U.S. patent application number 11/702817 was filed with the patent office on 2007-06-28 for roof cladding element with hidden fastening.
This patent application is currently assigned to Samesor Oy. Invention is credited to Rauno Keinanen, Pekka Saarenko.
Application Number | 20070144097 11/702817 |
Document ID | / |
Family ID | 32922107 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070144097 |
Kind Code |
A1 |
Saarenko; Pekka ; et
al. |
June 28, 2007 |
Roof cladding element with hidden fastening
Abstract
The objective of the invention is a roof cladding element with
hidden fastening, which roof cladding element has been manufactured
of plate material, and which roof cladding elements are adjacently
and in succession mountable such that the edges of roof cladding
elements will be placed a distance overlapping the edges of
adjacent roof cladding elements, and which roof cladding element
includes at least one step mainly transversal with the cladding,
which step has at least one locking recess for locking a roof
cladding element at least from one step to the next lower roof
cladding element, and which roof cladding element includes at least
one attaching shoulder placed at the upper edge of a roof cladding
element for fastening of the upper edge of a roof cladding element
to the fastening construction of the cladding and for tightening
and locking of at least the locking recess next to the lower edge
of a roof cladding element to the locking recess placed in the
upper part of the next roof cladding element placed lower.
Characteristic to the roof cladding element with hidden fastening
is that a locking recess has been formed to steps of a roof
cladding element such that the upper cladding surface before a step
is above the lower cladding surface placed a distance after the
step, and that viewed from side the step is mainly a straight part
of a roof cladding element slanting in regard to cladding surfaces,
in which case the longitudinal cross section of a roof cladding
element on the step area is Z shaped.
Inventors: |
Saarenko; Pekka; (Kuopio,
FI) ; Keinanen; Rauno; (Nilsia, FI) |
Correspondence
Address: |
HARRINGTON & SMITH, PC
4 RESEARCH DRIVE
SHELTON
CT
06484-6212
US
|
Assignee: |
Samesor Oy
|
Family ID: |
32922107 |
Appl. No.: |
11/702817 |
Filed: |
February 5, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/FI05/00343 |
Jul 28, 2005 |
|
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11702817 |
Feb 5, 2007 |
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Current U.S.
Class: |
52/539 |
Current CPC
Class: |
E04D 3/365 20130101;
B21D 19/082 20130101; E04D 3/30 20130101 |
Class at
Publication: |
052/539 |
International
Class: |
E04D 1/00 20060101
E04D001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 16, 2004 |
FI |
20041080 |
Claims
1. A roof cladding element with hidden fastening, in which roof
cladding element has been manufactured of plate material, roof
cladding elements are mountable adjacently and in succession such
that the edges of roof cladding elements will be placed a distance
overlapping the edges of adjacent roof cladding elements, the roof
cladding element includes at least one step mainly transversal with
the cladding, which step has at least one locking recess for
locking the roof cladding element at least from one step to the
next lower roof cladding element, the roof cladding element
includes at least one attaching shoulder placed at the upper edge
of a roof cladding element for fastening of the upper edge of a
roof cladding element to the fastening construction of the cladding
and for tightening and locking of at least the locking recess next
to the lower edge of a roof cladding element to the locking recess
placed in the upper part of the next roof cladding element placed
lower, the locking recess has been formed to steps of a roof
cladding element such that an upper cladding surface before the
step is above a lower cladding surface placed a distance after the
step, and viewed from side the step is mainly a straight part of a
roof cladding element slanting in regard to cladding surfaces,
whereby the longitudinal cross section of a roof cladding element
on the step area is Z shaped.
2. A roof cladding element in accordance with claim 1, in which the
locking recess (5a, 5b) measures mainly the entire width of a roof
cladding element broadwise of a roof cladding element.
3. A roof cladding element in accordance with claim 1, in which the
lower edge of a roof cladding element is between the middle of a
step and the lower corner between a step and the lower cladding
surface.
Description
FIELD OF THE INVENTION
[0001] This application is a continuation of International Patent
Application No. PCT/FI2005/000343.
[0002] The present invention relates to a roof cladding element
with hidden fastening, which roof cladding element has been
manufactured of plate material, and which roof cladding elements
are adjacently and in succession mountable such that the edges of
roof cladding elements will be placed a distance overlapping the
edges of the adjacent roof cladding elements, and which roof
cladding element includes at least one step mainly transversal with
the cladding which step has at least one locking recess for locking
a roof cladding element at least from one step to the next lower
roof cladding element, and which roof cladding element includes at
least one attaching shoulder placed at the upper edge of a roof
cladding element for fastening of the upper edge of a roof cladding
element to the fastening construction of the cladding and for
tightening and locking of at least the locking recess next to the
lower edge of a roof cladding element to the locking recess placed
in the upper part of the next roof cladding element placed
lower.
BACKGROUND OF THE INVENTION
[0003] Today known roof cladding elements, from which a cladding
equivalent to a profile cladding made of a cladding plate may be
assembled, are fastened to battens adjacently and in succession
with nails, screws or with some other suitable fastening elements.
Frequently these kinds of roof cladding elements are with hidden
fastening in which case fastening points are placed in locations,
which are hidden under the adjacent roof cladding element. To
ensure the remaining fastened of roof cladding elements and to
increase the tolerance of wind load there are roof cladding
elements which include fasteners remaining invisible, through which
fasteners adjacent or roof cladding elements in succession are
fastened to each other by means of separate fastening elements.
These kinds of roof cladding elements/bricks are presented in
patent publications U.S. Pat. No. 3,220,150 and U.S. Pat. No.
5,752,355. In addition, from international applications WO
2004001155 a brick figured roof cladding element made by forming
out of plate material is familiar and in it, there are locking
recesses at the points of valleys of the profile in vertical parts
of steps forming the brick figure, by means of which locking
recesses it is possible to fasten the roof cladding elements in
succession to each other by tightening the steps to be mounted one
on top of the other of roof cladding elements in succession against
each other by means of fold like attaching shoulders placed on the
upper edge of the upper roof cladding element.
[0004] With present fastening methods it is possible to fasten roof
cladding elements longlasting as such and the finished cladding
will be tight and uniform in appearance. Mounting of a cladding
made of roof cladding elements fastened in recognized ways
requires, however, fastening work of fastening elements such as
nails or screws taking much time. For example, joints between roof
cladding elements/bricks to be fastened to each other in various
ways presented in publications U.S. Pat. No. 3,220,150 and U.S.
Pat. No. 5,752,355 and others of the same kind are often slowening
and hindering mounting because joints need separate fastening
elements. A roof cladding elements in accordance with publication
WO 2004001155 is very fast and easy to be mounted and the roof
cladding elements fastened to each other and to fastening
constructions of the cladding remain in place regardless of the
loads on the cladding. The problem in a roof cladding element with
this kind of locking recesses is, however, the fact that
manufacturing of a locking recess used in a roof cladding element
by forming from thin metal plate requires a forming tool for a
locking recess to be mounted to a forming tool of steps. This kind
of forming tool is complex by construction as well as troublesome
to make and therefore relatively expensive by manufacturing costs.
Furthermore, since the forming of a locking recess has to be
carried out at the time when the forming tool of a step is in place
for a moment the forming of a locking recess limits the
manufacturing speed obtained with the forming device of a step.
SUMMARY OF THE INVENTION
[0005] The purpose of the invention is to provide a roof cladding
element with hidden fastening, with which the earlier mentioned
disadvantages related to present roof cladding elements are
eliminated. Especially the purpose of the invention is to provide a
roof cladding element, which may be fastened in succession to each
other without separate fastening elements between roof cladding
elements and which does not increase manufacturing costs of forming
device of a roof cladding element made by forming from a thin metal
plate and does not limit the manufacturing speed obtained with this
kind of forming device.
[0006] Characteristic to a roof cladding element in accordance with
the invention is that a locking recess has been formed to steps of
a roof cladding element such that the upper cladding surface before
a step is above the lower cladding surface placed a distance after
the step, and that viewed from side the step is mainly a straight
part of a roof cladding element slanting in regard to cladding
surfaces, in which case the longitudinal cross section of a roof
cladding element on the step area is mainly Z shaped. In this kind
of roof cladding element the lowest step of the next, upper roof
cladding element placed on the upper most step of the roof cladding
element is fastened due to locking recesses (originating from the Z
shape of the cross section of the step area) in the steps to the
step of the lower roof cladding element when the roof cladding
elements are tightened to each other in longitudinal direction of
the slope by means of attaching shoulders on the upper edge of the
roof cladding elements. Due to this, there is no need for separate
visible fastening elements between roof cladding elements. In
addition, for example while manufacturing these kinds of roof
cladding elements of a thin metal plate strip in a continuous
production line based on roll forming a locking recess included in
a roof cladding element may be made to a step of a roof cladding
element without a separate moulding phase of a locking recess and
without a separate forming tool of a locking recess to be mounted
to a forming tool of a step. Therefore, the forming tool of a step
of a forming device used in manufacturing of this kind of roof
cladding element may be realized as simply and with same
manufacturing costs as a forming tool of a step used in
manufacturing of a traditional roof cladding element with straight
steps or of a cladding plate. Furthermore, differently from most
traditional roof cladding elements without locking recesses these
kinds of roof cladding elements may be fastened in succession such
that all fastening elements necessary for fastening of roof
cladding elements remain hidden in a finished cladding.
[0007] In an advantageous application of the invention, a locking
recess measures mainly the width the entire roof cladding element
widthwise of a roof cladding element. Due to this, there is no need
to form shoulders into the forming tool of a step or some other
complex shapes in terms of manufacturing but the forming tool may
be very simple to be manufactured. In addition, with this kind of
locking recess it is possible to fasten the roof cladding elements
reliably to each other as the gripping surface of roof cladding
elements measures the entire width of a roof cladding element.
[0008] In the second advantageous application of the invention, the
lower edge of the roof cladding element is located between the
middle of a step and the lower corner between a step and lower
cladding surface. In this way, the connecting point of roof
cladding elements may be placed invisible under the upper cladding
surface placed on the lower cladding surface. Due to this, a
finished cladding will be uniform and seamless in appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Next, the invention will be explained in more detail with
reference to the accompanying drawings, in which,
[0010] FIG. 1 illustrates a roof cladding element with hidden
fastening viewed diagonally from above,
[0011] FIG. 2 illustrates a longitudinal cross section of a roof
cladding element placed in succession in accordance with FIG. 1 at
the connection point of elements, and
[0012] FIG. 3 illustrates functioning principle of the forming
device of a step used in manufacturing of a roof cladding element
in accordance with FIGS. 1 and 2.
[0013] FIGS. 1 and 2 illustrate a brick figured roof cladding
element with hidden fastening 1, which has been manufactured of a
coated thin metal plate strip in a continuous production line,
which includes an opening device for strip reel, a roll forming
device, a press type step forming device and a cutting device.
First, a transversal profile of a roof cladding element is formed
to the thin metal plate strip to be opened from a reel by forming
valleys 2 and peaks 3 with a roll forming device, which comprises a
suitable number of forming phases in succession (forming roll
pairs). The shape of the transversal profile in this case in
accordance with FIG. 1 symmetrically wavelike such that the valleys
2 and the peaks 3 of the profile are approximately of the same
width and height. After forming the transversal profile steps 4a
and 4b are formed at intervals of the length of a brick to the
strip by a step forming device after the roll forming device. The
steps are formed on principle presented in FIG. 3 with a forming
tool M, which moves between the holding tool P and the counter tool
V inclined downwards with respect to the profiled strip N kept at
place during forming and to opposite direction with respect to the
direction of motion of the strip. In this way the step will be
forwards inclined such that viewed from the ridge the upper
cladding surface 7a before the step extends for a distance on top
of the lower cladding surface 7b after the step, such forming
locking recesses 5a and 5b with the length of the width of the
entire roof cladding element. After forming the transversal
profile, steps (and locking recesses), the ready roof cladding
element strip is cut with a cutting device into roof cladding
elements. In this case roof cladding elements are of the length of
one space between brick figures (i.e. there are two steps 4a and 4b
in a roof cladding element) and their width is greater than the
length i.e. roof cladding elements are so-called horizontal
elements. Attaching shoulders 6 are formed while cutting to the
upper edge of roof cladding elements i.e. to the edge of a roof
cladding element on the ridge side of the roof in a finished
cladding. They are folds formed by cuttings from the upper edge
downwards near the upper most step as presented in FIG. 1. There
are attaching openings 8 in the upper part of attaching shoulders.
They are also made, in this case, with penetrating tools mounted to
be in connection with the blades of the cutting device or they may
be made separately during a separate working phase.
[0014] A roof cladding of the size of a roof, reminding a brick
cladding by appearance is made out of roof cladding elements in
accordance with FIGS. 1 and 2 by fastening roof cladding elements
to fastening constructions of the roof one horizontal line at the
time (usually from the right to the left, but in this case
assembling may be carried out also in opposite direction) from the
eaves to the ridge of the roof. Alternatively, roof cladding
elements may also be fastened a vertical line at the time,
proceeding from the eaves to the ridge. Roof cladding elements are
fastened to the fastening constructions of the roof (e.g. wooden
battens) by fastening openings 8 in attaching shoulders 6 with roof
nails or screws. Roof cladding elements may also be fastened with
other suitable fastening elements. For example, to battens made of
metal they may be fastened with suitable rivets or tin screws. In
any case, roof cladding elements of the next upper roof cladding
element row (nearer to the ridge of a roof) in respect to the lower
roof cladding element row are mounted in respect to the lower roof
cladding elements such that the lowest step 4b in the lower edge of
upper roof cladding elements is placed on upper most step 4a of the
lower roof cladding element row in accordance with FIG. 2. Each
roof cladding element is fastened by the attaching shoulders 6 in
the upper edge of a roof cladding element such that the lowest step
4b in the lower edge of a roof cladding element is tightened
against the upper most step 4a of the next lower roof cladding
element. In this case, the inclined steps (i.e. locking recesses 5a
and 5b) placed one on top of the other of roof cladding elements in
succession lock the roof cladding elements in succession to each
other. In addition, attaching shoulders 6 placed in the upper edge
of the lower roof cladding element and their fastening elements
remain hidden under the lower edge of the upper roof cladding
element such that in a finished cladding only attaching shoulders
of the upper most roof cladding element row reaching the ridge of
the cladding and fastening elements fastened to those shoulders
remain visible. Also these are covered when the sheet metal for the
ridge is placed on the ridge and extends over the attaching
shoulders of the upper most roof cladding element row. Since there
are no more roof cladding element rows after the lowest roof
cladding element row which is nearest to the eaves all roof
cladding elements for the lowest row must be fastened with separate
additional fastening elements between the lower part of the roof
cladding element and the batten (not presented in figures).
[0015] A roof cladding element in accordance with the invention may
differ in many parts from the presented example application and a
roof cladding element may be manufactured also of other suitable
material than a coated thin metal plate. Suitable materials are
e.g. many plate materials made of copper, aluminium or plastics.
Materials may be ready coated or without coating in which case
coating may take place after manufacturing of roof cladding
elements. The shape of traversal profiles, the number of steps (the
brick figure) as well as the number of profile peaks and valleys in
one roof cladding element may vary. All profile shapes to which
steps similar to application in accordance with FIGS. 1 and 2 may
be formed are possible in principle. The design of steps in roof
cladding elements may vary. In the application in accordance with
FIG. 2 the step is a part of a roof cladding element in inclined
position with respect to horizontal cladding surfaces of a roof
cladding element i.e. on the step area the longitudinal cross
section of a roof cladding element in Z shaped. Alternatively, the
step may be curved in a suitable way inwards or outwards, for
example, or it may be slightly S shaped. In the application in
accordance with FIGS. 1 and 2 the lower edge of a roof cladding
element (i.e. the cutting point during manufacturing) is placed
between the middle of the lowest step and the lower corner between
the lower cladding surface after it (in a roof cladding element
strip before cutting into roof cladding elements) and the step. For
obtaining greater stiffness and strong joint between locking
recesses the lower edge may be placed such that it is, for example,
c. 35 mm after the lower corner between the step and the lower
cladding surface after it (i.e. on the area of the lower cladding
surface). A this point the lower edge remains usually invisible in
the shadow of the upper cladding surface, since in the application
in FIGS. 1 and 2, for example, the upper cladding surface 7a
extends due to inclination of the step, c. 7 mm on the lower
cladding surface 7b.
[0016] Attaching shoulders placed in the upper part of a roof
cladding element are parts of a roof cladding element which extend
beneath the lowest point of the lower surface of a valley of a
transversal profile to the extent that nails or screws mounted in
attaching shoulders do not bend the upper edge of a roof cladding
element and that locking recesses to be placed one on top of the
other of successive roof cladding elements are tightened against
one another when attaching shoulders are fastened to fastening
constructions of a roof. Therefore, attaching shoulders may be
instead of folds made by cutting presented in FIG. 1 e.g.
depressions formed on the upper edge of a roof cladding element
which correspond to the folds of a roof cladding element in
accordance with FIG. 1 fastened at its place. In case so-called
drill screws are used as fastening elements in attaching shoulders
ready fastening openings are not necessary. In some applications
there are depressions made at the point of openings in attaching
shoulders, which depressions enable to screw ordinary wooden or tin
screws through the plate material of a roof cladding element.
[0017] Manufacturing of a roof cladding element may also be carried
out in many different ways differing from the presented example
application. The production line used in manufacturing must not
necessary be continuous as said earlier but the transversal profile
of roof cladding elements and steps, attaching shoulders and other
details formed in the way described earlier may be formed in some
suitable method, for example, to plate objects cut into pieces of
suitable size. Therefore, for example the transversal profile of
roof cladding elements may be manufactured instead of roll forming
by some press type forming device when using formable plate
materials. While manufacturing great series a continuous production
line based on roll forming or similar is, however, often more cost
efficient than this kind of manufacturing method forming separate
objects.
[0018] The invention is not limited to the presented advantageous
application but it can vary within the frames of the idea of the
invention formed in the claims.
* * * * *