ROOF ASSEMBLY

Abstract

The invention provides a roof assembly (2) comprising an outer roof component (4, 104, 204) that is arranged, in use, to be mutually interlocked with an inner roof component (6, 106, 206). The outer roof component (4, 104,204) comprises a depending key element (14) that is a snap-fit in an upwardly facing dovetail slot (36) provided in the inner roof component (6, 106, 206). Embodiments of the invention enable roofs of various pitches to be assembled, the components (204, 206) having mutually inter-engaging bulbous configurations for this purpose. The key element (14) and the inner roof component (6, 106, 206) are molded from foamed polystyrene. The invention also provides a method of forming a roof using the roof assembly (2).

Description

There now follows by way of example detailed descriptions of the invention in various forms and methods of forming a roof structure, which description is to be read with reference to the accompanying drawings in which:—

FIG. 1 shows an end elevation of a first embodiment of the invention;

FIG. 2 is an underside perspective view of an outer ridge component of the first embodiment shown in FIG. 1;

FIG. 3 is an upper perspective view of the component shown in FIG. 2;

FIG. 4 is a side elevation in the direction of the arrow IV of FIG. 3;

FIG. 5 is an underside view of the component shown in FIG. 4;

FIG. 6 is an upper perspective view of the inner ridge component of the first embodiment shown in FIG. 1;

FIG. 7 is an end section view through a ridge portion of a roof incorporating the first embodiment of the invention;

FIG. 8 is an upper perspective view of an inner component of a second embodiment of the invention;

FIG. 9 is an end section view through a ridge portion of a roof incorporating a second embodiment of the invention;

FIG. 10 is an upper perspective view of an inner component of a third embodiment of the invention;

FIG. 11 is an end section view through a ridge portion of a roof incorporating a third embodiment of the invention;

FIG. 12 is a cross-section of a pair of roof panels utilizing a roof assembly according to a further embodiment of the invention; and

FIG. 13 is an end section through a hip portion of a roof incorporating an embodiment of the invention.

As a departure from traditional roof construction for the roofs of dwellings, the present invention generally provides a novel roof assembly 2 comprising an outer ridge component 4 for mutual interlocking engagement, in use, with an inner ridge component 6 that is supported in a roof structure 8 comprising structural elements 10, see especially FIGS. 7, 9 and 11.

Specifically, the outer ridge component 4 comprises a half round ridge tile 12 of concrete, clay or plastic composition, which roof tile 12 is provided with a depending key element 14 integrated with the underside 16 thereof by a suitable means, see FIGS. 1 to 7. The key element 14, which is molded from a foamed polystyrene composition, comprises a depending portion 18 of truncated arrowhead cross-section, see particularly FIGS. 1, 2 and 7.

The key element 14 is of the same length as the roof tile 12 to which it is attached; however, the element 14 is offset along the length of the roof tile 12, as shown in FIGS. 2, 3, 4 and 5. This arrangement facilitates closure of a gap between adjacent tiles 12, in use on a roof, with an end portion 20 of a first roof tile 12 overlying a protruding end portion 22 of a key element 14 protruding from an adjacent roof tile 12 along a roof ridge.

The key element 14 provides support for two filler elements 24 and 26 attached to underside wing portions 28 and 30 respectively, see FIGS. 1, 2 and 5. Each filler element 24 and 26 is of a webbed comb-like configuration 27. The filler elements 24 and 26 are secured in situ on their respective wing portions 28 and 30 by any appropriate means, e.g. an adhesive.

The inner ridge component 6 is molded as an elongate element 32 of a foamed polystyrene composition and comprises a lower truncated arrowhead portion 34 and an upwardly facing, open topped, dovetail slot 36 extending along the length thereof, see FIGS. 1, 6 and 7. The elongate element 32 is supported, in use, on a ridge beam 38 of the roof structure 8 and is held captive by juxtaposed upper end portions 40 and 42 of roof elements 44 and 46 respectively, see FIG. 7. The end portions 40 and 42 are configured at 40a and 42a respectively to restrain from uplift portions 48 and 50 of the arrowhead portion 34 when the elongate element 32 is in use on a roof.

The elements 44 and 46 also provide engagement means such as battens 52 for roof tiles 54.

After assembly of the ridge beam 38 and the roof elements 44 and 46 of the roof structure 8, a series of elongate elements 32 is introduced at an end of the roof structure 8. The elements 32 are each moved along the roof and into place between adjacent roof elements 44, 44 and 46, 46. When in position, the elongate elements 32 are held captive by the configurations 40a and 42a of their respective roof elements 44 and 46, see FIG. 7.

Roof tiles 54 are then placed on the engagement means 52, as shown in FIG. 7, and the roof is completed by the assembly thereon of a series of the outer ridge components 4, the key elements 14 thereof being received in a snap-fit relationship within the dovetail slots 36 of associated inner ridge components 6, see FIG. 7.

A modified roof ridge assembly 102 of the invention is shown in FIGS. 8 and 9 wherein an outer ridge component 104 is the same as the outer ridge component 4 described herein; however, an inner ridge component 106 comprises a lower platform portion 134 that is received, in use, between configured end portions 140a and 142a of elements 144 and 146 respectively. The assembly of the first modified embodiment is essentially the same as that described above with reference to the FIG. 7 embodiment.

A further modified roof ridge assembly 202 of the invention is shown in FIGS. 10 and 11 wherein an outer ridge component 204 is the same as the outer ridge components 4 and 104 described herein; however, an inner ridge component 206 is provided with a lower bulbous configuration 234 that is received, in use, between configured end portions 240a and 242a of elements 244 and 246 respectively. The assembly of the further modified roof ridge assembly 202 is essentially the same as those described above with reference to the FIGS. 7 and 9 embodiments.

The roof ridge assembly 202 facilitates the formation of a roof of various pitch, that is, the bulbous configuration 234 enables the elements 244 and 246 to be set at any chosen angle within accepted limits for a roof.

It will be appreciated that many variations and modifications may be made within the scope of the present invention and the roof structures upon which the roof assemblies are used. For example, the roof structure is:—

a) a conventional trussed rafter configuration; or,b) of structural insulated panel (SIP) configuration; or,c) of SIP configuration pre-fitted with roof tiles; or,d) of a special type of SIP that includes cassettes for the location and support of roof tiles.

The outer ridge component is formed as a single molded unit of concrete, clay or any convenient moldable material.

The ridge tiles and the unitary molded outer ridge components may comprise over-locks and under-locks at opposite ends thereof for mutual interlocking in use and for sealing the ridge line of a roof against the ingress of driving rain, etc.

The foamed polystyrene may be replaced by any other suitable composition that may be readily molded and or machined to obtain the mutually interlocking configurations of the key element 14 and the elongate element 32.

The filler unit may also be changed for any like product commensurate with preventing the ingress of driving rain or snow to the inside of a roof.

Referring to the embodiment of the invention shown in FIG. 12, adjacent parts of two insulating roof panels 300, 302 are shown, having their side edges in mutual abutment. The panels are pre-assembled with standard roof tiles of which only two 308a and 308b are shown. Each of these standard roof tiles has an underlock 312 formed along one edge and an overlock 314 formed along the opposite side edge. The arrangement is such that, except as indicated below, each of the overlooks 314 mates with an underlock 312 of an adjacent tile to form a weatherproof joint. These roof tiles 308a, b etc. are secured to the panel 300 or 302 by means not shown.

In the case of the panel 300, the tile 310 pre-assembled thereon is a special tile having a different construction from that of the roof tiles 308a, b etc., being formed with a standard underlock 312 and another underlock 316 along the opposite side edge. The right hand side edge of the roof tile 310 is located short of the side edge 304 of the panel 300.

In the case of the panel 302, the left hand tile 308a pre-assembled thereon has a left hand edge located somewhat short of the left hand edge 306 of the panel 302.

The panel 300 has a channel 318 formed therein, adjacent the side edge 304. Along this channel is formed an element 320 defining an upwardly facing open-top dovetail slot 336. The channel 318 and the element 320 extend along the length of the panel, and are formed, for example by molding, from a foamed material such as foamed polystyrene.

After the insulating panels 300 and 302 have been positioned on a roof structure (not shown) and fixed thereto by suitable means, the joint between the panels is covered by a special roof tile 322, which is again of different construction from the roof tiles 308a, b etc., being formed with a standard overlock 314 and another overlock 324 along the opposite side edge. The arrangement is such that the overlooks 314, 324 mate with the underlocks 312, 316 of adjacent tiles 308a, 310 respectively to form a weatherproof joint.

The special roof tile 322 carries on its underside a depending key element 326 formed, for example, of a foamed material such as foamed polystyrene. The key element has, in cross section, a truncated arrowhead form, so shaped and formed to correspond to the dovetail slot 336 in the element 320, so as to be a snap-fit therein.

In this embodiment the insulating panel 300 constitutes the inner roof component of the present invention, while the special roof tile 322 constitutes the outer roof component.

It can be appreciated that the principles described above for constructing a ridge or the joints between pre-tiled insulated roof panels can be adapted to make the hips on a roof. Such a hip assembly is shown in FIG. 13 wherein an outer hip component in the form of a hip tile 412 is configured for inter-engagement with an inner hip component 406 supported by roof elements 444 and 446, in a manner similar to the embodiment shown in FIG. 9.

Claims

1. A roof assembly comprising an outer roof component configured for mutual interlocking engagement, in use, with an inner roof component, which is adapted to be supported in a roof structure, wherein said inner roof component comprises an aperture for receiving, in use, a depending key element of an outer roof component and wherein said outer roof component comprises a separately formed said key element.

2. The roof assembly according to claim 1, wherein said key element of said outer roof component is a snap fit, when in use, in said aperture of said inner roof component.

3. The roof assembly according to claim 1, wherein said key element of said outer roof component is configured with a shaped protrusion to facilitate the retention thereof in said aperture of said inner roof component, which aperture is configured to be of a shape corresponding to that of said key element.

4. The roof assembly according claim 1, wherein said outer roof component comprises a ridge or hip tile including a filler element and side seals to prevent, in use, the ingress of driving rain or snow.

5. The roof assembly according to claim 4, wherein said filler element is of a webbed comb-like configuration.

6. The roof assembly according to claim 1, wherein the inner roof component is in the form of a prefabricated insulated roof panel, the panel being pre-tiled except along at least one side edge, and the outer roof component is in the form of a separate roof tile, adapted to be positioned in use over the non-tiled side edge.

7. The combination of the roof assembly according to claim 1 with a roof structure, wherein said inner roof component comprises a molding configured to be retained and supported in complementary configurations formed in said roof structure.

8. The combination the roof assembly according to claim 1 with a roof structure, wherein said inner roof component is retained and supported by elements of said roof structure, which elements are provided with the complementary configurations for facilitating, in use, the retention and support of said inner roof component in said roof structure.

9. The combination according to claim 8, wherein said roof assembly is a ridge assembly and said complementary configurations of said elements are formed to facilitate the construction of roofs with various pitches.

10. A roof assembly comprising an outer roof component configured for mutual interlocking engagement, in use, with an inner roof component, which is adapted to be supported in a roof structure, wherein the inner roof component is in the form of an insulated roof panel comprising an aperture for receiving, in use, a depending key element of said outer roof component.

11. The roof assembly according to claim 10, wherein said key element of said outer roof component is a snap fit, when in use, in said aperture of said inner roof component.

12. The roof assembly according to claim 10, wherein said key element of said outer roof component is configured with a shaped protrusion to facilitate the retention thereof in said aperture of said inner roof component, which aperture is configured to be of a shape corresponding to that of said key element.

13. The roof assembly according to claim 10, wherein said outer roof component comprises a separately formed said key element.

14. The roof assembly according claim 10, wherein said outer roof component is made as a unitary component.

15. The roof assembly according to claim 1, wherein the inner roof component is in the form of a prefabricated insulated roof panel, the panel being pre-tiled except along at least one side edge, and the outer roof component is in the form of a separate roof tile, adapted to be positioned in use over the non-tiled side edge.

16. A method of forming a roof comprising the steps of:— a) providing a roof structure having provision for the retention and support of a series of inner roof components there-along;b) installing a series of inner roof components along said roof structure; and,c) securing a series of outer roof components in mutual engagement with said inner roof components along said roof structure, thereby to form a roof assembly,

17. The method according to claim 16, wherein the roof assembly comprises an outer roof component configured for mutual interlocking engagement, in use, with an inner roof component, which is adapted to be supported in a roof structure, wherein said inner roof component comprises an aperture for receiving, in use, a depending key element of an outer roof component and wherein said outer roof component comprises a separately formed said key element.

18. The method according to claim 16, wherein said series of inner roof components are offered up seriatim at one end of said roof structure and moved there-along to create a continuous line thereof along said roof structure to thereafter enable said series of outer roof components to be secured in mutual engagement therewith to form the roof.

19. The method according to claim 16, wherein said series of inner roof components are positioned in a continuous line thereof, each inner roof component being supported between an associated pair of retaining hangers to thereby provide support for said series of outer roof components arranged in a continuous line thereof, each of which is located in mutual interlocking engagement with an associated said inner roof component to thereby form a roof.

20. The method according to claim 16, wherein said inner roof components are each in the form of a pre-tiled insulated roof panel and are laid side by side from ridge to eaves, which thereafter enable said series of outer roof components to be secured in mutual engagement therewith to form the roof.

21. A method of forming a roof comprising the steps of:— a) providing a roof structure having provision for the retention and support of a series of inner roof components there-along;b) installing a series of inner roof components along said roof structure; and,c) securing a series of outer roof components in mutual engagement with said inner roof components along said roof structure, thereby to form a roof assembly,

22. The method according to claim 21, wherein the roof assembly comprises an outer roof component configured for mutual interlocking engagement, in use, with an inner roof component, which is adapted to be supported in a roof structure, wherein the inner roof component is in the form of an insulated roof panel comprising an aperture for receiving, in use, a depending key element of said outer roof component.

23. The method according to claim 21, wherein the said inner roof components are each in the form of a pre-tiled insulated roof panel and are laid side by side from ridge to eaves, which thereafter enable said series of outer roof components to be secured in mutual engagement therewith to form the roof.