail guns, hammers or power screwdrivers. The systems of the present invention provide solutions to these and other issues.
In one embodiment, the invention provides a method for making an eave for a roof on a building. As part of the method, a roof rip piece may be coupled with an eave trim piece prior to coupling the roof rip piece or the eave trim piece with the building. The roof rip piece and the eave trim piece each may be defined by two lengthwise edges and two sides. Furthermore, the width of the roof rip piece may be greater than the width of the eave trim piece.
When the roof rip piece and eave trim piece are coupled, the lengthwise edges of both pieces may be substantially parallel. Furthermore, after coupling, the first lengthwise edge of the eave trim piece may be either substantially planar with the first lengthwise edge of the roof rip piece or possibly extend beyond the first lengthwise edge of the roof rip piece. The coupled roof rip piece and eave trim piece may then be coupled with the top of a building. At this point, one side of the roof rip piece may possibly be substantially flush with the top of the building.
When the coupled roof rip piece and eave trim piece are coupled with the building, the eave for the roof of the building may be complete. In some embodiments this may complete the roof as well. In other embodiments a sheeting piece may be coupled with the top of the building to complete at least some portion of the roof. The sheeting piece may be defined by at least one edge and two sides. When coupled, one side of the sheeting may be substantially flush with the top of the building and one edge of the sheeting may be proximate to the roof rip piece.
Coupling in any of the steps and/or embodiments of the invention may, merely by way of example, include fastening with nails, fastening with screws, fastening with nuts and bolts, fastening with glue and/or fastening with staples. The roof rip piece, eave trim piece and sheeting piece may, merely by way of example, be made from oriented strand board, particle board, fibreboard, plywood, structurally insulated panels, wood, cement board, composite, plastic, polymer and/or metal.
In some embodiments, a drip edge piece may further be coupled with the first lengthwise edge of the roof rip piece. The drip edge piece may be configured to cover at least a portion of the interface between the roof rip piece and the eave trim piece. The drip edge piece may, merely by way of example, be a member with a square angled L-shape cross-section, an obtuse angled L-shape cross-section, a square U-shape cross-section, a parallelogram U-shape cross-section and/or a T-shape cross-section. The drip edge piece may, merely by way of example, be made from aluminum, steel, aluminum alloy, steel alloy, plastic, polymer and/or composite.
In another embodiment, the invention provides a kit for making a building with an eave. The kit may have a plurality of frame members which may be assembled to frame a structure with at least two sides and a roof frame, and a roof rip piece and eave trim piece which may be coupled with each other and further coupled with the roof frame to make an eave. The kit may include instructions instructing a user to couple the roof rip piece with the eave trim piece before coupling either piece with the building. The kit may, in some embodiments, also contain a sheeting piece which may be coupled with the roof frame to complete at least a portion of the roof. In other embodiments, the roof rip piece may complete at least a portion of the roof. The kit may further have a drip edge piece which may be coupled with the roof rip piece to cover at least a portion of the interface between the roof rip piece and the eave trim piece.
In another embodiment, the invention provides an alternative kit for making a building with an eave. The kit may have a plurality of frame members which may be assembled to frame a structure with at least two sides and a roof frame, and a roof rip piece coupled with an eave trim piece which may be coupled with the roof frame to make a roof with an eave. The kit may, in some embodiments, also contain a sheeting piece which may be coupled with the roof frame to complete at least a portion of the roof. In other embodiments, the roof rip piece may complete at least a portion of the roof. The kit may further have a drip edge piece which may be coupled with the roof rip piece to cover at least a portion of the interface between the roof rip piece and the eave trim piece.
The present invention is described in conjunction with the appended figures:
For the purposes of this description, an “eave” is defined as the part of a roof that extends outward from the walls of a structure. The “top of a building,” “top of a structure,” or similar terms, are defined as the part of a building or structure on which a roof is constructed.
In one embodiment, the invention provides a method for making an eave for a roof on a building. As part of the method, a roof rip piece may be coupled with an eave trim piece before either is coupled with the building. Coupling may, merely by way of example, include fastening with nails, fastening with screws, fastening with nuts and bolts, fastening with glue and/or fastening with staples. The roof rip piece and the eave trim piece each may be defined by two lengthwise edges and two sides. Furthermore, the width of the roof rip piece may be greater than the width of the eave trim piece. The roof rip piece and eave trim piece may, merely by way of example, be made from oriented strand board, particle board, fibreboard, plywood, structurally insulated panels, wood, cement board, composite, plastic, polymer and/or metal. The thickness of the roof rip piece may be between about ⅜ inch (0.010 meters) and about ¾ inch (0.019 meters). The thickness of the eave trim piece may be between about ⅜ inch (0.010 meters) and about 1-¼ inch (0.032 meters).
When the roof rip piece and eave trim piece are coupled, the lengthwise edges of both pieces may be substantially parallel. Coupling the pieces so that they are substantially parallel may ensure proper alignment with other building parts. Furthermore, after coupling, the first lengthwise edge of the eave trim piece may be either substantially planar with the first lengthwise edge of the roof rip piece or possibly extend beyond the first lengthwise edge of the roof rip piece. The first lengthwise edge of the eave trim piece may possibly extend, in some embodiments, beyond the first lengthwise edge of the roof rip piece up to about ½ inch (about 0.013 meters). This combined edge, in some embodiments, may become the outer edge of the eave of the building. Design constraints, manufacturing constraints, material availability and/or aesthetic preferences may determine whether the two pieces should be coupled so that their first lengthwise edges are substantially planar or offset as described above.
Once coupled together, the roof rip piece may be coupled with the top of a building. Coupling may, merely by way of example, include any of the methods discussed above. Once coupled, one side of the roof rip piece may be substantially flush with the top of the building and form part of the edge of the roof of the building.
It will now become apparent to those skilled in the art how coupling the roof rip piece with the eave trim piece prior to coupling the combined piece with the building ensures proper alignment of the roof rip piece and eave trim piece. When the roof rip piece and eave trim piece are coupled prior to coupling with the building, they may be coupled at a more typical working level such as on a work bench or other suitable apparatus, rather than an upside down and angled position as is common on most eaves. This makes achieving proper alignment less demanding for those practicing the method. Additionally, any tools possibly used to couple the two pieces may be more properly employed, free from obstruction of other, proximate building construction. Furthermore, coupling the two pieces can occur in a downward direction (i.e. driving of nails, screws, staples or other coupling devices), which those skilled in the art will recognize as an advantageous orientation. Finally, the eave trim piece can be painted more easily before it is attached for all of the same reasons discussed above.
The method discussed above may also be advantageous because it makes construction more economical. For instance, when coupling devices such as nails, screws and staples are more properly driven into the roof rip piece and eave trim piece, fewer coupling devices will be necessary to achieve the same level of strength in the coupling. Additionally, less work time will be consumed during such operations.
Paint may also be more evenly applied to such eaves, providing an incremental cost savings per eave constructed in this manner. Furthermore, because the two pieces are coupled prior to coupling with the top of the building, no touchup paint will have to be applied to the eave trim piece or other parts of the building after coupling with the building. The coupled roof rip piece and eave trim piece may only be coupled with the building from the top of the building, an area usually covered by other roofing materials, such as tar-paper and shingles, negating the need to apply touch up paint to any of the areas where these coupling operations occur.
In some embodiments a sheeting piece may be coupled with the top of the building to complete at least a portion of the roof. The sheeting piece may be defined by at least one edge and two sides. Multiple sheeting pieces may be necessary to complete the roof in some embodiments. The sheeting pieces may, merely by way of example, be made from any of the materials discussed above in regard to the roof rip piece and eave trim piece. When coupled, one side of the sheeting pieces may be substantially flush with the top of the building and one edge of the sheeting pieces may be proximate to the roof rip piece. The edge of the sheeting pieces may possibly abut the roof rip piece.
Those skilled in the art will now recognize that coupling the coupled roof rip piece and eave trim piece with the top of the building first will make it less troublesome to couple the sheeting piece with the top of the building. If the sheeting piece were to be coupled with the top of the building first, then on most roof frames, which are angled, the sheeting piece could slide off after it is laid on the top of the building, but before it is firmly coupled. The coupled roof rip piece and eave trim piece, once coupled with the top of the building, provide a “stop” at the bottom part of the roof for the sheeting piece to abut against until it is firmly coupled with the building. Additionally, it is more efficient to use the coupled roof rip piece and eave trip piece to hold the sheeting piece in place prior to coupling than it is a human laborer.
In other embodiments, the roof rip piece may complete the roof. In these embodiments the roof rip piece will be larger than those discussed in previous embodiments. The coupled larger-roof rip piece and eave trim piece, once coupled with the top of the building, will complete both the eave and the roof of the building.
A drip edge piece may further be coupled with the first lengthwise edge of the roof rip piece. The drip edge piece may be configured to cover at least a portion of the interface between the roof rip piece and the eave trim piece. This may assist in diverting water from the roof away from the interface between the roof rip piece and the eave trim piece where degradation and erosion of the pieces may be more likely. The drip edge piece may, merely by way of example, be a member with a square angled L-shape cross-section, an obtuse angled L-shape cross-section, a square U-shape cross-section, a parallelogram U-shape cross-section and/or a T-shape cross-section. The drip edge piece may also, merely by way of example, be made from aluminum, steel, aluminum alloy, steel alloy, plastic, polymer and/or composite. The drip edge pieces may be made through numerous methods, including extrusion, form-casting, fabrication techniques and/or machining methods. Some exemplary drip edge pieces might be made from formed sheet-metal. The thickness of the drip edge piece at any point in its cross-section may, merely by way of example, be between about 0.010 inch (0.0003 meters) and about 0.100 inch (0.0025 meters).
In another embodiment, the invention provides a kit for making a building with an eave. The kit may, merely by way of example, be used by consumers and/or professional builders to assemble a building with a roof with an eave. The kit may have a plurality of frame members which may be assembled to frame a structure with at least two sides and a roof frame, and a roof rip piece and an eave trim piece which may be coupled with each other and further coupled with the roof frame to make a roof with an eave. The kit may include instructions instructing a user to couple the roof rip piece with the eave trim piece before coupling either piece with the building. In some embodiments the kit may also contain a sheeting piece which may be coupled with the roof frame to complete at least a portion of the roof. In several embodiments, the roof rip piece may complete at least a portion or an entirety of the roof. The kit may further have a drip edge piece which may be coupled with the roof rip piece to cover at least a portion of the interface between the roof rip piece and the eave trim piece.
In another embodiment, the invention provides an alternative kit for making a building with an eave. The kit may have a plurality of frame members which may be assembled to frame a structure with at least two sides and a roof frame, and a roof rip piece coupled with an eave trim piece which may be coupled with the roof frame to make a roof with an eave. In some embodiments the kit may also contain a sheeting piece which may be coupled with the roof frame to complete at least a portion of the roof. In several embodiments, the roof rip piece may complete at least a portion or an entirety of the roof. The kit may further have a drip edge piece which may be coupled with the roof rip piece to cover at least a portion of the interface between the roof rip piece and the eave trim piece. In some embodiments, the kit may have the drip edge piece pre-coupled with the roof rip piece.
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The aforementioned pieces may be used to practice a method of the invention, or may partially or completely form a kit provided by the invention. The various frame members assembled to form a structure 110, when supplied in a kit, may be supplied wholly unassembled or partially unassembled. The frame members may possibly include horizontal members, vertical members, roof members, and/or siding. These frame members may, merely by way of example, be made from oriented strand board, particle board, fibreboard, plywood, structurally insulated panels, wood, cement board, composite, plastic, polymer and/or metal. Additionally, the kit may have other building supplies necessary to assemble the structure, and other parts of the kit, such as fastening pieces (i.e. nails, screws, nuts and bolts, glue and staples) and joint pieces (i.e. sheet metal joint-forms with fastener apertures).
In
In
The roof rip pieces 140, 170 and the eave trim piece 150 may be coupled using a variety of methods known in the art such as using nails, screws, nuts and bolts, glue and staples. In some kit embodiments, the roof rip pieces 140, 170 and the eave trim piece 150 may be pre-coupled in numerous ways, including the two configurations 200, 201, 300, 301. As discussed above, the advantages of coupling the roof rip piece 140, 170 and eave trim piece 150 prior to attachment with the top of the building 110 are numerous, and include ease of construction, quality of construction, and cost savings.
In some kit embodiments of the invention, the roof rip piece 140, 170 and the eave trim piece 150 may be pre-coupled. In these embodiments, the roof rip piece 140, 170 and eave trim piece 150 may, merely by way of example, be pre-coupled in a configuration such as shown in either
In
In other embodiments, different configurations of the coupled roof rip piece 140 and eave trim piece 150 may be coupled with the roof frame 130 of the structure 110. For example, the configuration 300 shown on
In
In other embodiments the sheeting piece 160 may be coupled with the roof frame 130 of the structure 110 so that it is merely proximate to the roof rip piece 140. In some embodiments there may be a plurality of sheeting pieces 160 employed to complete the roof of the structure 110. In a kit embodiment, the sheeting pieces 160 may be sized so that when they are coupled with the roof frame 130 of the structure 110, they complete the roof of the building 110 without excess sheeting pieces 160 protruding from the peak of the roof. As described above, other embodiments may not require sheeting pieces 160 to complete the roof. In these embodiments, larger roof rip pieces 170 may obviate the need for sheeting pieces 160.
In
In other embodiments of the invention, kits are provided which contain components that may be used to carry out various methods of the invention. In some of these kit embodiments, the roof rip piece 140, 170 may be pre-coupled with the eave trim piece 150. In other kit embodiments, the roof rip piece 140, 170 and eave trim piece 150 may not be pre-coupled, but the kit may contain instructions directing the user of the kit to couple the roof rip piece 140, 170 with the eave trim piece 150 prior to coupling either piece with the building.
The invention has now been described in detail for purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims.
