Patent Publication Number: US-2007094999-A1

Title: Construction of convservatory roofs

Description:
This invention concerns improvements in and relating to construction of conservatory roofs.  
      Conservatory roofs are generally constructed by mounting glazing panels between roof beams supported at one end from a ridge beam and at the other end from an eaves beam. The roof beams are fixed at each end by means of screws/bolts through the roof beams into the ridge or eaves beam. The positioning of the roof beams has to be marked out to ensure that the roof beams are positioned accurately. If the roof beam positioning is incorrect, the aesthetic appearance of the roof may be impaired and a proper seal with the glazing panels may not be achieved. An object of this invention is to provide an improved way of securing roof beams in constructing a conservatory roof.  
      According to the invention it is proposed that roof beams be provided at least at one end a connector that can engage a cooperating formation of an eaves and/or ridge beam or a component of a roof system associated with either the ridge or eaves beam, preferably in a snap-fit manner. Preferably also the connectors will lock in place.  
      The invention further provides a conservatory roof comprising a ridge beam, an eaves beam and roof beams engaged with either or both of the ridge and eaves beams by means of connectors engage cooperating formations of the ridge and/or leaves beams, preferably in a snap-fit manner. Preferably also the connectors will lock in place.  
      A roof beam connector of the invention is preferably arranged to engage with a ridge or eaves beam or a component associated therewith in sliding fashion. Preferably the connector will have an end face that can rest against a corresponding face of the ridge or eaves beam or component associated therewith.  
      In a preferred embodiment of the invention a roof beam connector has a first connector part for hooking over part of a ridge or eaves beam or an associated component thereof. The connector preferably has a second connector part for engaging in a groove or slot of a ridge or eaves beam or an associated component thereof. The second connector part of the roof beam connector preferably comprises a lug on a resilient finger of the connector. The connector preferably has a third connector part comprising a foot for a groove or slot of a ridge or eaves beam or a component associated therewith.  
      Preferably the connector of the invention has means for attachment thereof to a roof beam end. The connector preferably has a stem that is shaped to receive a roof beam end or a stem that is shaped to fit into a roof beam end. Preferably the connector is adapted for use with roof beams of the type described in our co-pending application (P5139)  
      Such roof beams comprise a core profile of metal, a plastics member Fitted to the core profile and providing at least one ledge for carrying an edge of a sheet of glazing material and a cap mountable on the plastics member for retaining the glazing sheet thereon.  
      In a first preferred embodiment the core profile is a hollow extrusion and the plastics member is a sheath for the core profile. In another preferred embodiment, the plastics member is mountable on top of the core profile. For example, the plastics member may be a sliding fit or a snap fit on the top of the core profile. Reinforcement may be provided internally of the core profile, such as in the form of steel profiles inserted into the core profile. Such reinforcement is mainly intended for use with core profile lengths over a predetermined threshold for additional strength. The core profile and or the sheath are preferably shaped to reduce direct contact between them. For example, the sheath may have on its inner spaced surface ribs or the like to provide the only lines of contact with the core profile in certain regions. Additionally or alternatively, the core profile bar can have spaced feet or flanges that make end contact with the sheath.  
      A preferred sectional profile for the core profiles used in the invention is that of a trapezium having a narrow base and wider top. The sheath preferably has a corresponding profile.  
      The plastics member, such as the sheath, preferably has a pair of ledges one each side of a connection formation for attachment of the cap. The ledges preferably have gasket material, such as of rubber or other suitable elastomeric material, thereon for sealing against the underside of glazing material. The gasket material may be fitted in grooves or the like in the ledges or may be bonded to or co-extruded onto the ledges. Between the ledges and the connection formation, the sheath preferably has longitudinal channels to provide drainage passages in case of water penetration through the roof beam.  
      The connection formation of the plastics member, such as the sheath, is preferably in the form of a slot whose sides extend upwardly from the top of the sheath. The sides end with internal lips, whose top surfaces are preferably chamfered for ease of entry of a connection formation of the cap. The cap preferably has an, in use, depending connection formation having at least one pair and preferably two pairs of ribs thereon that can be pushed into the slot of the plastics member and retained there with glazing material sandwiched between the cap and the ledges of the plastics member. Two pairs of ribs are preferably provided on the cap connection formation, so as to allow the cap to be fitted at two different heights relative to the plastics member to accommodate glazing materials of different thickness. Alternatively, the cap may have a single pair of ribs and the slot of the plastics member may have two pairs of internal barbs or the like to allow the cap to be fitted over two different thicknesses of glazing material.  
      The cap is preferably generally of T-section, the stem of the T providing the connection formation. The cross bar of the T-section preferably has gasket material at ends thereof, such as of rubber or other suitable elastomeric material, for sealing against the topside of glazing material. The gasket material may be fitted in grooves or the like in the ends of the cap crossbar or may be bonded to or co-extruded onto the ends thereof. The cross bar of the cap is preferably arcuate and ends thereof preferably depend to meet the glazing material.  
      A ridge beam for use with roof beam connectors of the invention is preferably a hollow extrusion having on one or both sides a formation for receiving a connector of the invention. The formation preferably provides a sloping face against which an end face of the connector can abut. Above the end face the ridge formation preferably has a ledge over which a hook formation of the connector can sit. The end face of the ridge formation preferably also includes a slot or groove to receive a lug or the like of a resilient finger of the connector. The lug preferably snaps into the slot or groove when the connector is attached to the ridge beam, to prevent the connector being lifted out of engagement with the ridge beam formation. Extending outwardly from the end face of the ridge beam formation, there is preferably a channel shaped flange to receive a foot of the connector.  
      To facilitate erection of a conservatory roof using connectors of the invention, it is further proposed that the ridge beam connection formation be notched at the required intervals for positioning of the roof beams. Such notches are preferably provided in the ledge for the hook formation of the connector. Then the connector can have a nib on the underside of the hook formation to locate in an appropriate notch of the ridge connector formation. This will allow the positioning of the roof beams to determined in the factory and the appropriate notches cut or formed, so that erection of the roof on site is facilitated.  
      An eaves beam for use with roof beam connectors of the invention is preferably a hollow extrusion having on one side a formation for receiving a connector of the invention. The formation preferably provides a sloping face against which an end face of the connector can abut. Above the end face the eaves formation preferably has a ledge over which a hook formation of the connector can sit. The end face of the eaves formation preferably also includes a slot or groove to receive a lug or the like of a resilient finger of the connector. The lug preferably snaps into the slot or groove when the connector is attached to the eaves beam, to prevent the connector being lifted out of engagement with the eaves beam formation. Extending outwardly from the end face of the eaves beam formation, there is preferably a channel shaped flange to receive a foot of the connector.  
      To facilitate erection of a conservatory roof using connectors of the invention, it is further proposed that the eaves beam connection formation be notched at the required intervals for positioning of the roof beams. Such notches are preferably provided in the ledge for the hook formation of the connector. Then the connector can have a nib on the underside of the hook formation to locate in an appropriate notch of the eaves connector formation. This will allow the positioning of the roof beams to determined in the factory and the appropriate notches cut or formed, so that erection of the roof on site is facilitated.  
      At corners of a conservatory roof, it may be convenient to provide eaves beam connectors rather than join lengths of eaves beam together directly. Such eaves beam connectors will preferably have formations adapted to receive the roof beam connectors of the invention in a similar manner.  
      For connection of roof beams at the end of the ridge beam it is proposed to provide a ridge end component having locations adapted to receive roof beam connectors of the invention in a similar manner to the ridge beam itself. It is envisaged that the ridge end component will have specific locations for roof beam connectors at fixed radial angles to each other. The ridge end component will preferably have a stem adapted to fit within the end of the ridge beam.  
      Where a ridge beam is to be connected to an existing wall, a flashing plate is preferably provided, over which flashing material can be provided that is fixed into the existing brickwork. The flashing plate is preferably locatable on the ridge cap. The flashing plate preferably has scribed lines or grooves to demark removable strips of the plate to take it to a height below a suitable brick course level for the flashing material. 
    
    
      This invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:  
       FIG. 1  is a plan view of a typical Victorian style conservatory roof;  
       FIG. 2  is a plan view of a typical Georgian style conservatory roof;  
       FIG. 3  is an end view of part of a conservatory roof showing a roof beam for use with a connector of the invention;  
       FIG. 4  is and end view of a ridge beam and roof beam connectors according to the invention;  
       FIG. 5  is a perspective view of the ridge beam and connectors of  FIG. 4 ;  
       FIG. 6  shows the ridge of  FIGS. 4 and 5  with decorative cappings added;  
       FIG. 7  is an end view of the ridge shown in  FIG. 6 ;  
       FIG. 8  is a view from below of the ridge of  FIG. 6 :  
       FIG. 9  shows the ridge of FIGS.  4  to  6  with a ridge end connector component;  
       FIGS. 10, 11  and  12  are respectively plan, front and side elevational views of an alternative ridge end connector component;  
       FIGS. 13 and 14  are perspective views from above and below the ridge cap at a wall end of the ridge;  
       FIG. 15  shows the ridge end from above;  
       FIG. 16  is a section through an eaves beam for a conservatory roof of the invention;  
       FIG. 17  shows the eaves beam with a roof beam connector in section;  
       FIG. 18  is an external view of the eaves beam of  FIG. 16  with a roof beam connector attached;  
       FIG. 19  is an internal view of the eaves beam of  FIG. 16  with a roof beam connector attached;  
       FIG. 20  shows a right angle eaves corner arrangement from the interior with roof beam attached;  
       FIG. 21  is an external view of the corner arrangement of  FIG. 20  without the roof beam;  
       FIG. 22  is an internal view of the corner arrangement of  FIG. 20  without the roof beam;  
       FIG. 23  is an internal view of a 135° eaves corner arrangement;  
       FIG. 24  is an external view of the eaves arrangement of  FIG. 23 ; and  
       FIG. 25  is an internal view of the eaves arrangement of  FIG. 23  with internal trim in place. 
    
    
      Referring to  FIG. 1  of the drawings a typical Victorian conservatory roof  1  has a first part  2  having a central ridge  3  with rectangular roofing panels  4  sloping down to an eaves beam  5  and supported between roof beams  14 . One end of the ridge is abutted against a wall and at the opposite end of the ridge is a radius end  6  having its roof formed of triangular roofing panels  7 .  
       FIG. 2  of the drawings shows a typical Georgian style hipped roof  8  having a first part  9  having a ridge  10  and transom roof beams  14  extending at right angles therefrom down to eaves  12 . The hipped part  13  of the roof has a pair of hipped roof beams  15  extending to corners of the roof and jack rafters  16  connecting those beams  15  to the eaves.  
      Turning to  FIG. 3  of the drawings a hipped roof beam  15  comprises a core profile  17  of hollow section extruded from aluminium, an extruded plastics sheath  18  fitted over the core profile and a cap  20  mounted on the sheath and trapping edges of the glazing panels between the sheath and the cap. The core profile is a trapezium in section having a narrower base  22  than top  24 . The base has along opposite edges ribs  26  that act as feet for the base and provide minimal contact between the base and the sheath in that region. The top  24  of the core profile beam has a pair of flanges  27  extending upwardly and outwardly therefrom that provide surfaces  28  that contact the inside surface of the sheath.  
      The sheath has a corresponding sectional profile to that of the core profile. Its sidewalls  30  each have a longitudinal rib  32  that serves to space the core profile from the sheath to minimise contact between them. Similarly, the top wall  34  of the sheath has depending ribs  35  again that space the top wall of the core profile from the inside surface of the sheath top wall. Within its top corners the sheath has a pair of ledges  36  that form channels  38  to locate the flanges  26  of the core profile.  
      The top wall  34  of the sheath has near its side edges gasket material  35  of rubber or other suitable elastomeric material co-extruded or bonded thereon for sealing against the underside of glazing panels  12  mounted on the roof beam. Centrally of the top wall  34  of the sheath is an upstanding connection formation  40  for attachment of the cap to the sheath. Either side of the formation  40  is a groove  42  providing a drainage passage for any water or condensation that may collect on the sheath.  
      The connection formation  40  is in the form of a slot having a relatively narrow opening between lips  46  at the top ends of the slot sides  48 . The cap  20  is generally T-shaped in section and has an arcuate top  50  and a depending limb  52  that has two pairs of barbs  54  on opposite sides thereof. The barbs are shaped so as to pass relatively easily into the slot  40  but to be difficult to remove or displace therefrom. Two pairs of barbs are provided to allow the cap to accommodate two different thicknesses of glazing panel. The cap top has its ends  58  turned downwards and gasket material  59  of rubber or other suitable elastomeric material co-extruded or bonded onto the ends  58  for sealing against the top surfaces of the glazing panels. Because the cap is extruded of plastics material it has some inherent resilience, so that when pushed down onto the sheath and located thereon, the positioning of the barbs will enable the cap ends to exert holding and sealing pressure on the glazing panels.  
      It is to be noted that the transom or radius end roof beams  14  are of similar construction to the roof beams  15  but with caps that have shorter sides compared to sides  58  and a shorter stem  52 .  
      The hollow nature of the roof beam bar allows for fitting of roof beam plastics connectors  70  that can cooperate with formations of a ridge beam and eaves beam ( 72 ,  74 ) for ease of fitting. The connectors  70  permit snap fitting with cooperating formations of the ridge and eaves beams. The connectors  70  may alternatively be made of metal.  
      In FIGS.  4  to  8  of the accompanying drawings, a ridge beam  72  for a conservatory roof is formed as a hollow aluminium extrusion having a base  76 , a top  78  and sides  80  and  82 . The base  76  has at each side a depending L-shaped ledge  84 , the ledges providing attachment locations for a decorative cover  86  below the ridge as shown in  FIGS. 6 and 7 . The base also has a further pair of L-shaped ribs  88  that face each other and provide a channel for receiving a wedge or nut  90 , which is part of an arrangement for holding down top decorative cover  92  on the ridge, which will be described in detail below.  
      The sides  80  and  82  of the ridge beam are shaped to provide roof beam connector receiving formations. These formations comprise flanges  96  extending laterally from the bottom of each of the sides  80  and  82  and are in the form of upwardly open channels. A minor lower part  98  of each side  80  and  82  protrudes relative to the major upper part of each side. Spaced above the protrusions  98  is a second larger box-section protrusion  100  having a bottom wall that with the protrusion  98  forms a slot  102 , an outer abutment face  104  and a top  106  having an outer higher part  108  and an inner lower part  110  that forms with side  80  or  82  a channel  112 .  
      The roof beam connectors  70  have a stem  120  that fits into the end of a core profile  16 . The stem  120  has bolt holes  122  for receiving bolts (not shown) to fix the connector in the end of the roof beam. The ribs  26  of the core profile of the roof beam provide turning restraint for the bolt heads or nuts. The connector  70  has connecting formations to allow it to be connected to the connector formations of the ridge  72 . The connector formations comprise a hook  124  that fits over the top  106  to sit in channel  112 , a foot  126  to sit in the channels of flanges  96  and a lug  128  on resilient finger  130  to snap fit into the slot  102  (see also  FIG. 14 ). In forming a connection between a connector  70  and the ridge beam  72 , the opposite end of the connector  70  to the stem has a face  130  that is slid down the abutment face  104  of the ridge beam until the hook and the foot of the connector sit in their appropriate channels and the lug snaps into its groove. The connector cannot then be released without retraction of the lug from its groove.  
      In order to ensure correct positioning of a connector  70  and hence its roof beam on the ridge, the top  106  of the box-section protrusion  100  is notched at appropriate intervals and the underside of the hook  124  of the connector  70  has a nib  132  that locates in the appropriate notch. Thus, the ridge beam can be prepared in the factory with notches at the correct intervals, to facilitate erection of the roof on site.  
      The top  106  of the protrusion  100  has its outer higher part  108  formed as a longitudinal channel  138  with its sides having inner lips  140 . These channels are to receive plastics sealing trims  142  between the roof beams (see  FIG. 7 ).  
      The top  78  of the ridge beam  72  has a pair of generally upstanding flanges  150 , on which locate rain baffles  152 . The rain baffles  152  are generally L-shaped, one leg  154  having a slot to locate the rain baffle on a flange  150  and a second leg  156  having co-extruded gasket material strips  158  and  160  extending normally to the end of the leg  156 . The cover  92  sits on the second legs of the rain baffles  152  and is held down by captive bolts  162 . The bolts have a rectangular head  164  with lips  166  on its shorter sides. The bolts have a stem  168 , which has a lower part serrated on opposite sides for receiving a wedge shaped retaining element  90  with a generally U-shaped slot therein having in the base of the U-shaped slot a web that is engageable in a serration  172  of the stem  168  of the bolt  162  (see  FIG. 8 ).  
      On the underside of the cover  92  is a channel formation  174  having returned edges  176 . The channel  174  is wide enough to receive the head of a bolt with its longer sides parallel thereto, when the bolt can be turned through 90°, so that the lips  168  of the head of the bolt are retained by the returned edges of the channel  174 . At its other end the bolt stem passes through an aperture in the base  76  of the ridge beam. The flanges  88  extending below the base provide a slot for receiving the wedge shaped element  90 . The element has on its sides retaining ribs, one of which extends along the full length of the element and the other being shorter, whereby the element can be maneuvered into the slot. Once there, the element is slid along to engage and retain the stem of the bolt.  
      The decorative cover  92  has an aesthetic profile but it is also capable of receiving in snap-fit fashion other decorative ridge elements, such as cresting pieces.  
      Also in  FIGS. 6 and 8  of the drawings can be seen a generally U-shaped trim  93  that snap fits under the roof beam  16  to conceal any gaps due to cutting tolerances.  
      Referring now to FIGS.  9  to  12  of the accompanying drawings, at a ridge end remote from a wall against which a conservatory is erected, the ridge beam is provided with a ridge end member moulded of plastics material or alternatively made of metal.  FIG. 9  shows a ridge end member  200 A with provision for attachment of three radially arranged roof beams and FIGS.  10  to  12  show a ridge member  200 B for receiving four radially arranged roof beams. The ridge end members  200  each have a stem  202  shaped to be slidingly received in the end of a ridge beam  72 , where it may be secured by means of screws through the ridge beam or by any other suitable securing means, such as bolts or by crimping.  
      The ridge end members have locations generally designated  204  for receiving roof beam connectors  70  of the type already described above. Such locations  204  comprise a channel closed at its bottom end and having a base  206  with returned side edges  208 . The side edges  208  provide lateral restraint and guidance for the connectors. Each location provides a lower slot  210  for the foot of a connector  70 , a ledge  212 , past which the lug of the connector can snap as the connector is lowered, and the hook of the connector can sit over the free edge of the base  206 .  
      At the wall end of the ridge beam, as shown in  FIGS. 13 and 14  of the drawings, there is provided a flashing trim  310 . The flashing trim  310  has a wall plate  312  and a connector part  314  projecting therefrom. The wall plate  312  has a series of parallel scribed lines or grooves  316 , whereby the height of the plate can be altered to match a suitable brick course height, at which flashing material to overlie the wall plate is to be fixed. The connector part  314  is shaped to be a snap-fit onto the top of the ridge cap  92 .  
      As shown in  FIG. 15  of the drawings at the ridge end of the roof a cover trim  320  is provided over the ends of the roof beams. The trim is shaped to the contours at the ridge end and has a groove  322  in its underside to receive silicone sealant, which is spread by the action of pressing down the trim onto the tops of the roof beams.  
      FIGS.  14  to  22  illustrate arrangements at the eaves of a conservatory roof according to the invention. In constructing a conservatory roof an eaves beam  74  is fixed on top of windows or walls forming sides of the conservatory. The eaves beam  74  is formed as a hollow aluminium extrusion and has a base  242 , an outer wall  244 , an inner wall  246  and a sloping top  248 .  
      The outer wall  244  has upper and lower longitudinal slots  250 ,  252  for receiving snap-in external cladding  254  of plastics material. The inner wall  246  is shaped in a similar fashion to the side of the ridge beam  72  to provide locations for attachment of roof beam connectors  70 . Thus, the inner wall  246  has a flange  256  extending therefrom in the form of a channel to receive the foot of a connector  70 . Above the flange is a groove  258  for receiving the snap-in lug of a connector  70  and the top of the eaves beam provides a location over which the hook part of a connector  70  can sit. As with the ridge beam, locations for the connectors are provided in the top of the eaves beam in the factory in the form of notches at predetermined intervals, in which the nibs of connectors can locate.  
      Between the roof beams internal plastics cladding pieces  260  and  262  are added to the eaves beam. The cladding piece  260  fits over the top of the eaves beam and locates in a channel  266  in the top of the eaves beam. On top of the cladding piece  260  is a strip of double-sided tape  261 , onto which glazing panels will sealingly sit. The cladding  260 , being generally U-shaped in that region will be able to move as the glazing expands and contracts in different temperature conditions. Externally of the roof, the cladding piece  260  has co-extruded gasket material  270  along its depending edge to form a weather and thermal seal with the external cladding  254 .  
      The external cladding has upper and lower grooves  290  and  292  that provide locations for attachment of gutter brackets. Conventionally, the presence of gutters at the eaves of a conservatory roof will provide some thermal insulation. However, with the arrangement illustrated gutters are not essential and the presence of the external cladding  254  can provide thermal insulation for the eaves of the roof.  
      The second internal cladding piece  262  locates in a groove  272  on the underside of flange  256  and in one or other of three grooves  274  in an extension  276  of the base of the eaves beam. Three grooves are provided, so that the cladding piece position can be adjusted relative to the position of the window frame, on which the eaves beam is mounted, in order to accommodate on site building tolerances.  
      At corners of the conservatory roof plastics or metal connectors  280  are used to join eaves beam lengths. These connectors  280  are shaped to slidingly fit into ends of eaves beams and also to receive roof beam connectors  70  (see FIGS.  18  to  22  of the drawings). FIGS.  18  to  20  show a right angle corner  280 A, such as in a Georgian style conservatory roof and  FIGS. 21 and 22  show a 135° corner  280 B, such as in a Victorian style conservatory roof. The corner connectors  280  have locations for roof beam connectors  70  of a similar type to those provided in the ridge beam end pieces. The provision of corner connectors means that eaves beam sections can be square cut at their ends, which makes preparation work easier and reduces wastage.  
      Internally of corners of the roof at the eaves are corner pieces  300  that conceal junctions between the roof beams and the internal cladding pieces (see  FIG. 23 ). That allows for tolerances in the cutting of roof beams and cladding pieces.  
      The ridge beam, roof beams and eaves beams can all be cut to length in the factory and have roof beam positions cut in the ridge and eaves beams as appropriate. Also, the roof beams can be fully assembled in the factory, i.e. with connectors  70  added and claddings and weatherproofing trims for the eaves and ridge beam can be fitted in the factory, because the positioning of the roof beams has already been determined and allowed for. Altogether this will help to simplify and speed up the assembly of a conservatory roof on site.