NZ623760B2 - A Structural Assembly - Google Patents

Abstract

623760 Disclosed is a structural assembly using bolted (rather than screwed) connection between a top hat batten and a purlin so as to provide stronger loading against strong wind conditions.

Description

A Structural Assembly CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional application of New Zealand Application No. 600086, filed on 18 May 2012, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION The present invention relates to a structural assembly and a method for connecting structural elements. In particular, the present invention relates to means for the connection of battens to purlins in a roofing structure. In some embodiments, the invention is directed to the connection of top hat battens to purlins, trusses to battens, or purlins to trusses, although the scope of the invention is not necessarily limited thereto.

BACKGROUND In architecture, structural engineering or construction, a batten is a horizontal structural member in a roof that runs parallel to the ridge beam and the long sides of a building. It spans between beams, purlins and trusses. Battens provide structural support for roofing material or sheathing and are supported by rafters, the building walls, beams, purlins or trusses. Top hat battens are so named due to their distinctive “top hat” shape. Top hat battens are also known simply as top hats.

A purlin is a formed structural element, typically C- or Z-shaped in cross- section, that is typically made from wood, plastic or metal. Purlins are used in construction to hold members of a structure together, provide structural support, integrity and framing or to provide a fixing point. When considering the application of purlins within the roofing industry purlins are installed as a vertical structural member in a roof that runs perpendicular to the ridge beam and batten. Battens are used for attaching a primary roof system such as tile or iron.

Typically, a batten is attached to a purlin or truss by use of a self tapping screw such as a Tek® screw. Self tapping screws are preferred due to the fact that they make constructions relatively quick and easy and provide a satisfactory result under typical conditions.

Structural engineering standards typically involve the consideration of climactic conditions (such as the prevalence of strong wind conditions within a particular area).

In general, geographic regions that experience higher force winds will require stricter construction standards than those that experience low wind conditions.

A significant disadvantage of using a self tapping screw to connect structural elements is that, under high or extreme wind conditions (such as cyclones and the like), the screw may be exposed to forces of sufficient magnitude to shear the screw off, resulting in the loss of part, or all, of the roof structure. Alternatively, in windy or cyclonic conditions the screw may loosen, become threaded and/or come apart from the purlin and batten resulting in the loss of part, or all, of the roof structure. Not only does this cause damage to the buildings and structures by removing their roofs, but it also exposes the interior of the building to the elements, including rain. Further, the removal of part or all of the roof creates a significant hazard to other buildings, infrastructure and people through the generation of flying metal debris. Thus the traditional system of using a self tapping screw is not ideal for use in high wind regions.

It is an aim of the invention to provide a means for connecting structural elements (such as battens and purlins) which overcomes or ameliorates one or more of the disadvantages or problems described above, or which at least provides the consumer with a useful or commercial choice.

It will be clearly understood that any reference herein to background material or information, or to a prior publication, does not constitute an admission that any material, information or publication forms part of the common general knowledge in the art, or is otherwise admissible prior art, whether in Australia or in any other country.

DESCRIPTION OF THE INVENTION In one aspect of the present invention, the present invention provides a structural assembly for a roof system, the assembly comprising at least one top hat batten and at least one purlin, wherein at least one top hat batten and purlin are attached to one another using one or more nuts and bolts.

The batten may be of any suitable size, shape and configuration. For instance, the batten may be substantially flat, have a raised or curved portion or region or the like. The batten may be fabricated from any suitable material, or combination of materials, such as, but not limited to, metal (steel, stainless steel, aluminium and so on), plastic, wood, fibreglass or the like.

In a preferred embodiment of the invention, the batten includes a raised region.

More preferably, the batten includes one or more flange portions, preferably located on each side of a central raised region. Thus, in a most preferred embodiment of the invention, the batten comprises a top hat batten. In this embodiment of the invention, it is envisaged that the one or more flange portions are adapted to be brought into abutment with the purlin in order to facilitate the connection of the batten and the purlin.

In embodiments of the invention in which the batten is a top hat batten, it is preferred that a bolt used to connect the batten and purlin passes through one or both of the flanges positioned on either side of the central raised region. In some embodiments, a plurality of nuts and bolts may be provided on one or more of the flanges of the batten.

The batten may comprise one or more apertures through which the bolt passes.

The apertures may be of any suitable size or shape, although it will be understood that the size and shape of the apertures will be largely dependent on the size and shape of the bolt to be used.

The apertures may be formed in the batten using any suitable technique, and a skilled addressee will understand that a variety of techniques could be employed.

However, in a preferred embodiment of the invention, the apertures may be formed by punching. The step of forming the apertures in the batten may be included during the fabrication of the batten or may be carried out post-fabrication.

The batten may be arranged in any suitable arrangement relative to adjacent battens. Preferably, however, the batten is arranged so as to overlap adjacent battens.

In a preferred embodiment of the invention, the batten is lapped about 15% of its span relative to one or more adjacent battens.

If desired, adjacent battens may also be connected together using a nut and bolt.

The purlin may be of any suitable size, shape or configuration. For instance the purlin may be a C-section purlin or a Z-section purlin. The purlin may be fabricated from any suitable material, or combination of materials, such as, but not limited to, metal (steel, stainless steel, aluminium and so on), plastic, wood, fibreglass or the like.

The purlin may be positioned in any suitable orientation relative to the batten.

For instance, the purlin may be positioned substantially above the batten when the structural assembly is in use. Preferably, however, the purlin is positioned substantially below the batten when the structural assembly is in use.

The batten may be adapted for connection to any suitable part of the purlin. For instance, the batten may be adapted for connection to the central web of the purlin.

Preferably, however, the batten is adapted for connection to a flange of the purlin. It will be understood that the term flange typically refers to a portion of the purlin depending from the central web.

The one or more nuts and bolts may be of any suitable size, shape or configuration. For instance, the bolt may be of any suitable gauge and be of any suitable length. A skilled addressee will understand that the exact type of bolt used will be dependent on the size of the batten and purlin to be connected, the duty to which the structural assembly is to be put, and the climactic conditions that the structural assembly is likely to experience. For instance, in regions prone to cyclonic activity, the bolt may be thicker and longer than those used in regions that experience strong winds only.

The nut may be of any suitable configuration, although a skilled addressee will understand that the configuration of the nut will be largely dependent on the configuration of the bolt. Notwithstanding, the nut may be a conventional hex nut, a lock nut or the like. In some embodiments, a bolt may be associated with a plurality of nuts in order to improve the wind resistance of the structural assembly.

The nut may be retained on the bolt simply through a screw-threaded engagement between the nut and the bolt. Alternatively, additional retention means may be used. For instance, the nut may be permanently fixed to the bolt (for instance, by welding, brazing or the like) or the engagement of the nut and bolt may be enhanced through the use of adhesives, such as Loctite®.

The bolt may pass through the structural assembly in any suitable orientation. In a preferred embodiment, however, the bolt passes through the structural assembly from below when the structural assembly is in use. Specifically, it is envisaged that the head of the bolt will abut a lower face of the purlin and the screw-threaded portion of the bolt will project through the batten. In a preferred embodiment, the nut will abut an upper surface of the batten when the structural assembly is in use.

It will be understood that, when a plurality of nuts and bolts are present, the bolts may be positioned in different orientations to one another as desired in order to enhance the wind resistance of the structural assembly.

In some embodiments of the invention, one or more sealing members may be used in association with at least one of the one or more nuts and bolts. Any suitable sealing member may be used, such as one or more gaskets, washers or the like. Any suitable type of washer may be used, such as a plain washer, split washer, conical washer, wave washer or the like, or a combination thereof. The one or more sealing members may be provided between the nut and a surface of the structural assembly, between the head of the bolt and a surface of the structural assembly, between nuts (if a plurality of nuts is associated with a single bolt), or a combination thereof.

It will be understood that a function of the sealing means is to evenly distribute the load of the nut, thereby enhancing the screw-threaded engagement of the nut and bolt.

The one or more sealing members may be of any suitable shape. However, in some embodiments of the invention, if a sealing member is provided between the nut and a surface of the batten, the sealing member may be rectangular in shape. This is particularly the case in embodiments of the invention in which the batten is provided with a channel, groove or the like (particularly a rectangular channel or groove) in which the nut and bolt is located. It is envisaged that, by providing a rectangular washer, the washer and therefore the nut may be precluded from rotation within the channel or groove, thereby providing added security.

In another aspect, the invention resides broadly in a method for connecting a top hat batten to a purlin comprising the step of connecting the top hat batten and purlin together using a nut and bolt.

In a further aspect, the present invention provides a wind-resistant roof assembly comprising one or more purlins and one or more top hat battens, wherein at least one of the one or more top hat battens and one or more purlins are connected to one another using a nut and bolt.

While the present invention has been described with particular reference to a roof assembly, it will be understood that the structural assembly of the present invention could equally be used in connection with windows, doorways, archways and the like.

There are a number of advantages provided by the present invention. Firstly, additional security is provided to the structural assembly through the use of a nut and bolt in that disengagement of the purlin from the batten is less likely. Secondly, the use of a nut and bolt provides greater wind resistance for the structural assembly in comparison to the use of screws (including self-tapping screws). The reason for this is that in high wind conditions (including cyclonic conditions) a nut and bolt is less prone to shearing than conventional screws used to connect battens and purlins. In addition, a nut and bolt ensures that connection of the batten to the purlin is relatively strong compared to screws, wherein the batten and purlin may become disengaged from one another under windy conditions.

BRIEF DESCRIPTION OF THE DRAWINGS One or more preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a schematic diagram of a structural assembly according to an embodiment of the present invention; Figure 2 is a plan view of a structural assembly according to an embodiment of the present invention; Figure 3 is a view from below of a structural assembly according to an embodiment of the present invention; Figure 4 is a perspective view of a structural assembly according to an embodiment of the present invention; and Figure 5 is a perspective view of a wind-resistant roof assembly according to an embodiment of the present invention.

BEST MODE Referring now to the drawing in detail, there is shown Figure 1 a schematic diagram of a structural assembly 10 according to an embodiment of the present invention. In Figure 1, a top hat batten 11 is connected to a purlin 12 using a nut 13 and bolt 14. The purlin 12 is positioned substantially transversely to the batten 11.

In the embodiment of the invention shown in Figure 1, the purlin 12 is a C- section purlin comprising a central web 16 with an upper flange 17a and a lower flange 17b depending from the central web 16.

In this embodiment, the upper flange 17a is connected to the batten 11. The bolt 14 passes through the purlin 12 and then the batten 11 such that the head of the bolt 14 abuts a lower surface of the upper flange 17a. The screw-threaded tail portion 18 of the bolt 14 projects upwardly, allowing the nut 13 to be brought into screw- threaded engagement with the bolt 14. A rectangular washer 15 is positioned between the nut 13 and an upper surface of the batten 11 to assist in evenly distributing the load of the nut 13.

In the embodiment of the invention shown in Figure 1, it may be seen that the batten is associated with adjacent battens 19 by lapping the battens across about 15% of the battens’ span. The batten 11 and the adjacent battens 19 are connected to one another using self-tapping screws 20 (such as Tek® screws).

Referring now to Figure 2, a plan view of a structural assembly 10 according to an embodiment of the present invention is shown. In Figure 2, a top hat batten 11 is connected to a purlin 12 using a nut 13, bolt 14 and washer 15.

In this Figure, the rectangular washer 15 may be more clearly seen. The rectangular washer 15 is positioned in a channel 21 in the batten 11 between the main top hat portion 22 and an outer lip 23 of the batten 11. By being positioned in the channel 21 in this manner, the washer 15 is precluded from rotating relative to the channel 21 due to its shape.

Turning now to Figure 3, view from below of a structural assembly 10 according to an embodiment of the present invention is illustrated. In this Figure, it may be seen that the batten 11 comprises a channel 21 positioned on either side of the main top hat portion 22. The batten 11 is connected to the purlin 12 by a bolt 14 located on each side of the top hat portion 22.

In the embodiment of the invention shown in Figure 3, a washer 23 is positioned between the head of the bolt 14 and the lower surface of the purlin 12 in order to assist in distributing the load of the bolt 14.

The self-tapping screws 20 used to connect the batten 11 to an adjacent batten 19 may also be more clearly seen in this Figure.

In Figure 4 there is illustrated a perspective view of a structural assembly 10 according to an embodiment of the present invention. It may be more clearly seen in this Figure that a bolt 14, nut 13 and washer 15 is positioned in a channel 21 located on each side of the top hat portion 22 of the batten 11. The presence of a lip 23 on the outer edge of the batten 11 precludes the washer 15 from rotation relative to the channel 21.

In this Figure it may be seen that the purlin 12 is connected to a further structural member, such as a wall panel (not shown) or column 24.

In Figure 5 there is illustrated a perspective view of a wind-resistant roof assembly 30 according to an embodiment of the present invention. The assembly 30 comprises a pair of battens 11 positioned substantially parallel to one another. Each of the battens 11 is connected to a purlin 12 positioned substantially transversely to the battens 11 using a bolt 14, nut 13 and washer 15 in the manner previously described in connection with the earlier Figures.

In the embodiment of the invention illustrated in Figure 5, the purlin 12 is connected to a rafter, column or the like (obscured) using a plate 31, while the battens 11 are connected to adjacent battens 19.

The assembly 30 also includes a number of bracing members 32 positioned at an angle to both the purlin 12 and the battens 11. The bracing members 32 are used to provide additional strength to the assembly 30 as required.

It is envisaged that additional purlins (not shown) and battens (not shown) may form part of the wind-resistant roof assembly 30. It is envisaged that additional purlins (not shown) will be positioned substantially parallel to the purlin 12, while additional battens (not shown) will be positioned substantially parallel to the battens The foregoing embodiments are illustrative only of the principles of the invention, and various modifications and changes will readily occur to those skilled in the art. The invention is capable of being practiced and carried out in various ways and in other embodiments. It is also to be understood that the terminology employed herein is for the purpose of description and should not be regarded as limiting.

In the present specification and claims (if any), the word "comprising" and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers unless the context of use indicates otherwise.

Reference throughout this specification to “one embodiment”, or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims (15)

CLAIMS 1.:

1. A structural assembly for a roof system, the assembly comprising: at least one top hat batten including: one or more flange portions located on each side of a central raised region, each of the flange portions including: a channel, and at least one purlin, wherein at least one top hat batten and purlin are attached to one another using one or more nuts and bolts, the one or more nuts and bolts being located in the channels of the flange portions, and wherein one or more substantially rectangular washers are associated with each of the nuts and bolts, the substantially rectangular washers being adapted to substantially preclude rotation of the washers within the channels.

2. A structural assembly according to claim 1 wherein the one or more flange portions are brought into abutment with the purlin to facilitate the connection of the top hat batten and the purlin.

3. A structural assembly according to any one or the preceding claims wherein the top hat batten comprises one or more apertures through which the one or more bolts pass.

4. A structural assembly according to claim 3 wherein the one or more apertures are formed by punching.

5. A structural assembly according to any one or the preceding claims wherein the top hat batten is connected to a flange of the purlin.

6. A structural assembly according to any one of the preceding claims wherein the purlin is a C-section purlin or a Z-section purlin.

7. A structural assembly according to any one of the preceding claims wherein the top hat batten is arranged so as to overlap adjacent battens.

8. A structural assembly according to claim 7 wherein the top hat batten is lapped at about 15% of its span relative to the adjacent top hat battens.

9. A structural assembly according to any one of the preceding claims wherein at least one of the one or more nuts is permanently fixed to the respective bolt.

10. A structural assembly according to any one or the preceding claims wherein one or more sealing members is used in association with at least one of the one or more nuts and bolts.

11. A method for connecting a top hat batten to a purlin comprising the step of connecting the top hat batten and purlin together using a nut and bolt.

12. A roof assembly comprising one or more purlins and one or more top hat battens, wherein at least one of the one or more top hat battens and one or more purlins are connected to one another using a nut and bolt.

13. A structural assembly substantially as hereinbefore described with reference to the drawings.

14. A method for connecting a top hat batten to a purlin substantially as hereinbefore described with reference to the drawings.

15. A roof assembly substantially as hereinbefore described with reference to the drawings. 19 17a 20 19