Variable pitch roof support assembly and components thereof

An assembly for securing roof panels at selectable pitch angles includes an extruded ridge bar having a horizontal ledge and a horizontally extending arcuate flange which form a horizontal slot in which the roof panels are supported at the desired pitch. Horizontally extending end portions of the arcuate flange are removable to set the angle of the slot for the desired pitch. Roof support bars extending along the side edges of the roof panels are connected to the ridge bar at the selected pitch by hinge assemblies having their pivot axes coincident with the center of curvature of the arcuate flange. A header supporting the panels at the eave comprises two extruded channel members pivotally connecting one flange of each channel member. A bifurcated arcuate end portion of the other flange on one channel member straddles the arcuate end portion of the other flange on the other channel member as the channel members are rotated to set the selected roof pitch. A pivot bracket joining the roof support bars to vertical support bars includes pivot bars connected to the support bars and rotatably connected by a pivot pin extending through transverse bores in mating bosses. Set screws or roll pins secured in holes drilled in each boss in alignment with a groove in the other boss, engage the groove to fix the support bars at the selected pitch.

BACKGROUND 
1. Field of the Invention 
This invention relates to an assembly for supporting roof panels at 
selected pitch angles and standardized components thereof which can be 
adjusted to provide the selected roof pitch. 
2. Background Information 
In adding lean-to type structures to existing or new construction, the 
pitch of the roof of such an addition is often dictated by details of the 
main structure and conditions at the site. This makes it difficult to 
construct such lean-tos from standardized components. 
Typically, the roof of a lean-to addition is connected to the main 
structure by a ridge bar which supports the roof at the required pitch 
angle. A popular type of lean-to addition is the sun room in which the 
roof, as well as the walls, are constructed of glass panels. In many of 
these installations, a header is provided along the eave where the wall 
panels join the roof panels. This header also must accommodate the pitch 
of the roof panels. Furthermore, support bars which support the side edges 
of the glass panels in the roof must be supported at the ridge and the 
eave at the same pitch angle as the panels. 
At the present time, the available ridge bars, headers, and supports for 
the roof support bars are designed for only one roof pitch. Thus it is 
necessary to manufacture and maintain an inventory of ridge bars, headers, 
and support bar supports for several different roof pitches. This is 
clearly expensive and inconvenient. Furthermore, it is only practical to 
maintain an inventory of components for a few standardized roof pitches. 
It is a primary object of the present invention to provide an assembly for 
supporting roof panels at selected roof pitch angles. 
It is another important object of the invention to provide such an assembly 
which is constructed from standardized adjustable components. 
It is a more specific object of the invention to provide a ridge unit for 
such an assembly which secures both the roof panels and panel support 
members at the selected pitch. 
It is another specific object of the invention to provide a header unit 
which joins the roof panel to wall panels at the eaves at the selected 
pitch. 
It is still another object of the invention to provide such a ridge bar and 
header unit which are extruded. 
It is yet another specific object of the invention to provide a pivot 
bracket for joining the roof support members to vertical supports at the 
selected pitch, and for rigidly fixing the supports at the selected angle. 
SUMMARY OF THE INVENTION 
These and other objects are realized by an assembly which includes a ridge 
unit for securing roof panels at the ridge at selectable pitch angles, and 
for securing roof support bars at the same selected pitch angle. The 
invention further includes an adjustable header for securing the roof 
panels at the selected pitch angle at the eaves, and a pivot bracket for 
securing the roof support bars to vertical support bars at the eaves at 
the same pitch angle. 
The ridge unit includes an elongated ridge bar, preferably extruded from 
aluminum, having a generally longitudinally extending ledge projecting 
laterally from a generally planar base and a generally longitudinally 
extending arcuate flange which projects laterally from the base and curves 
toward the ledge to form a longitudinal slot in which the glass panels are 
secured. End portions of the arcuate flange are removable, such as by 
bending along score lines, to adjust the angle of the elongated slot and 
therefore the pitch of the roof panels. The roof support bars are secured 
to the ridge bar by a hinge assembly which has its hinge point coincident 
with the center of curvature of the arcuate flange so that the support bar 
can easily be rotated to the plane of the roof panels. 
The adjustable header at the eaves comprises two generally U-shaped channel 
members pivotally connected along one flange. Preferably, the one flange 
on one channel member terminates in a bead which defines a longitudinally 
extending cylindrical surface, while the one flange on the other channel 
member terminates in a rib which defines a groove with a cylindrical 
surface which mates with the cylindrical surface on the bead to form the 
pivoted connection between channel members. The other flanges on the 
channel members terminate in arcuate portions curved about the pivot axis 
of the first flanges. These arcuate portions of the other flanges remain 
in close overlapping relation with one another as one channel member is 
rotated relative to the other. Preferably, one of the arcuate portions is 
bifurcated to form an arcuate groove into which the arcuate portion of the 
other flange extends so that it is straddled by the bifurcated flange. 
The pivot bracket, which adjustably joins the roof support bars and 
vertical support bars, includes a pair of pivot bars each of which is 
secured at one end to a support bar. A boss extending along one side from 
the other end of each pivot bar defines a transverse bore. A pivot pin 
extending through the bores pivotally connects the pivot bars and 
therefore the support bars so that the roof support bars can be rotated to 
any selected pitch. An elongated member is secured in a hole drilled in at 
least one boss so that it interferes with and prevents relative rotation 
of the support bars once the pitch has been set. Preferably, each boss 
defines a transverse groove which is engaged by a set screw into a tapped 
hole drilled in the other boss in alignment with the groove. 
Other features and advantages of the invention will become evident from the 
following detailed description which follows.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
FIG. 1 illustrates a lean-to structure 1 in accordance with the invention 
which includes a single pitch roof 3 secured at the ridge 5 to a vertical 
portion of a main structure 7 by a ridge bar 9. A header 11 along the eave 
12 joins the roof 3 to a vertical wall 13 of the lean-to structure 1. As 
best seen in FIG. 2 the roof 3 includes panels 15 of double pane glass, 
main roof support or glazing bars 17 running from the ridge to the eave 
between the glass panels 15, sealing bars 19, and muntin assemblies 21 
(See FIG. 1). The main roof support or glazing bars 17 are hollow, 
generally rectangular, preferably aluminum, extrusions which have upwardly 
projecting longitudinal ribs 23 upon which adjacent glass panels 15 are 
supported with thermal break material 25 inbetween. The glass panels are 
clamped in place by the sealing bar 19 which is secured to the main roof 
support bar 17 at spaced locations by screws 27. Sealing strips 29 make 
the connection water tight, and fluted cap strips 31 which snap into the 
sealing bar 19 conceal the screws 27 and provide a decorative finish. 
As seen in FIG. 1, the muntin assemblies 21 seal the horizontal joints 
between glass panels 15. The ridge bar 9 which supports the ridge 5 of the 
roof 3 is, as seen in FIGS. 1 and 2, and in the enlargement of FIG. 3, an 
extrusion preferably of aluminum, having a generally planar base portion 
33 which extends transversely to the longitudinal axis 35 of the 
extrusion. The base 33 is bolted to the vertical section of the main 
structure by bolts 37 and 39. A longitudinally extending ledge 41 projects 
laterally from one face 43 of the base portion 33 to form a lower support 
for the top edge of the glass panels 15. Preferably, a resilient strip 45 
of insulating material, secured by an undercut tongue 47 which engages an 
undercut groove 49 in the ledge 41, provides a thermal barrier and a 
resilient seat for the glass panels 15. 
A longitudinally extending arcuate flange 51 projects transversely from the 
one face of the base portion 33 a spaced distance above the ledge 41, and 
curves downward in a vertical plane transverse to the longitudinal axis 35 
of the ridge bar 9. The arcuate flange 51 forms with the ledge 41 a 
longitudinally extending slot 53 in which the upper edges of the glass 
panels 15 are received. A sealing strip 55 extruded with two longitudinal 
passages 57, which provide resiliency and thermal barriers, is wedged into 
the slot 53 between the glass panels 15 and the arcuate flange 51 to lock 
the glass panel to the ridge bar 9. Molded fingers 15, and a longitudinal 
groove 61 which fits tightly over the arcuate flange 51 serve to secure 
the sealing strip in place. 
A pair of longitudinal flanges 60 with confronting lips 62 extend 
horizontally from the base portion 33 between the ledge 41 and arcuate 
flange 51 to form an undercut groove for retaining thermal break material 
64 which is applied in liquid form and allowed to harden in place. After 
the thermal break material 64 has hardened a longitudinally extending 
debridging slot 66 is milled along the length of the planar base portion 
33 of the ridge bar 9 to create the thermal break. The thermal break 
material 64 is a resin having a low thermal conductivity which can be cast 
in place. A suitable thermal break material is BAYDUR 600. The debridged 
parts of the ridge bar 9 are connected by the hardened resin which is 
locked to the parts by the lips 62 and protrusions 68. 
The main roof support bars or glazing bars 17 are secured to the ridge bar 
9 by a hinge assembly 63 which includes a hinge member 65, a hinge pin 67, 
and a pair of hinge clips 69, all shown in FIG. 4. The hinge member 65 is 
preferably cast from aluminum with a generally planar body 71 with flanges 
73 extending along the side edges of the top face. One end of the planar 
body 71 is bifurcated by a slot 75 to form parallel extensions 77 which 
terminate in transverse cylindrical bosses 79. A through bore 81 in each 
boss 79 receives the hinge pin 67 which is secured to the ridge bar 9 by 
the clips 69. The clips 69, also preferably cast from aluminum, have slots 
83 opening toward the rear face 85 for receiving the hinge pin 67, and 
have counterbored, bolt receiving slots 84 which open from the lower edge 
of the clip. The clips 69 have horizontal grooves 87 extending across the 
rear face 85 which mate with longitudinal ribs 89 on the ridge bar 9 to 
aid in alignment (See FIGS. 1 and 3). The top edge of each clip 69 is 
provided with a radius 91 corresponding to the radii of the cylindrical 
bosses 79 on the hinge member 85. 
The underside of the ledge 41 is provided with a longitudinal recess 93 
which defines an internal cylindrical surface which receives the 
cylindrical bosses 79 on the hinge member 65 and the cylindrical end 
surfaces 91 of the clips 69. The arrangement is such that the center of 
curvature of the arcuate flange 51 is coincident with the axis of the 
hinge pin 67. 
In order to secure a main roof support bar 17 to the ridge bar 9, the hinge 
member 65 is inserted into the end of the main support extrusion as shown 
in FIGS. 1 and 2. An integral tapered pin 95 projecting from the underside 
of the hinge number 65 provides support while four screws 97 are inserted 
through holes punched in the extrusion 17 and screwed into tapped bores 99 
in the top surface of the hinge member 65. The hinge member 65 is then 
positioned with the bosses 79 in the cylindrical groove 93 in the bottom 
of the ledge 41 and the hinge pin 67 protruding from the bores 81 in the 
bosses 79. The clips 69 are then slipped over bolts 39 which have been 
loosened, but not removed, and with the ends of the hinge pin 67 captured 
in the slots 83, the bolts 39 are tightened to pivotally secure the roof 
support bar 17 to the ridge bar 9. 
The pitch angle of the roof 3 in the assembly shown in FIG. 1 is 45 
degrees. In order to accommodate other pitch angles, the arcuate flange 51 
is frangible along longitudinal score lines 101 and 103. Removing the 
section 51' at the score line 101 adjusts the opening of the slot 53 to 
receive the glass panels 15 at a 30 degree pitch angle as shown in FIG. 5. 
Similarly, removing also the section 51" to the score line 103 rotates the 
opening of the slot 53 to support the glass panels 15 at a pitch angle of 
15 degrees as shown in FIG. 6. Of course, the length of the arcuate member 
51 and the number and angles of the score lines 101, 103 can be varied to 
provide any desired range of selectable pitch angles. Since the main roof 
support bars 17 are pivotally mounted for rotation about an axis 105 
coincident with the center of curvature of the arcuate flange, the pitch 
of the roof support bars 17 is easily adjusted to that set for the glass 
panels 15. 
The main roof support bars 17 are supported at the eaves 11 by vertical 
support bars 107 of similar construction. A mitered joint 109 between the 
main roof support bar 17 and the main vertical support bar 107 is 
structurally supported by a pivot bracket 111 which is illustrated in side 
elevation in the cutaway view of the joint in FIG. 7, and in plan in the 
cutaway view in FIG. 8. The pivot bracket 111 is formed of two identical 
pivot bars 113 preferably cast from aluminum. These pivot bars 113 are 
sized to fit snugly at their ends into the extrusion forming the main roof 
support bar 17 and the main vertical support bar 107, but are of reduced 
cross section in the intermediate section 115. Extending along one side of 
one end of each pivot bar 113 is a boss 117 with a counterbored transverse 
bore 119. A radius 121 at one end edge of the boss is centered on the bore 
119. The other corner edge of the boss 117 is rabbeted to form a 
transverse groove 123. 
The pivot bars 113 are inserted into the respective support bars 17 and 107 
and secured by screws 125 received in tapped bores 127. The bosses 117 are 
then pivotally connected by a pin 129 inserted in bore 119 and held in 
place by bolts 131. The main roof support bar 17 is then rotated relative 
to the main vertical support bar 107 to the selected pitch angle. A hole 
133 is then bored and tapped in each boss 117 in alignment with the groove 
123 in the other boss. Elongated members such as slotted set screws 135 
screwed into these holes 133, interfere with the other boss to lock the 
pivot bracket 111 securely at the selected pitch angle. Alternatively, a 
roll pin may be press fit into an untapped bore 133 to provide the 
required interference. 
The header 11 includes two pivotally connected channel members 137 and 139. 
These channel members, which preferably are extruded from aluminum, each 
have a central web 141 and a pair of longitudinally extending flanges 143, 
145 and 147, 149, respectively, projecting laterally from the web 141. One 
flange 143 of the channel member 137 terminates in a bead 151 extending 
along the flange. The bead 151 is extruded with a groove 153 to reduce the 
material required in the extrusion, however, the bead 151 still defines at 
least a partial cylindrical surface. One flange 147 on the channel member 
139 terminates in a rib 155 which defines a longitudinal groove 157 having 
a partial internal cylindrical surface. The cylindrical surface of the 
groove 157 mates with the cylindrical surface on the bead 151 for rotation 
relative thereto about the common longitudinal axis 159 to form a pivot 
connection between the two channel members 137 and 139. The other flange 
145 on the channel member 137 terminates in an arcuate portion 161 which 
has as its center of curvature the common longitudinal axis 159. The other 
flange 149 on the channel member 139 terminates in a bifurcated arcuate 
portion 163 which defines an arcuate groove 165 also having as its center 
of curvature the common longitudinal axis 159. The bifurcated portion 163 
of flange 149 straddles the arcuate portion 161 of flange 145 so that as 
the channel members 137 and 139 are rotated relative to one another the 
arcuate portion 161 slides within the arcuate groove 165 in overlapping 
relation with the bifurcated portion 163 of flange 145. A flange 167 on 
the end of arcuate portion 161 substantially spans the radial width of the 
arcuate gap 165 to form a pocket to receive a sealant or caulking compound 
168 which effects an airtight and water tight seal. Confronting ribs 169 
on the flanges 143, 145 and 147, 149 form recesses for retaining thermal 
barrier material 171. As in the case of the ridge bar, debridging slots 
172 are milled along the entire length of the webs 141 to form a thermal 
break after the thermal break resin 171 has hardened in place. The channel 
members 137 and 139 are secured to the edges of the glass panels 15 
forming the vertical wall 13 and roof 3 respectively by muntin assemblies 
21. The desired roof pitch is set by rotating the channel members 137, 139 
making up the header 11 relative to one another. 
Thus, in accordance with the invention, a lean-to structure can be 
constructed with a roof having a selected pitch using standardized 
adjustable components. The angle at the ridge is set by adjusting the 
length of the arcuate flange 51 on the ridge bar 9 and the angle of the 
hinge assembly 63. The angle between the roof support bars and vertical 
support bars is set by rotating the pivot bracket 111 to the selected 
angle, and fixing that angle by drilling holes 133 and inserting set 
screws or roll pins 135. The pitch is set at the eaves by rotating the 
pivoted channel members 137, 139 making up the header 11 to the desired 
angle. This arrangement does away with the necessity of maintaining an 
inventory of components only suitable for one roof pitch. 
The invention has been described as applied to a lean-to structure with a 
straight eave. That is, a structure in which the planar roof panels meet 
the wall panels at the pitch angle. In some installations, the plane of 
the roof curves into the plane of the wall. There is no header at the eave 
in these installations, and support bar sections curved to accommodate the 
curvature between the roof support bars and the wall support bars must be 
provided for each roof pitch. However, even in these installations, the 
ridge bar unit of the invention offers a single, adjustable assembly for 
selected roof pitches. 
While specific embodiments of the invention have been described in detail, 
it will be appreciated by those skilled in the art that various 
modifications and alternatives to those details could be developed in 
light of the overall teachings of the disclosure. Accordingly, the 
particular arrangements disclosed are meant to be illustrative only and 
not limiting as to the scope of the invention which is to be given the 
full breadth of the appended claims and any and all equivalents thereof.