ROOFING SYSTEM

Abstract: A roof panel having a filler (13) between an outer weatherproof sheet (11) and an inner sheet (12). The roof panel has male and female connectors (17, 18) along edges for push together edge-to-edge connection. The edge connectors come together with a space therebetween to carry electrical and other services.

Description: Title: "ROOFING SYSTEM" FIELD OF THE INVENTION THIS INVENTION relates to a roofing system and various improvements and adaptations to roofing materials. BACKGROUND TO THE INVENTION Many different forms of roofing have been devised to take advantage of various techniques and materials as have been developed over time, and to meet changing standards as more is asked of buildings such as in cyclone prone regions. Whilst much has been devised there is always a need for fresh approaches with cost savings in materials and labour in mind, as well as other factors such as the need for skilled labour, ease of transport, reduction of on site fabrication, etc. OBJECT OF THE INVENTION The invention has as its object an improved roofing system. Other more specific objects and various advantages will hereinafter become apparent. The present roofing system is preferably integrated with the building system set out in prior Australian Patent specification, serial number 582298 (69217/87) to the same applicants. NATURE OF THE INVENTION The invention achieves its object in providing a roof panel for establishing a roof wherein a plurality of the roof panels are laid edge to edge to panel over the roof, the roof panel comprising: a first outer sheet of weatherproof material; a second inner sheet; a layer of filler material between the first and second sheets; and edge connectors whereby adjoining roof panels may be interconnected one with the other. the first outer sheet being extended to overhang at least one edge of the roof panel to provide a seal to the join between adjoining panels by overlap of the adjoining panel edge by the overhand; the opposed edge connectors being opposed male and female elongate push together connectors extended the length of opposed edges, to mate, in use, with a free space therein along the length of the connection. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to the accompanying drawings in which FIGS. 1 to 5 are views showing details of a roofing sheet as may be used in the roofing system of this invention; FIG. 6 shows how two roofing sheets as set out in FIGS. 1 to 5 may be fitted together; FIG. 7 is a schematic section through a roof showing one embodiment of the invention; FIG. 8 is a schematic section through a roof showing a second embodiment of the invention; FIG. 9 is a schematic section through a roof showing a third embodiment of the invention; FIG. 10 is a detail showing a box gutter structure in accordance with the invention; FIG. 11 is a side view of a roof panel for establishing curved roofs; and FIG. 12 shows a variation in the roof panel. DETAILED OUTLINE OF THE INVENTION In FIGS. 1 to 6 is seen a roof panel 10 and its various features. The panel 10 comprises a outer sheet 11 spaced from an inner sheet 12 by a filler 13 to create a composite panel. The sheet 11 may be a corrugated sheet such as a metal corrugated sheet and it may be provided with an outer colour bond facing. The filler 13 may be a foam material such as a foam plastic. The roof panel 10 may have an over-hang 14 in its outer sheet at one end. The longitudinal edge 19 may be provided with an overhang also. The overhangs enable lay up with edges of adjoining panels butted together with the join overlapped by an overhang to seal the butted edges of adjoining panels. The longitudinal edges of the panel are provided with male and female edge connectors 17 and 18 fitted into the panel between the inner and outer sheets 11 and 12. The edge connectors come together as in FIG. 6 to hold the panel edges with an enclosed volume therebetween which can be used in a number of ways as set out below, such as for insertion of anchorages for fascias and for passage of electrical wiring. With joins formed this way, the edges of adjoining sheets 12 are butted neatly at 20 and over hang 19 overlaps the adjoining panel to seal the outer faces of the edge connectors 17 and 18. In FIG. 7 is seen a section through a hip roof showing two eave treatments. Roof panels 21 and 22 are joined at the hip to a beam structure 23 and weatherproofed with a ridge capping 24. The two roof panels 21 and 22 are held at the upper end by a suitable means such as hexagonal headed roofing screws 25 and 26 which may be applied to every second corrugation into the ridge beam 23 when the building is in a cyclone prone area. Similar connectors 27 may be fitted at the eaves connecting to an extrusion 32 at the top of a wall 31 which may have the character set out in prior specification number 582298. The eave in this arrangement might be finished with a timber barge 33 to which gutter brackets 34 may be attached to support a gutter in the usual way. An alternate finish to the eaves is shown at the right of FIG. 7 where timber blocks 28 are fitted into the space within the mated edge connectors between two adjoining roof panels. The ends of timber blocks 28 can be used for attachment of timber barge 29 and a length of shaped timber 30 may be fitted behind as shown. In FIG. 8 is seen a detail showing an internal wall 35 fitted beneath a roof panel 38 fixed by roofing screws 39 to extrusion 36 in similar manner to the external wall of FIG. 7. The extrusion 36 accommodates a tie down rod 37 and provides a channel for electrical wiring. Timber trims such as 40 may be applied to provide a suitable finish. FIG. 9 shows an extension of the roof at a different pitch between roof panels 41 and 42 with the extended end 43 of the outer sheet of panel 41 over lapped over the edge of panel 42 to provide a seal. Panel 41 is mounted to an outer wall as before. Panel 42 is mounted at its inner edge by roofing screws (as before) passed into a timber batten 44 which may be screwed to the wall. The span of panel 42 may be supported over posts 46 to which a longitudinal timber beam 47 may be bolted to receive roofing screws 48 through panel 42. In FIG. 10 is shown a detail through a valley between the lower ends of two roof panels 50 and 51 meeting over a gutter 52 which may be shaped as shown. The two roof panels 50 and 51 may be screwed (as before) into valley beams 54 and 53 with overhangs 55 and 56 draining into the gutter 52. In FIG. 11 is seen a side view of a roof panel which has been produced with a curve therein as indicated to enable curved roofs to be put in place. The elements of this panel may be as before except that the elements which extend along the longer length of the panel are provided with a curve therein. The longitudinal elements may be given a curve of chosen radius by roll forming, crimping, etc, as required in order that an element be given its chosen curvature. With the appropriate curves established, the elements may be bought together to form the finished curved roof panel which may then be used as described above with respect to the flat panels. The above described roofing system enables a variety of roof geometries to be achieved with a prefabricated roof panel which is able to be produced in a factory situation at light weight for convenient transport to a site and relatively easy handling in erection of a roof. The roofing system involves use of the panel in conjunction with a relatively small range of special extrusions and basic finishing timbers. In performance of the above invention there is achieved a roof which is crossed by channels through which electricians are able to provide concealed wiring. In the panel of FIGS. 1 to 6, a modification is possible wherein the male female extrusions may be applied along one or both short edges so as to enable the connection of roof panels end to end as well as side to side so as to span greater distances with channels running in both orthogonal direction's over the roof. In FIG. 12 the roof panel is configured as before except that a greater thickness of infill is used. The same edge extrusions as used before are bought into play with connectors 58 and 59 in panels with inner sheets 60 and 61 spaced from outer sheets 62 and 63 with infill 64 and 65 therebetween. The connectors 58 and 59 adjoin their inner sheets 60 and 61 with a body of foam 66 between the connectors and their outer sheets which extends to the adjoining edges of the panel. This layout uses the one same set of extrusions to produce panels which may thereby have greater thickness and as a consequence greater insulation properties. The outer layer may be a corrugated metal sheet glue fixed to a foam infill which may, in turn, be glue fixed to a fibrous cement lining. The connectors can be extruded aluminium. In production of the roof panel, the outer sheet may have any of the standard contours and be provided with any of the range of finishes as are applied to sheet metal products of this kind. Any profile which may be rolled or crimped to a curve might be used in producing the curved sheet. Any form of fill providing spacing of the inner and outer sheets can be used preferably with good thermal insulation properties and a foam fill has been found advantageous. The inner sheet might be chosen from a broad range for its decorative qualities or its ability to take a coat of paint etc. The inner sheets will be of a material able to take the curve required in curved roofs.

Claims: CLAIMS 1. A roof panel for establishing a roof wherein a plurality of the roof panels are laid edge to edge to panel over the roof, the roof panel comprising: a first outer sheet of weatherproof material; a second inner sheet; a layer of filler material between the first and second sheets; and edge connectors whereby adjoining roof panels may be interconnected one with the other, the first outer sheet being extended to overhang at least one edge of the roof panel to provide a seal to the join between adjoining panels by overlap of the adjoining panel edge by the overhang; the opposed edge connectors being opposed male and female elongate push together connectors extended the length of opposed edges to mate, in use, with a free space therein along the length of the connection. 2. A roof panel as claimed in Claim 1 wherein: the edge connectors are outwardly opened, generally H-shaped extrusions extended the length of the panel at opposed edges, the legs of the H-shaped section being extended into the panel to bond thereto with an open, essentially C-shaped configuration at the panel edge, the arms of the male C-shaped configuration slotting inside those of the female. 3. A roof panel as claimed in Claim 2 wherein: the arms of the male C-shaped configuration are stepped to provide a shoulder into which a protrusion on the arms of the female connector locks, in use, to lock the connectors together. 4. A roof panel as claimed in Claim 3 wherein: the edge connectors are recessed into the filler material such that only the mating arms of the male C-shaped configuration project beyond the panel edge. 5. A roof panel as claimed in Claim 4 wherein: the first outer sheet overhangs the edge from which the arms of the male C-shaped configuration project to establish the overhang at the least one edge. 6. A rood panel as claimed in any one of the preceding claims wherein: the first outer sheet is a corrugated metal glue fixed to a foam infill and the second inner sheet is a fibrous cement sheet glue fixed to the foam infill. 7. A roof panel as claimed in Claim 6 wherein: the edge connectors have a width which is less than the thickness of the layer of filler material, the edge connectors being adjoined to the second inner sheet. 8. A roof panel as claimed in any one of Claims 1 to 5 wherein: the edge connectors are provided at each pair of opposed edges of a rectangular panel. 9. A roofing system using roof panels as claimed in any one of Claims 1 to 7 wherein: the roof panel edge connectors provide a system of channels through the roof in which electrical and other services might be installed. 10. A roofing system as claimed in Claim 9 wherein: the channels receive therein timber blocks to which a barge or fascia may be fixed. 11. A roofing system as claimed in Claim 9 wherein: the roof panels are made in a length sufficient to span a roof from ridge beam to outer wall beam, the panels being held thereto by roofing screws. the upper end and roof screws thereat being overlaid by a ridge capping cover.

Inventors: EMBLIN ALAN GAYNE, KILPATRICK IAN ALAN, EMBLIN, ALAN, GAYNE, KILPATRICK, IAN, ALAN
Applicants: EMBLIN ALAN GAYNE, KILPATRICK IAN ALAN, EMBLIN, ALAN, GAYNE, KILPATRICK, IAN, ALAN
Application year: 1991
Main classification: E04D3
IPC codes: E04B7, E04D3, E04D13