Patent Description:
The present invention also relates to a support group, a mechanical machining group, a pressing method for making the anchoring bracket, and the method for attaching the guide, or anchoring device, to the roofing.

The term "roofing" is intended to refer to both industrial and civil/residential construction. In particular, "roofing" may mean the roof of a building or the roofing of an interior space (e.g., attic, loft, etc.).

As is well known, these days it is becoming increasingly common to install photovoltaic systems for obtaining clean energy or solar thermal systems for heating water. It is also required that gangways or other installations such as air conditioning or other equipment are installed on roofings, especially in the case of industrial construction.

There are numerous fastening systems on the market, for example, for photovoltaic systems and installations of various kinds to be applied to corrugated roofing. It is known to the person skilled in the art that the phrase "corrugated roofing" means roofing made with at least one pair of corrugated sheets.

Currently, the fastening systems consist of guides that are fastened to the roofing using screws, and, on these guides, supports of various configurations are then secured to which the anchoring elements of the photovoltaic panels are finally engaged.

Other systems involve plates that are fastened, again by screws, to the roofing to which guides are then applied to accommodate supports and anchoring devices for panel structures.

Still other systems involve the attaching of pipes to the roofing to which bearings are fastened on which plates are then positioned to which supports are applied for the subsequent engagement of the panels. Also in this case, the pipes are engaged to the underlying structure by screws.

All the systems illustrated above, as well as many others used, make use of a variety of guides, brackets, profiles, supports, and more, but the systems are all characterized by a single common denominator, which is the drilling of corrugated sheets, metal sheets, and/or other materials used for the roofing.

The problem that makes the systems illustrated above unreliable and ineffective over time is due to the multiple holes that are made in the corrugated roofing sheets for anchoring the various fastening systems of the panels. The high number of punctures causes water infiltration phenomena that are difficult to resolve and may cause damage to the underlying structures if not discovered in time.

To prevent water infiltration, the systems previously mentioned provide for gaskets, which may be made of rubber, sponge, neoprene, or be silicone-based gaskets, which, however, over time, are subject to cracking, crazing, splitting and drying due to harsh winter temperatures and high summer temperatures. As an example, it should be noted that in the summer period, with radiation temperatures of <NUM>-<NUM>, a metal sheet may reach <NUM>-<NUM>; as a result, elastomeric materials loose sealing capacity because they soften considerably and, at the same time, dry out, reducing their insulating function. In winter, on the other hand, low temperatures stiffen elastomeric materials to the point that gaskets often crystallize and, following storms, wind, and/or stress, crack and crumble, leaving screw holes unprotected and uninsulated. Furthermore, changing seasons and weathering cause wear and tear on the gaskets, which gradually begin to allow moisture and water to seep in, which, within a short time, causes considerable damage not only to the roofing but also to the underlying structures.

In addition to that what has been explained so far, when an operator decides to remove solar panels from the roof because they have reached the end of their operational life or decides to replace them because they are damaged, for example due to a heavy hailstorm, the roofing has to be completely redone as it is full of holes that may not be used for a new system or new panels, since it is not possible for the screws inserted in the fastening holes to adequately tighten the structure, and thus it is not possible to ensure the tightness and stability of both the structure and the system.

These situations involve considerable operation and maintenance costs in addition to the fact that the infiltration is difficult to resolve without dismantling the system that triggered it.

Among the various ways of fastening panels, gasket riveting systems are also used, but these have shown poor reliability and limited security, as rivets tend to move as a result of stress from rain and wind, as well as temperature changes. Over time, the rivet movements tend to wear out the gaskets and as a result trigger water infiltration phenomena.

The systems outlined above, while yielding results, do not ensure tightness over time; moreover, each panel installation provides for its own fastening system, and the holes in the roofing may never be reused.

As previously mentioned, in recent times, there has been a need to also install other structures on roofings, for example, gangways, scaffolding or the like, which may also be temporary installations or used for short periods during maintenance, inspection or other operations; therefore, the anchors to the underlying structure must not puncture and thus ruin the roofing sheets.

A possible solution to the above-mentioned problems has been disclosed in <CIT> (<CIT>), filed by the same Applicant, where an anchoring bracket consists of an L-shaped profile provided with a folded edge at the free end, while at the opposite end there is a molded sector to be interposed between the pair of corrugated sheets. The molded sector comprises a fastening hole that may be engaged by the screws already provided for the mutual fastening of the sheets.

Disadvantageously, the folded edge of the free end at least partially covers the fastening hole and thus makes the operations to couple the bracket to the corrugated sheets complicated.

The object of the present invention is substantially to solve the problems of the prior art by overcoming the above-described difficulties by means of an anchoring bracket that allows the roofing's corrugated sheets not to be pierced.

A second object of the present invention is to construct an anchoring bracket capable of being used on both new and existing roofing.

Another object of the present invention is to provide an anchoring bracket that may adapt to any type of corrugated sheet on the market.

Another object of the present invention is to provide an anchoring bracket that has a limited footprint and is easily and smoothly assembled and disassembled even by unskilled personnel without losing its functional and practical features.

A further object of the present invention derives from being able to have an anchoring bracket that allows for high operational accuracy and significant infiltration sealing security.

Finally, an object of the present invention is to make an anchoring bracket of simple construction and good functionality.

These objects and others, which will become more apparent in the course of the present description, are substantially achieved by an anchoring bracket, a support group, a mechanical machining group, a pressing method, and a method for fastening the guide (or anchoring device) to the roofing, as claimed hereinafter.

Further features and advantages will become more apparent from the detailed description of an anchoring bracket, a support group, a mechanical machining group, a pressing method, and a fastening method, according to the present invention, made hereinafter with reference to the attached drawings, provided for illustrative purposes only and therefore not limiting, wherein:.

In the following description, elements common to the various embodiments represented in the drawings are indicated with the same reference numerals.

In said drawings, the reference numeral <NUM> indicates an anchoring bracket according to the invention as a whole.

In the invention, the anchoring bracket <NUM> for a roofing <NUM> comprises a sheet engaging portion <NUM>, an installation engaging portion <NUM>, and a connecting portion <NUM>.

The sheet engaging portion <NUM> is suitable for being interposed between a pair of corrugated sheets <NUM>, <NUM>. Furthermore, this sheet engaging portion <NUM> is suitable for being coupled and fastened to a first sheet <NUM> and a second sheet <NUM> of the aforesaid pair of corrugated sheets <NUM>, <NUM>. In particular, the coupling and fastening of the sheet engaging portion <NUM> to the first <NUM> and second <NUM> sheets may be achieved by a mechanical connection and/or shape coupling and/or force coupling. The mechanical connection is either removable, as in the case of bolting, or non-removable, as in the case of welding or bonding.

The installation engaging portion <NUM> is configured as a support suitable for fastening a guide <NUM> or an anchoring device. Examples of guides and anchoring devices are beams, profiles, pipes and the like.

An installation <NUM>, such as a photovoltaic system, an air conditioning system, a solar thermal system, a gangway, a scaffolding or any structure installable on the roofing <NUM>, is mountable on the guide <NUM> (or on the anchoring device).

The connecting portion <NUM> connects the sheet engaging portion <NUM> to the installation engaging portion <NUM>; preferably, the connection between the connecting portion <NUM> and the sheet engaging portions <NUM> and the installation engaging portions <NUM> is seamless.

The connecting portion <NUM> is folded to form a housing pocket <NUM> suitable for accommodating an end portion <NUM> of the first <NUM> or second <NUM> sheet.

Preferably, the anchoring bracket <NUM> is made from a metal sheet that has been appropriately punched and deformed to obtain the final shape of the anchoring bracket. Therefore, the connecting portion <NUM> is obtained by folding the metal sheet so that it forms a pair of walls <NUM>, <NUM> facing each other that define the housing pocket <NUM> (<FIG>).

In accordance with an embodiment illustrated in the attached <FIG>, the housing pocket <NUM> has a pocket width L that is such to allow the insertion with clearance of the end portion <NUM> of the first <NUM> or second <NUM> sheet into such housing pocket <NUM>.

Preferably, the pocket width L is between <NUM> and <NUM>.

It should be noted that the pocket width L represents the maximum distance separating the pair of walls <NUM>, <NUM> from each other and is measured orthogonally with respect to a development direction of the depth of the housing pocket <NUM>.

According to the embodiment depicted in <FIG>, the sheet engaging portion <NUM> comprises a plate-like element <NUM> connected to the connecting portion <NUM> and lying on a roofing coupling plane Pc.

Such a plate-like element <NUM> is suitable for being interposed between the first <NUM> and second <NUM> sheets so that, by inserting the anchoring bracket <NUM> between the pair of corrugated sheets <NUM>, <NUM>, the weight of the overlying first sheet <NUM> limits the movement of the anchoring bracket <NUM> with respect to the underlying second sheet <NUM>.

For the purposes of this discussion, the terms "overlying", "underlying" and derivatives thereof are intended to refer to the anchoring bracket <NUM> in its condition of use.

Preferably, rather than limiting, the weight of the overlying first sheet <NUM> locks and holds the anchoring bracket <NUM> in place.

In particular, the end portion <NUM> of the overlying first sheet <NUM> is insertable into the housing pocket <NUM>.

In an embodiment not shown in the figures, the sheet engaging portion <NUM> also comprises an inclined element connected to the plate-like element <NUM>. The inclination of the aforesaid inclined element is such to conform the sheet engaging portion <NUM> to the shape of the pair of corrugated sheets <NUM>, <NUM> whereby the sheet engaging portion <NUM> may be interposed with shape coupling between the pair of corrugated sheets <NUM>, <NUM>. In other words, the geometry of the plate-like element <NUM> and the inclined element follow the shape of the pair of corrugated sheets <NUM>, <NUM> to allow the interposition of the sheet engaging portion <NUM> between the first <NUM> and the second <NUM> sheet.

According to the embodiment shown in the attached <FIG> and <FIG>, a sheet engaging hole <NUM> is obtained on the sheet engaging portion <NUM>. When the anchoring bracket <NUM> is inserted between the pair of corrugated sheets <NUM>, <NUM>, this sheet engaging hole <NUM> is suitable for being coaxially aligned with a first coupling hole <NUM> and a second coupling hole <NUM> obtained in the first <NUM> and second <NUM> sheets, respectively. The anchoring bracket <NUM> is suitable for being secured to the pair of corrugated sheets <NUM>, <NUM> by at least one screw <NUM> engageable with the sheet engaging hole <NUM> and with said first <NUM> and second <NUM> coupling holes.

Preferably, the sheet engaging hole <NUM> is obtained on the sheet element <NUM>.

In accordance with the embodiment depicted in the attached <FIG> and <FIG>, the sheet engaging portion <NUM> and the connecting portion <NUM> form a trapezoidal profile. In particular, the connecting portion <NUM> coincides with an inclined section, and the sheet engaging portion <NUM> coincides with a horizontal section of the trapezoidal profile.

In the present case, the connecting portion <NUM> lies on an inclined plane, and the housing pocket <NUM> defines the aforesaid inclined section. Therefore, the development direction of the depth of the housing pocket <NUM> also lies on said inclined plane. On the other hand, the horizontal section of the trapezoidal profile coincides with the plate-like element <NUM> lying on the roofing coupling plane Pc.

The trapezoidal profile is visible by observing the anchoring bracket <NUM> from the side, or by sectioning the sheet engaging portion <NUM> and the connecting portion <NUM> along a shear plane C orthogonal to the roofing coupling plane Pc.

Furthermore, the trapezoidal profile is suitable for defining a shape coupling with the pair of corrugated sheets <NUM>, <NUM>. In other words, the trapezoidal profile is counter-shaped to the pair of corrugated sheets <NUM>, <NUM> to be interposed therebetween where the first sheet <NUM> overlaps the second sheet <NUM> (<FIG>).

According to the embodiment shown in the attached <FIG>, the installation engaging portion <NUM> comprises a support element <NUM> in an overturned "L" shape. Said support element <NUM> comprises a first arm <NUM> connected to the connecting portion <NUM>, and a second arm <NUM> orthogonally connected to said first arm <NUM> so as to be arranged parallel to the sheet engaging portion <NUM>.

Preferably, the first arm <NUM> lies on a reach plane PL orthogonal to both the shear plane C and the roofing coupling plane Pc. Therefore, the reach plane PL, the roofing coupling plane PC and the shear plane C form a triplet of Cartesian planes orthogonal to each other, and the anchoring bracket <NUM> is oriented in space along the aforesaid triplet of Cartesian planes.

In particular, the second arm <NUM> extends on the opposite side with respect to the sheet engaging portion <NUM>; therefore, the second arm <NUM> does not cover the sheet engaging portion <NUM>, i.e., there is no overlap between the second arm <NUM> and the sheet engaging portion <NUM>.

Furthermore, this second arm <NUM> is configured as a fastening plate for the guide <NUM> or the anchoring device on which the installation <NUM> is mountable.

Preferably, the second arm <NUM> is parallel to the roofing coupling plane Pc where the plate-like element <NUM> lies.

In one embodiment, the sheet engaging portion <NUM> comprises the plate-like element <NUM>, the installation engaging portion <NUM> comprises the support element <NUM>, and the connecting portion <NUM> comprises the pair of walls <NUM>, <NUM> facing each other.

According to the embodiment depicted in accordance with the attached <FIG>, the installation engaging portion <NUM> comprises at the free end an edge <NUM> orthogonally folded to stiffen the anchoring bracket <NUM> and promote the grip of said anchoring bracket <NUM> by an operator.

Preferably, this edge <NUM> is obtained at the free end of the second arm <NUM> and is bent so as to lie parallel to the first arm <NUM>, i.e., the reach plane PL. Furthermore, the edge <NUM> is bent toward the connecting portion <NUM>.

In accordance with an embodiment illustrated in the attached <FIG> and <FIG>, an installation engaging hole <NUM> is obtained on the installation engaging portion <NUM>, suitable for being engageable by a clamping screw <NUM> for fastening either the guide <NUM> or the anchoring device on which the installation <NUM> is mountable, to the bracket <NUM>.

Preferably, the installation engaging hole <NUM> is located on the second arm <NUM>.

In the present case, the anchoring bracket <NUM> is usable with any corrugated sheet configuration and made with profiles of metal material, preferably sheet metal. These profiles vary in thickness depending on the type of roofing <NUM> and/or the load to be supported by the anchoring bracket <NUM>.

Preferably, the housing pocket <NUM> is substantially lying on the inclined plane to conform to the inclination of the end portion <NUM> of the first <NUM> or second sheet <NUM> to be inserted inside the housing pocket <NUM>.

In one embodiment, the anchoring bracket <NUM> is painted in any color to adapt aesthetically or blend in with the roofing <NUM> or the installation <NUM> to be supported.

Preferably, the anchoring bracket <NUM> is made in one piece, i.e., it is not made by joining several parts coupled together by welding/bonding.

Alternatively, the anchoring bracket <NUM> is obtained as a single piece, i.e., obtained by joining a plurality of pieces seamlessly coupled together. For example, the plurality of pieces may comprise a plurality of metal sheet portions that are welded or bonded together so as to obtain the anchoring bracket <NUM>.

In accordance with the present invention, a support group <NUM> comprising the pair of corrugated sheets <NUM>, <NUM>, the anchoring bracket <NUM> and at least one screw <NUM> is also disclosed. This screw <NUM> is engaged to the sheet engaging hole <NUM> obtained on the sheet engaging portion <NUM>, to the first coupling hole <NUM> obtained on the first sheet <NUM>, and to the second coupling hole <NUM> obtained on the second sheet <NUM>.

According to a further aspect of the present invention, an installation assembly comprising the support group <NUM> and the guide <NUM> or the anchoring device is also disclosed on which the installation <NUM> may be mounted.

In accordance with the present invention, a mechanical machining group is also proposed for making the anchoring bracket <NUM>. This mechanical machining group comprises a cutting and bending station <NUM> and a deformation unit <NUM>.

The cutting and bending station <NUM> is suitable for cutting a metal sheet <NUM> having a main extension along a longitudinal axis L, so as to obtain a desired longitudinal length. Furthermore, the cutting and bending station <NUM> comprises a deformation punch <NUM> suitable for bending a free end of the metal sheet <NUM>, so as to obtain the edge <NUM> orthogonally folded with respect to the longitudinal axis L.

Preferably, the width of the metal sheet <NUM> is measured along a transverse axis T orthogonal to the longitudinal axis L, and this width is already coincident with the final width of the anchoring bracket <NUM>.

The deformation unit <NUM> is suitable for giving the metal sheet <NUM> the final shape of the anchoring bracket <NUM>; furthermore, the deformation unit <NUM> in turn comprises a first station <NUM>, a second station <NUM>, and a third station <NUM>.

The first station <NUM> comprises a first die <NUM>, a counter-flange <NUM>, and a first punch <NUM>.

The first die <NUM> is suitable for acting as a support for the metal sheet <NUM>, while the counter-flange <NUM> is suitable for acting as an abutment surface for the folded edge <NUM>. In particular, when the metal sheet <NUM> is resting on the first die <NUM>, the edge <NUM> abuts against the counter-flange <NUM>, so that the deformation of the metal sheet <NUM> by the first punch <NUM> may then be carried out.

The first punch <NUM> is shaped to deform the metal sheet <NUM> so as to obtain a pilot bend <NUM>' in a connecting portion <NUM>. Preferably, the pilot bend <NUM>' is either "V" or "U" shaped.

The shape of the first punch <NUM> is suitable for simultaneously bending also the installation engaging portion <NUM> so as to define the first arm <NUM> and the second arm <NUM> and give said installation engaging portion <NUM> an overturned "L" shape.

The second station <NUM> comprises a second punch <NUM> suitable for accentuating the pilot bend <NUM>' to obtain a semi-machined pocket defined by the pair of walls <NUM>, <NUM> facing each other.

Preferably, the second station <NUM> also comprises a second die <NUM> complementary to the second punch <NUM>.

The third station <NUM> comprises a third punch <NUM> suitable for compressing the semi-machined pocket so as to obtain the housing pocket <NUM>. In particular, the distance between the pair of walls <NUM>, <NUM> is such that the housing pocket <NUM> is suitable for accommodating the end portion <NUM> of the first sheet <NUM> or the second sheet <NUM>.

Preferably, the third station <NUM> also comprises a third die <NUM> complementary to the third punch <NUM>.

For the purposes of this discussion, the adjective "final" is intended to refer to the geometric shape of the anchoring bracket <NUM> in conditions of use.

Preferably, in the anchoring bracket <NUM> the pair of walls <NUM>, <NUM> are substantially parallel (<FIG>), or they are flared and form a flaring angle with a maximum width of <NUM>°. In this case, the flaring angle is the convex angle measured between a first wall <NUM> and a second wall <NUM> of said pair of walls <NUM>, <NUM>.

According to the embodiment shown in the attached <FIG>, the first station <NUM>, the second station <NUM> and the third station <NUM> of the deformation unit <NUM> are placed sequentially next to each other, so that the same operator may monitor the plastic deformation process to give the metal sheet <NUM> the final shape of the anchoring bracket <NUM>.

Preferably, the cutting and bending station <NUM> and the deformation unit <NUM> are engaged and made integral with each other. In other words, the mechanical machining group is a machining island that allows for the finished product, i.e., the anchoring bracket <NUM>, to be obtained from the metal sheet <NUM>.

A pressing method for making the anchoring bracket <NUM> is also the subject matter of the present invention. The operation of this pressing method comprises the steps of:.

In accordance with one aspect of the invention, a method for fastening a guide <NUM> or anchoring device to the roofing <NUM> is also disclosed. This fastening method comprises the steps of:.

In particular, the screw <NUM>, in addition to engaging the sheet engaging hole <NUM>, also uses the first <NUM> and second <NUM> coupling holes, i.e., the same holes that are already used for the mutual fastening between the first <NUM> and second <NUM> sheets. In other words, the first <NUM> and the second <NUM> coupling holes are already provided to fasten the pair of corrugated sheets <NUM>, <NUM> together and are also used to fix the anchoring bracket <NUM> to the roofing <NUM>. In this case, the screw <NUM> may be the same screw that is already used to secure the first <NUM> and second <NUM> sheets together.

Preferably, for executing the fastening method, the guide <NUM> or anchoring device should also be provided.

In accordance with an embodiment of the fastening method, a step of mounting the installation <NUM> on the guide <NUM> or the anchoring device is provided. For example, the installation <NUM> is a photovoltaic system, an air conditioning system, a solar thermal system, a gangway, a scaffolding or any structure installable on the roofing <NUM>.

Preferably, for the execution of the fastening method, the installation <NUM> should also be provided.

Innovatively, the anchoring bracket, the support group, the mechanical machining group, the pressing method and the fastening method fulfill their intended objects.

Advantageously, the anchoring bracket in question allows not to drill holes in the roofing, as the holes already provided are used to join and bind the pair of corrugated sheets together. Therefore, all the problems to the underlying structure from water infiltration and deterioration of the sheets due to the holes required to anchor the guide on which the installation is then mounted are avoided.

Advantageously, the anchoring bracket may be used on both new and existing roofings and is able to adapt to any type of trapezoidal roofing on the market.

Another advantage of the anchoring bracket according to the present invention is that it has a small footprint, may be easily and smoothly assembled and disassembled even by unskilled operators without losing its functional and practical features, and is able to be absolutely operable in an efficient way from the moment of its installation.

In addition to what has been described so far, the anchoring bracket offers high operational accuracy and considerable security for that which is anchored thereon.

In particular, the structure of the anchoring bracket allows it to be shaped in accordance with all types of corrugated sheet profiles on the market.

A further advantage provided by the anchoring bracket in question derives from the fact that it does not require periodic inspections or maintenance resulting in considerable savings in the construction of roofings, photovoltaic systems and other installations both fixed and temporary that may be present on a roofing.

Furthermore, the anchoring bracket is extremely flexible and may be easily moved so that the positioning of the installation on the roofing may be changed.

According to yet another advantageous aspect, the anchoring bracket is able to offer high positioning accuracy for timely and precise fastening of guides (or anchoring devices) to which the installation may then be mounted; furthermore, the anchoring bracket also allows any type of guide (or anchoring device) to be attached, a condition hitherto unthinkable with the fastening methods used in the prior art.

An additional advantage of the present anchoring bracket derives from its simple structure that avoids the need for all the complicated anchoring systems currently used.

A further advantage of the present invention is that it is remarkably easy to use, with simple implementation and good functionality.

Advantageously, the anchoring brackets may be inserted between the pair of corrugated sheets at regular intervals, and after being secured to the first and second sheets, the guides (or anchoring devices) are fastened on the second arms of the aforesaid brackets with clamping screws. In this way, should the clamping screws lose their tightness over time due to wear and tear of the gaskets, the infiltration water does not pass under the roofing, but remains external, ending up on the outer surface of the roofing.

The anchoring bracket has a housing pocket to accommodate the end portion of the first or second sheet and to promote the insertion of the bracket into the overlap area between the first and second sheet.

According to an advantageous aspect, the support group is extremely versatile, as the anchoring bracket is able to absorb the different thermal expansions/contractions of the pair of corrugated sheets and the guide. In particular, referring to <FIG>, <FIG> and <FIG>, the pair of corrugated sheets tends to expand/contract along the direction defined by the transverse axis of the bracket; on the other hand, the guide (<FIG>) expands/contracts along the direction defined by the longitudinal axis of the anchoring bracket. The first arm, by spacing the pair of corrugated sheets away from the guide, is able to absorb both transverse stresses due to the corrugated sheets and longitudinal stresses due to the guide. The different stresses are caused by the fact that the corrugated sheets and the guide are orthogonal to each other and therefore expand/contract along different directions.

Claim 1:
An anchoring bracket (<NUM>) for a roofing (<NUM>) comprising:
- a sheet engaging portion (<NUM>) suitable for being interposed between a pair of corrugated sheets (<NUM>, <NUM>), said sheet engaging portion (<NUM>) further being suitable for being coupled and fastened to a first sheet (<NUM>) and a second sheet (<NUM>) of said pair of corrugated sheets (<NUM>, <NUM>), for example by means of a mechanical connection and/or shape coupling and/or force coupling;
- an installation engaging portion (<NUM>) configured as a support suitable for fastening a guide (<NUM>) or an anchoring device on which to mount an installation (<NUM>), such as a photovoltaic system, an air conditioning system, a solar thermal system, a gangway, a scaffolding or any structure installable on the roofing (<NUM>);
- a connecting portion (<NUM>), wherein
said connecting portion (<NUM>) connects the sheet engaging portion (<NUM>) to the installation engaging portion (<NUM>), characterized in that said connecting portion (<NUM>) is folded so as to form a housing pocket (<NUM>) suitable for accommodating an end portion (<NUM>) of the first (<NUM>) or second (<NUM>) sheet.