ATTACHING MUTUALLY TRANSVERSE ELEMENTS, ESPECIALLY FOR ROOFING

Abstract

A batten support (5) is provided for supporting a batten (2a, 2b) in a roof structure. The batten support (5) has a base portion (51) shaped to lie on or against a roof support member (1). The base portion (51) is configured to be secured to the roof support member (1) by a fastener (3) passing through the base portion (51) into the roof support member (1). The batten support (5) also has a ledge portion (52) projecting at an angle relative to the base portion (51), to lie against a lateral surface of the batten (2a, 2b), thereby supporting the batten (2a, 2b). A method of forming the roof structure is also provided, the roof structure when formed comprising the batten (2a, 2b), the roof support member (1) and the batten support (5). The method comprises: arranging the base portion (51) of the batten support (5) on, or against, a surface of the roof support member (1); arranging a surface of the batten (2a, 2b) on, or against, a ledge portion (52) of the batten support (5), the ledge portion (52) projecting at an angle to the base portion (51); and passing the fastener (3) through at least one of the base portion (51) and the ledge portion (52) into the roof support member (1).

Claims

1. A batten support for arranging at the end of a roof support member of a roof structure, wherein the roof structure when constructed comprises at least one batten, at least one roof support member and a batten support, wherein the batten support comprises: a base portion configured to be secured to the roof support member by a fastener passing through the base portion into the roof support member; and wherein the batten support comprises a ledge portion configured to project at an angle relative to the base portion, to lie against a lateral surface of the at least one batten to provide support thereof.

2. A batten support according to claim 1, wherein the ledge portion is configured to project at an angle which is substantially perpendicular with respect to the base portion.

3. A batten support according to claim 1, wherein the ledge portion is configured to support the lateral surface of the at least one batten over a length of at least 25 mm.

4. A batten support according to claim 1, wherein the batten support is configured to project in a substantially horizontal direction out beyond the edge of the upper surface of the roof support member.

5. A batten support according to claim 1, wherein the batten support comprises a fastener-penetrable region comprising a plurality of openings, wherein the openings are spaced apart in a regular array.

6. A batten support according to claim 5, wherein the fastener-penetrable region defines at least 20%, of the plate portion.

7. A batten support according to claim 5, wherein each of the plurality of openings has a longitudinal and transverse dimension, wherein one of the longitudinal and transverse dimensions is not more than twice the other dimension, and/or wherein the spacing between the plurality of openings is not more than three times the maximum longitudinal and/or transverse dimension of the openings.

8. A batten support according to claim 1, wherein the base portion comprises one or more elongate clearance openings having a longitudinal dimension parallel to the ledge portion.

9. A batten support according to claim 1, comprising one or more indentations formed at the angle between the base portion and the ledge portion, the one or more indentations projecting between the base portion and the ledge portion.

10. A batten support according to claim 1, wherein the base and/or ledge portions are dimensioned to receive the end of only a single batten.

11. A batten support according to claim 1, wherein the roof support member defines a hip blade roof arranged between two adjacently angled roof planes of the roof structure, wherein a roof batten of one of the roof planes is arranged to co-terminate with a roof batten of the other roof plane substantially half-way across the hip blade, wherein the batten support is configured with mutually angled ledge and base portions to support the ends of two batten ends.

12. A batten support according to claim 1, wherein the batten support comprises a plurality of support portions defining a multi-unit length, wherein the support portions are connected end-to-end through integral links which are separable to obtain the plurality of support portions for separate use.

13. A batten support according to claim 12, wherein the integral links are provided by pre-cutting along part of the boundary between adjacent support portions leaving one or more support portions uncut, optionally the, or each, integral link is arranged adjacent to an edge of the batten support, further optionally, wherein first and second integral link are arranged at opposite exposed edges of the batten support.

14. A batten support according to claim 1, wherein the batten support comprises an L-section plate, with a flat base plate and a substantially perpendicular side plate constituting the ledge portion.

15. A batten support according to claim 1, comprising a second ledge portion configured to project at an angle relative to the base portion and arranged at a side of the base portion opposite to the ledge portion.

16. A batten support according to claim 15, wherein the batten support comprises a U-section defined by the ledge portions and the base portion, optionally wherein a spacing between the ledge portions is about 40 mm or about 50 mm.

17. A batten support according to claim 16, wherein at least one of the ledge portions is outwardly inclined relative to the perpendicular from a plane parallel to the base portion of the batten support.

18. A batten support according to claim 15, wherein the batten support has a Z-section defined by the ledge portions and the base portion, wherein the second ledge portion projects from the base portion in the opposite direction to the ledge portion, optionally, wherein the ledge portions extend in opposite but substantially parallel directions.

19. A batten support according to claim 1, wherein at least one of the base portion and the ledge portion comprises a pre-formed opening for receiving a preliminary fastener for fixing the batten support to the roof support member before the at least one batten is positioned on the batten support.

20. A roof structure comprising at least one batten, at least one roof support member and a batten support according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Examples are now described with reference to the accompanying drawings, in which:

[0045] FIG. 1 is a perspective view of a conventional batten joint above a rafter;

[0046] FIG. 2 is a similar view showing a similar batten joint using a batten support of the present disclosure;

[0047] FIG. 3(a) to (d) are top, end, side, and perspective views of a batten support of the present disclosure;

[0048] FIGS. 4(a) and (b) are top and perspective views of a slightly different arrangement of the batten support;

[0049] FIG. 5(a) to (d) are top, end, side, and perspective views of a batten support for use adjacent a valley board;

[0050] FIG. 6 is a view from above showing use of the FIG. 5 batten support;

[0051] FIGS. 7(a) to (d) are respectively top, side, end and enlarged fragmentary end views of a further arrangement of batten support for use above a rafter;

[0052] FIGS. 8, 9 and 10 show a valley board batten support and two arrangements of rafter batten support with other structures for facilitating the passage of batten fasteners;

[0053] FIGS. 11 and 12 show a batten support plate of the FIG. 7 pattern with an array of stamped openings and a part-processed blank for it;

[0054] FIG. 13 shows a single-batten;

[0055] FIG. 14 shows a stamped blank for a further valley board batten support; and

[0056] FIG. 15 is a fragmentary view of a valley board batten support in the form of a multi-unit length of multiple connected sub-units.

DETAILED DESCRIPTION

[0057] FIG. 1 shows a conventional batten joint for the ends of two battens 2a,2b resting on the top surface 11 of a rafter 1. Arrow A shows the vertical direction, arrow B is a horizontal in the length direction of the battens. As is well known a roof structure will include many such batten joints: perhaps from 20 to 50. The batten ends are cut square and so as to meet closely, roughly half-way across the rafter top surface 11. Typical rafters 1 are 51 mm (2 inch) across, but they may be wider: this is not critical. In normal practice a nail 3 is driven through the end of each batten 2a,2b and down into the rafter to hold the batten ends in place.

[0058] In usual practice a flexible layer such as a felt lies on top of the rafters and under the battens, held in position by independent nails into the rafters and also by the battens and by the nails that fasten the battens. This layer is not shown in the drawings so that the rafter can be seen.

[0059] FIG. 2 shows a batten joint using according to the present disclosure. The rafter 1 and battens end 2a, 2b are as before. A metal support plate 5 in channel form, with upstanding side flanges 52 between which the batten ends are a close fit, lies across the top surface 11 of the rafter projecting out symmetrically to either side. A central retaining nail 9 has been hammered through the centre of the base plate of the support 5, down flush with the plate, to hold it in place. Then, with the batten ends in place, a batten-retaining nail 3 (only one is shown, to avoid obscuring the figure) is hammered through the end of each batten and through the plate into the rafter 1. The batten-retaining nails 3 may be driven obliquely in the conventional way.

[0060] FIGS. 3 and 4 show details and structural variants of batten support plates according to our ideas. Some dimensions are shown by way of example. The dimensions are optional, and distinct from the conformation concepts shown, but they are significant because they correspond to standard batten sizes. They are all in mm.

[0061] FIG. 3 shows the batten support plate 5 formed as a single bent piece of 0.8 mm galvanised mild steel plate. Dimensions are as shown. A 12 mm rise on the support ledges 52 corresponds to half the depth of a conventional batten. For simplicity, economy, and symmetry each of the base plate 51 and support ledges 52 is generally rectangular in form. The support ledges have radiused safety corners 56. The base plate 51 has a central hole 54 to facilitate positioning and driving in the retaining or locating nail 9. Independently, this arrangement shows longitudinally-elongate fastener clearance slots 55 distributed in a symmetrical array towards each end. These may facilitate passage of the nails 3. The slot form is because a worker can easily judge a position half way across a batten, but the longitudinal position of the nail's passage through the plate may vary. The slot form may also allow for additional batten support: see below.

[0062] In fact, a conventional (e.g. 3 inch) nail can readily be driven through 0.8 mm steel plate so that clearances such as slots 55 are optional. See FIG. 4, which shows a variant providing only the central hole 154 for the locating nail 9. In case of using thicker plate or smaller nails, so that a hole is necessary, it would also be possible to form the support plate with larger clearances or holes towards either end so that the batten-retaining nails 3 could pass without hindrance.

[0063] Note that the support ledges 152 of the FIG. 4 arrangement have the same height as in the FIG. 3 arrangement, and the plate 151 is of the same length but narrower, corresponding to a snug fit with a narrower standard batten width.

[0064] Look again at FIGS. 1 and 2. If a worker treads on the batten 2b near the joint, bending, and consequent damage to the batten (and felt) are resisted only by engagement of the nail 3 resisting sliding of the batten end down the rafter, and the frictional support of the batten end on half the width of the rafter surface 11. By contrast, in FIG. 2 (with both fasteners 3 in place) the end of the batten 2b is supported by its respective fastener nail 3 relative to the rafter as before. Additionally, the lower support ledge 52 of the support plate 5 supports the batten end against slipping/bending downwards. The support plate is held in place additionally by its locating nail 9, by engagement with the other batten end 2a via engagement with the upper and lower support ledges 52 and thereby by the fastener 3 of the other batten end. Additionally, in the case that the batten fasteners 3 pass through the support plate base 51 in close engagement with it, e.g., through narrow slots or by direct penetration of the plate, the fasteners 3 also hold the support plate 5 in place on the rafter 1 and increase the mutual support.

[0065] Thus, by a simple means the end of a batten can be substantially reinforced against damage. Little or no extra work and few fasteners are required. It will be appreciated for example that the locating fastener 9 is optional, since the batten fasteners 3 will hold the arrangement in place and one batten end will support the other via the support plate. If one or both batten fasteners 3 engage the plate base 51 directly, there will be further support. Indeed, there is support even if one batten fastener is entirely forgotten or comes out.

[0066] FIGS. 5 and 6 show a different form of batten support plate 7 for a valley board. FIG. 6 shows how the end of the batten 2, extending horizontally in line with one plane of the roof valley, terminates against the side surface 82 of the obliquely-rising timber valley board 8. In a conventional way, the batten end is sawn obliquely to lie close against the side surface 82. Conventionally a fastener such as a nail 3 is driven sideways through the batten end and into the valley board 8 to hold it in place.

[0067] The illustrated support plate 7see FIG. 5is a symmetrical (reversible) structure made from simple bent 0.8 mm steel plate like the arrangements shown above. It has a cross-sectional shape which is generally a right-angled Z-shape, with a pair of generally identical rectangular ledge plates 72 offset from one another by a central riser plate or side base plate 71. Some suggested dimensions are given: the most significant is the height of the central plate 71 because this should be at least the depth of the batten used e.g., 25 mm (1 inch). The support plates 72 are provided with pre-formed holes 74 for retaining fasteners. The riser portion 71 may have one or more pre-formed fastener clearance openings 75 e.g., elongate slots as shown.

[0068] In use the batten end is cut to conform to the timber side surface 82 as before. The support plate 7 is positioned with a lower one of the support flanges 72 lying under the batten end to support it, and the upper one lying on top of the roof timber, e.g., valley board 8, as shown in FIG. 6. In this position a retaining fastener 3 e.g., a nail can be driven through the batten end and support plate, and/or one or more plate-retaining fasteners 3 (nails or screws) driven through corresponding openings 74 in the upper support flange 72 to secure the support plate 7 against pulling away from the valley board 8. In this position the lower flange 72 gives substantial additional support against displacement of the batten end 2 in the event that someone stands on it.

[0069] FIG. 7 shows a further arrangement which in general nature and dimensions is similar to that of FIG. 3, with a base plate 251 having a central hole 254 for preliminary location and an array of fastener clearance slots 255. As before, a pair of upstanding side support flanges 252 is provided, projecting up along the top and bottom edges of the base plate 251 and opposing one another. As before, they are about 12 mm high in this arrangement.

[0070] As a first refinement, at the angle 257 where each support flange 252 meets the base plate 251 small inward indentations (sometimes called cleats) are pressed integrally into the plate. As previously, the plate is preferably galvanised steel e.g., 0.8 mm thick. In the arrangement shown, each angle has two of these indentations 259. Because they project inwardly of the angleperhaps as best seen in FIGS. 7(c) and (d)they provide a tensile reinforcement against outward bending, i.e., they effectively strengthen the support effect of the flange 252 without requiring additional components or additional manufacturing steps.

[0071] A second refinement is that the side flanges 251 diverge outwardly relative to the perpendicular, as seen most clearly in FIGS. 7(c) and (d). A single divergence angle, indicated as , in this arrangement is about 8, and functionally speaking means that each flange 252 has about 1 mm more clearance at the top than at the bottom adjacent the angle 257. The two flanges 252 being identical and symmetrical, overall the mouth is about 2 mm wider than at the base. This enables the support plate to accept insertion of battens which are damp or which have been cut slightly oversize, while preserving an adequately close fit with slightly smaller battens.

[0072] FIGS. 8 to 10 show the use of a batten fastener-penetrable region 9 in various forms, representing alternatives to the previously described slots and to driving fasteners directly through the plate. The issue is to deal with the inevitably inexact positioning of the batten fasteners (because they are usually driven at an angle, and with the batten obscuring the plate beneath), without having to drive the fastener through the full strength of the plate and yet still achieving some mechanical connection between the two.

[0073] FIG. 8a valley board support plate 107shows a fastener-penetrable region 9 having an array of small openings 91 formed integrally in the riser portion 171 of the plate e.g. by pressing or stamping. FIG. 9a rafter-type support plate 305provides the fastener-penetrable region by means of a piece of metal mesh or gauze 92 fixed into a central window opening 355 in the metal plate, e.g., by adhesive, riveting, soldering, or welding according to the material. FIG. 10 shows a support plate 405 of the rafter type which preserves the locating hole 354 for locating the plate 405 relative to the rafter before the battens are positioned, with a pair 9a,9b of fastener-penetrable regions with meshes 93 towards either end for passage of the respective batten fasteners.

[0074] The manner of providing the fastener-penetrable region 9 with an array of small openings is not particularly limited, and any of the above proposals may be used with any of the types of batten support plate described herein, e.g., in combination with the specific features described in the earlier arrangements. Also, as mentioned above, the fastener-penetrable region 9 may be replaced by actual window openings, e.g., in the FIG. 10 arrangement the plate may rely on the locating opening 354 to locate the plate, the window regions 93 to either endfor passage of the batten fastenersbeing left entirely open.

[0075] FIGS. 11 and 12 show a plate similar to that of FIG. 7, here in 0.8 mm steel, with an array of holes stamped in the base portion of the blank (FIG. 12) before bending into shape (FIG. 11). Dimensions are shown, and the holes are to scale: 2 mm squares at 2 mm spacing longitudinally and transversely. The hole pattern has a central narrowing feature to show the half-way length point, e.g., for taking an initial positioning nail. This arrangement has a good combination of strength and ease of nailing. The holes are sufficiently small that the plate material will be deformed and grip when a typical nail, e.g., a 2 inch nail, is driven through.

[0076] FIG. 13 shows a shorter single-batten support e.g., 40 to 60 mm long, to support a batten end on top of a gable verge or hip blade.

[0077] FIG. 14 shows a blank, before folding, whereby a stamped hole array is used to provide each of the central, top, and bottom nailing zones on a Z-bracket which is otherwise as seen in FIGS. 5 and 8.

[0078] FIG. 15 shows a set of support plates 207, for use on valley boards, and of the same general type as shown in FIGS. 5, 8 and 14, manufactured as a multi-unit length 200 which may include e.g. 10 or more individual plate units 207 so that the overall length L might be 0.5 m or greater, or 1 m or greater. FIG. 15 shows it fragmentarily, i.e., only the end units, with most of the intermediate units omitted to fit the drawing on the page.

[0079] Here each of the riser portion 271 and the top and bottom perpendicular flanges 272 of each unit plate 207 has a respective fastener-penetrable region 9 formed of a regular array of circular through-holes. The array 9 on the riser 271 facilitates possibly angled insertion of a nail through the batten end, in the FIG. 6 situation. Having penetrable arrays 9 on the top and bottom flanges means that the bracket can be used either way round (only the top flange needs to be nailed), and a nail gun can be used for fast work because the exact position of the nail need not be controlled. In this arrangement, the openings of the array are circular, but they may be square as shown in FIG. 14.

[0080] Pre-cut openings 201 in the form of elongate slots are formed along the boundaries between adjacent unit plates 207, in the same operation that forms the openings of the fastener arrays 9, and extend continuously from part-way across one flange 272, across the riser 271 and to part-way across the other flange 272, leaving link regions or unions 202 holding the plates together at the edges. In use, these unions can easily be cut with tinsnips to separate the unit plates for use. The option also exists to use the plates in combinations of two or more in special situations. Indeed, it is possible to lay a complete multi-unit length up along a rafter or valley board, e.g., in situations where the exact positions of the battens are not yet known or might vary, or simply for convenience.

[0081] The following numbered paragraphs (paras.) contain further statements of various aspects and embodiments of the present invention: [0082] 1. A batten support for arranging at the end of a roof support member of a roof structure, wherein the roof structure when constructed comprises at least one batten, at least one roof support member and a batten support, wherein the batten support comprises: [0083] a base portion configured to be secured to the roof support member by a fastener passing through the base portion into the roof support member; [0084] wherein the batten support comprises a ledge portion configured to project at an angle relative to the base portion, to lie against a lateral surface of the at least one batten to provide support thereof. [0085] 2. A batten support according to para. 1, wherein the ledge portion is configured to project at an angle which is substantially perpendicular with respect to the base portion. [0086] 3. A batten support according to para. 1 or para. 2, wherein the ledge portion is configured to support the lateral surface of the at least one batten over a length of at least 25 mm. [0087] 4. A batten support according to any one of paras. 1 to 3, wherein the batten support is configured to project in a substantially horizontal direction out beyond the edge of the upper surface of the roof support member. [0088] 5. A batten support according to any one of paras. 1 to 4, wherein the batten support comprises a fastener-penetrable region comprising a plurality of openings, wherein the openings are spaced apart in a regular array. [0089] 6. A batten support according to para. 5, wherein the fastener-penetrable region defines at least 20%, of the plate portion. [0090] 7. A batten support according to para. 5 or para. 6, wherein each of the plurality of openings has a longitudinal and transverse dimension, wherein one of the longitudinal and transverse dimensions is not more than twice the other dimension, and/or wherein the spacing between the plurality of openings is not more than three times the maximum longitudinal and/or transverse dimension of the openings. [0091] 8. A batten support according to any one of paras. 1 to 7, wherein the base portion comprises one or more elongate clearance openings having a longitudinal dimension parallel to the ledge portion. [0092] 9. A batten support according to any one of paras. 1 to 8, comprising one or more indentations formed at the angle between the base portion and the ledge portion, the one or more indentations projecting between the base portion and the ledge portion. [0093] 10. A batten support according to any one of paras. 1 to 9, wherein the base and/or ledge portions are dimensioned to receive the end of only a single batten. [0094] 11. A batten support according to any one of paras. 1 to 9, wherein the roof support member defines a hip blade roof arranged between two adjacently angled roof planes of the roof structure, wherein a roof batten of one of the roof planes is arranged to co-terminate with a roof batten of the other roof plane substantially half-way across the hip blade, wherein the batten support is configured with mutually angled ledge and base portions to support the ends of two batten ends. [0095] 12. A batten support according to any one of paras. 1 to 11, wherein the batten support comprises a plurality of support portions defining a multi-unit length, wherein the support portions are connected end-to-end through integral links which are separable to obtain the plurality of support portions for separate use. [0096] 13. A batten support according to para. 12, wherein the integral links are provided by pre-cutting along part of the boundary between adjacent support portions leaving one or more support portions uncut, optionally the, or each, integral link is arranged adjacent to an edge of the batten support, further optionally, wherein first and second integral link are arranged at opposite exposed edges of the batten support. [0097] 14. A batten support according to any one of paras. 1 to 13, wherein the batten support comprises an L-section plate, with a flat base plate and a substantially perpendicular side plate constituting the ledge portion. [0098] 15. A batten support according to any one of paras. 1 to 13, comprising a second ledge portion configured to project at an angle relative to the base portion on an opposite side of the base portion to the ledge portion. [0099] 16. A batten support according to para. 15, wherein the batten support comprises a U-section defined by the ledge portions and the base portion, optionally wherein a spacing between the ledge portions is about 40 mm or about 50 mm. [0100] 17. A batten support according to para. 16, wherein at least one of the ledge portions is outwardly inclined relative to the perpendicular from a plane parallel to the base portion of the batten support. [0101] 18. A batten support according to para. 15, wherein the batten support has a Z-section defined by the ledge portions and the base portion, wherein the second ledge portion projects from the base portion in the opposite direction to the ledge portion, optionally, wherein the ledge portions extend in opposite but substantially parallel directions. [0102] 19. A batten support according to any one of paras. 1 to 18, wherein at least one of the base portion and the ledge portion comprises a pre-formed opening for receiving a preliminary fastener for fixing the batten support to the roof support member before the at least one batten is positioned on the batten support. [0103] 20. A roof structure comprising at least one batten, at least one roof support member and a batten support according to any one of paras. 1 to 19. [0104] 21. A method of constructing a roof structure, the roof structure when constructed comprises at least one batten, at least one roof support member and a batten support; wherein the method comprises: [0105] arranging a base portion of the batten support on, or against, a surface of the roof support member; [0106] arranging a surface of the batten on, or against, a ledge portion of the batten support, the ledge portion projecting at an angle to the base portion; and [0107] passing a fastener through at least one of the base portion and the ledge portion into the roof support member. [0108] 22. A method according to para. 21, wherein the method comprises arranging the base portion against an upper surface of the roof support member such that the ledge portion contacts a side surface of the at least one batten. [0109] 23. A method according to para. 22, wherein the batten support is configured to support the ends of two battens forming a joint at the roof support member, wherein the method comprises arranging the batten support with the base portion lying on the upper surface of the roof support member, the ledge portion running substantially in a lateral direction of the rafter and extending either side of a centre line of the roof support member to support the ends of two battens at the joint formed therebetween. [0110] 24. A method according to para. 21, wherein the method comprises: arranging the base portion against a side surface of the roof support member so that the ledge portion extends out from the base portion in a substantially horizontal direction; and, arranging the end of the at least one batten at the side surface of the roof support member such that the ledge portion is arranged underneath the end of the batten. [0111] 25. A method according to para. 24, wherein the batten support comprises a second ledge portion configured to project at an angle relative to the base portion, the second ledge portion arranged at an opposite side of the base portion to the ledge portion, wherein the batten support has a Z-section defined by the ledge portions and the base portion, wherein the second ledge portion projects from the base portion in the opposite direction to the first ledge portion, wherein the method comprises arranging the second ledge portion against the upper surface of the roof support member. [0112] 26. A method according to paras. 24 or 25, wherein the batten support is configured to receive the end of a single batten, wherein the method comprises arranging the batten support on a roof support member which defines a junction between two angled roof planes; and arranging the end of the single batten on the ledge portion of the batten support. [0113] 27. A method according to any one of paras. 21 to 26, wherein the method comprises driving a fastener through the at least one batten and then through the batten support. [0114] 28. A method according to para. 27, wherein the method comprises fixing the batten support to the roof support member before the at least one batten is positioned on the batten support. [0115] 29. A method according to para. 28, wherein the method comprises passing a preliminary fastener through at least one of the base portion and ledge portion, before arranging the at least one batten on the batten support.