AU2008229962B2 - Soffit System - Google Patents

Abstract

- 14 Abstract A soff installation system (and apparatus for use in the system) where a proximally located bracJet cxtencs to engage both a fascia and regions, including a distal region, of the soffit.

Description

Regulation 3.2 AUSTRALIA PATENTS ACT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: KEITH MICHA EL RJSSEIL Actual Inventor: RUSSELL, Keith Michael Address for service in A J PARK, I.evel 11, 60 Marcus Clarke Street, Canberra ACT Australia: 2601, Australia Invention Title: Soffit System The following statement is a full description of this invention, including the best method of perfonning it known to me.

-2 This invention relates to a soffit system suitable, inter alia, for residential housing. Composite panels hitherto have been the product of choice for soffits. This is a flat formed panel which has to be awkwardly shuffled into position before it is nailed to its support members, being the ribbon board and soffit bearer. The ribbon board and soffit bearers must be fixed to the building 5 prior to fascia and soffit installation. The ribbon board usually consists of a 4x2 inch board being nailed up around the entire perimeter of the building. The soffir bearers usually have to be cut at a certain width and nailed onto the ribbon board and to the end of the rafter individually. Also cutting this panel, if a cementitious board, can be hazardous to your health ifit has to be cut with an angle grinder. The panel will also have to be painted by hand. 10 The time consuming tasks can thus be listed thus: 1 - Having to erect a soffit bearer and fascia bracket separately 2. Having to nail in the soffit bearer to both the ribbon board and rafter end 3. Having to nail in the soffit panel 4. Having to paint the soffit paneL 15 The object of the present invention is to eliminate at least some of this time of labour usage and/or and provide an easier or alternative solution to installing soffits. A further or alternative object is the provision of soffit assemblies or sub assemblies, soffit assembly or sub assembly components, combinations of components for soffit assemblies, and related methods and procedures including systems which will at least provide the public with a useful choice. 0 In the case of, for example, the support of a soffit preferably a still further and alternative objection is the provision of a combined fascia and soffit support bracket, one end region being adapted to be proximal to a building envelope or some support feature thereof and the other adapted to support at least in part a fascia, a less distal region preferably being supportable from a roof bearer or other such support. 5 The present invention in an aspect relates to any one or more of the following as hereinafter exemplified or equivalents thereto: a) overall assembly (ic, when in situ or, as if, in situ) b) sub-assemblies, c) each individual component, d) combinations (unassembled) of two or more individual components e) a system of soffit installation (ie, both apparatus and method) f) a method of soffit installation, -3 g) etc In an aspect the invention is a soffit installation system comprising or including the steps, in any suitable order, of locating and/or engaging the proximal end region of each of a series of combined soffit and 5 fascia brackets to a feature or features of the building, attaching a more distal region of each of the series of brackets to a rafter or like supporting feature, engaging the fascia to the brackets more distally than the more distal regions of attachment, and 10 attaching and/or otherwise associating the soffit to and/or with said brackets. Optionally the brackets are unitarily formed or are fabricated as an assembly, whether on site or otherwise. Optionally the soffit is of profiled full soffit width panels and/or the soffit at at least some of the building perimeter is fabricated to full width required. 15 A system of any one of the preceding claims wherein feature(s) of the building is a ribbon member. Preferably said features) is(are) of a metal or like long run form Optionally said ribbon is in the form of a channel into with a proximal end region of each of a series of combined soffit and fascia brackets can be inserted in a spaced relationship. !0 Optionally the ribbon can take the form of any suitable outstand able to engaged into or with the proximal end region of a said bracket (eg, a ledge to be received in a slit of the bracket). Preferably said combined soffit and fascia bracket is of metal. Preferably said combined soffit and fascia bracket is of a general channel like form with the exterior of the base of the channel form being formed to receive, in a shape interfering click fit type 25 manner, the suitable said soffit. Preferably the soffit and brackets inter-engage in a male into female, or vice versa, or both, manner at one or more zones across the soffit width. Preferably said combined soffit and fascia bracket includes an upstand distally to underlie an upper and lapping region of a said fascia. 0 Preferably includes below said upstand a downward protuberance behind which a lower part of the fascia can be received.

-4 Preferably said fascia includes a lap to overly inwardly the upstand of said bracket and/or a recessed portion to be inserted behind the lower part of said bracket there to receive therein a distal part of a said soffit. Preferably said soffit is a long run member with shape engaging features longitudinally thereof and/or with one or both edges adapted for association with (a) proximally with a said ribbon and/or distally with a lower part of a said fascia. The system optionally involves components, subassemblies, or procedures, substantially as herein described with reference to any one or more of the accompanying drawings. In another aspect the invention is a soffit of sheet material formed with longitudinally male strengthening forms from its upper surface, whether with drainage openings or not, able to be received and retained by female receiving forms of a support bracket. In another aspect the invention consists in a soffit and fascia support bracket having a proximal and distal region adapted for (i) from building or a building anchored ribbon proximal support, (ii) more distal rafter support, (iii) distal fascia support, and (iv) multiple female receipt from below of male forms of a soffit as aforesaid In still a further aspect the invention consists in a combination of a soffit and a soffit and facia support bracket as aforesaid. The invention is also a procedure of installation of the system. In another aspect the invention is a soffit installation procedure or methodology ("procedure") comprising or including the steps, in any suitable order but preferably progressively, of locating and/or engaging the proximal end region of each of a series of combined soffit and fascia brackets to a feature or features of the building, attaching a more distal region of each of the series of brackets to a rafter or like feature, engaging the fascia to the brackets more distally than the more distal regions of attachment, and attaching and/or otherwise associating the soffit to and/or with said brackets. Preferably said feature(s) of the building is a ribbon member preferably not a board and most preferably of a metal or like long run form. Preferably said ribbon is in the form of a channel into with a proximal end region of each of a series of combined soffit and fascia brackets can be inserted in a spaced relationship.

-5 In less preferred forms the ribbon can take the form of any suitable outstand able to engaged Into or with the proximal end region of a said bracket (eg, a sheet metal ledge into a slot). Preferably said combined soffit and fascia bracket is of metal. Preferably said combined soffit and fascia bracket is of a general channel like form with the 5 exterior of the base of the channel form being formed to receive in a shape interfering click fit type manner the suitable said soffit eg, preferably there are transverse recesses of any of the kinds herein after described or any equivalent thereto. In less preferred forms there can be hybridisation of male and/or female members, or the reverse arrangement can be used. 10 Preferably said combined soffit and fascia bracket includes an upstand distally to underlie an upper and lapping region of a said fascia. Preferably each said bracket includes below said upstand a downward protuberance behind which a lower part of the fascia can be received. Preferably said fascia includes a lap to overly inwardly the upstand of said bracket and/or a 15 recessed portion to be inserted behind the lower part of said bracket there to receive therein a distal part of a said soffit. Preferably said soffit is a long run member with shape engaging features longitudinally thereof and/or with one or both edges adapted for association with (a) proximally with a said ribbon and/or distally with a lower part of a said &scia. 20 Preferably said procedure involves component subassemblies, or the like, or procedures, as substantially as herein after described with or without reference to any one or more of the accompanying drawings. In another aspect the invention is a soffit assembly resulting from such a procedure and/or system. 25 In another aspect the invention is a long run soffit assembly where a long run soffit underlies, but is held to, outstanding brackets that also support a long run fascia. Preferably each bracket has been nosed into the building or brackets or a ribbon thereof and has been fixed more distally to the building. Preferably the long run soffit is at least in part supported by plug fits with the brackets. 50 In yet a further aspect the invention consists in a soffit installation procedure or system as hitherto described which results in an assembly substantially as hereinafter described with reference to any one or more of the accompanying drawings.

-6 In a further aspect the invention consists in a combined fascia and soffit bracket which is adapted to be at least coextensive with the lateral extent of the soffit to be associated therewith. Preferably said fascia and soffit bracket is of a metal Any reference to metal sheet gauge herein is purely by way of example only (eg a 0.7 gauge 5 soffit panel can be used with, say, a 1mm thick bracket), but either or both be thicker and/or thinner. Preferably said fascia and soffit bracket is elongate (a) with a proximal edge region adapted for association with an appropriate feature or features of a building (eg, a ribbon), (b) has at its bottom one or more shape features adapted to engage a complimentary soffit (c) has distally an upstand for association under a lap region of a fascia and/or (d) has distally below that upstand an inner region to 10 receive and to have retained thereagainst a lower region of the fascia. In a further aspect the invention consists in combination any one or more of the components of a system or procedure or assembly as herein described. In a further aspect the invention consists in any individual component, combination of components or subassemblies or assemblies of components substantially as herein defined and/or 15 substantially as herein described with reference to any one or more of the accompanying drawings. As used herein the term "and/or" means "and" or "or", or both. As used herein the term "(s)" following a noun includes, as might be appropriate, the singular or plural forms of that noun, In this specification where reference has been made to patent specifications, other external 20 documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art. The term "comprising" as used in this specification means "consisting at least in part of'. 25 When interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Preferred forms of the present invention will now be described with reference to the accompanying drawings in which 30 Figure 1 shows an isometric view of a preferred ribbon component in accordance with the present invention. Figure 2 shows an isometric view of a preferred combined fascia and soffit bracket in accordance with the present invention, the bracket over much of its soffit support region having a -7 channel form with shaped recesses laterally thereof on the exterior of the base of the channel form adapted to engage complementary features of a suitable soffit, the proximal end of the bracket being shown to the left and the distal fascia engaging region being to the right, there being an upstand to be overlapped by a suitable complementary fascia and a feature at the base to receive there behind (ie, 5 inwardly towards the proximal end region) the lower part of a suitable complementary fascia, Figure 3 is an isometric or perspective view of a preferred long run soffit member in accordance with the present invention, the enlargements showing options for the shape retaining features to complement the enlarged features shown in Figure 2 in the bracket, and Figure 4 is a view looking longitudinally along a long run (roll formed or pressed) sheet metal 10 soffit member that has been engaged into the shape retaining grooves (as female engagement features with the male engagement shapes of the soffit), the combined fascia and soffit bracket being shown laterally in elevation with its left hand end nosed into and retained in a building encircling ribbon or skeletal parts thereof and with its other end receiving a distal edge region of the soffit under that part of the fascia support region that is to have a bottom region thereof inwardly retained in that condition, 15 Figure 5 is a similar view to the embodiment of Figure 4 but showing the structure related more into the building structure including the truss framing, no gutter nor dedicated brackets for the guttering being shown, Figure 6 shows a short length of a preferred soffit member in accordance with the present invention, 0 Figure 7 shows an exploded three dimensional form components of an assembly in accordance with the present invention, Figure 8 shows an appropriate assembly using the components of Figure 7, Figure 9 shows an alternative embodiment insofar as the bracket is concerned, Figure 10 shows an alternative embodiment insofar as the soffit is concerned, 6Figure 11 shows an installation of the soffit bracket of Figure 9 in conjunction with the soffi of Figure 10, the extension bracket being cut to length, Figure 12 shows an extension bracket, Figure 13 shows an alternative rib form with a breather/soak hole shown, and Figure 14 shows edge modification of the soffit to allow a flush panel edge/panel edge fit. In the preferred form, solely as one embodiment option, shown there are three components to make a complete soffit system, a ribbon bar 1, a fascia/soffit bracket 2 and a soffit panel 4. All three components can be made from suitable metal. However each could also be manufactured from plastic or even wood.

The ribbon bar 1 is formed from 1mm gauge metal in the form of a u-shaped elongated component. The ribbon bar 1 can be of various lengths and will have fixing holes punched out through the centre of the ribbon bar I at approximately 3 0mm spacings. This will allow the ribbon bar I to be easily fixed to the framing of the building. The ribbon ar 1, intended u-shape, is to retain one 5 end of the fascia/soffit bracket securely so it will require no fixings. However a L-shaped bar could be used and could be replaced with milled wood. The fascia/soffit bracket 2 is the key component of the invention. It will act as a retainer bracket for the soffit panel and a retainer bracket for the fasci panel and will be installed as one unit. The elongated channel section of the fascia/soffit bracket 2 will fit tightly into the ribbon bar 1, as 10 shown in Figure 4, at this point the ribbon bar 1 will retain the elongated channel section of the fascia/soffit bracket and will ensure an adequate fixing, retaining the elongated channel section from moving up and down. Once the end of the bracket has been put into place, the opposite end of the bracket which acts as the retainer for the fascia panel 6, can be fixed to the end of the rafter 7 using either screws or nails, as shown in Figure 4. The channel section of the fascia/soffit bracket 2 will have 5 retainer slots 3 machined pressed in, to accommodate the soffit panels ribs 5 as shown in Figure 4 in the exploded diagram. The shape of the retainer slots 3 could be of various shapes but as shown in the exploded view in Figure 2, they are either hexagonal or spheric. It is preferred a u-shaped channel is used on the elongated part of the bracket however a L-shaped could also be satisfactory the preferred material of the bracket would be a suitable metal. However a moulded plastic bracket could be used. The soffit panel 4 can be a pre-finished product such as colorsteel, it will be made from a suitable metal and a preferred thickness of 0.55 gauge. It will have five more or less ribs 5 machine pressed in or rolled formed laterally, these ribs 5 will act as support and strength and also act as retainment for the soffit panel 4 which is highly desirable. The preferred material will be a suitable metal, however a moulded plastic panel could also be used. The fascia panel 6 can be a conventional metal fascia with an overhead lip 9 for hanging the fascia on the bracket while the bottom consecutively clips onto each bracket. It will at the bottom of the panel have a soffit retaining strip 8 roll-formed into the panel and this will acts mooing for the edge of the soffit panel 4, as shown in Figure 4. In operation the ribbon bar I is fixed to the framing of the building with screws around the etire perimeter of the building. The fascia/soffit bracket 2 is arrested into the ribbon bar 1 at one end (the proximal end) and fixed by screws or nails onto the rafter 7 at the other or more distally. A fascia/soffit bracket 2 can be installed to every rafter 7 around the entire building.

-9 The fascia panel 6 can also be installed onto the fascia/soffit bracket 2 around the perimeter of the building. The fascia panel 6 can be hooked to the top of the bracket and clipped-in to the bottom of the bracket. Finally, but a different sequence can be used; the soffit panel 4 can be lodged into place by 5 pressing the ribs 5 in to their locating slots 3, one at a time, starting from the fascia end. The soft panel may be mitred ar internal and external corners of the building with the use of metal snips or pneumatic sheets. The fascia/soffit bracket 10 shown in Figure 9, as an alternative embodiment, could be stamped by press from suitable metal as a flat form, rather than having an elongated U-shaped channel at the 10 lower region of the bracket. While eliminating the U-shape channel will create weakness in this area, strengthening ribs 11, can be pressed in to the soffit retaining part of the bracket to obtain strength. The soffit panel 4, alternatively, could be rolled formed as two or more sections adjoining together to create a full panel. As shown in Figure 10 there are five sections 12, that have been roll formed or tnachine pressed singularly. 15 Where the soffit width is greater than the formed soffit panel and/or the fascia/soffit bracket, an extension could be used to create wider distance such as entrance ways. This extension would adapt to the end of the fascia/soffit bracket 10, and be retained to the proximal end of the building by the ribbon bar 1. It can be fixed to support framing (which will be part of the building structure) with screws. The extension bracket 13 can be machine pressed from, for !0 example, lmm gauge suitable metal. As shown in Figure 11, the soffit bracket 10 will be installed as previously explained, then when a greater width is required the extension bracket 13 can be cut to length. The extension bracket 13 could be rolled formed or machined pressed to a length of up to 6m. It will be preferably L-shaped but a U-shaped bracket could also be suitable, 5 In Figure 12 1 have shown an isometric view of the extension bracket 13. Here can be seen support ribs formed into the side of the bracket, with at the lower end of the bracket, a female retainment for location of the soffit panel, and pre- stamped holes for fixing to the support framing. As shown in Figure13, a breather or soak hole may be required to allow condensation to be released from the soffit panel 4. This breather/soak hole 15 can be stamped out as it is formed 9 trough the roll forming machine at suitable spacings. It can be located on one side of the rib 5, but could also be located on both sides of the ribS. It could be of any shape but a rectangle shape has been shown in Figure 13. It will be just big enough to allow condensation to be released but not affecting the strength of the rib 5.

- 10 As shown in Figure 14, in order to provide soffit pancl/soffit panel flush fitting, at one end of the soffit panel 4, there will be 5 0rnm toggled edge 16, able to receive an overlapping soffit panel 4, so when in final position, the over and underlapping soffit panels will have a flush finish. This will also act as a retainment for the lapping soffits, as the overlapping soffit will clip into the recessed end of the 5 underlap of the already positions soffit panel. Figure 14 shows this all as an exploded view and a cross-section view of the toggled edge. After the soffit panel has been roll formed, the panel may have to have one end placed into a press machine to receive the recessed or toggled end. In this specification where reference has been made to patent specifications, other external 10 documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, ate prior art, or form part of the common general knowledge in the art

Claims (22)

1. A method of installing a soffit system comprising or including the steps, in any suitable order, of - locating and/or engaging a proximal end region of each of a series of combined soffit and fascia brackets to a feature or features of a building, - attaching a more distal region of each of the series of brackets to a rafter which extends substantially past an end of a ceiling joist which forms an eave, and - engaging the fascia to the brackets more distally than the attachment to the rafter, the brackets fully supporting the fascia in a non-penetrative manner, and - attaching soffit sections, to form a soffit panel, to said brackets at a male - female engagement that engages in a shape interfering click fit type manner, each soffit panel comprising at least two separate and substantially coplanar sections adjoining each other to create a full panel, wherein an innermost section runs parallel and adjacent said feature or features of the building and an outermost section runs parallel and adjacent a lower edge of the fascia.

2. A method of claim 1 wherein the brackets are unitarily formed.

3. A method of claim 1 wherein the brackets are fabricated as an assembly whether on site or otherwise.

4. A method of any one of the preceding claims wherein the soffit is of profiled full soffit width panels.

5. A method of any one of the preceding claims wherein the soffit at at least some of the building perimeter is fabricated to full width required.

6. A method of any one of the preceding claims wherein feature(s) of the building is a ribbon member.

7. A method of claim 6 wherein said feature(s) is(are) of a metal or like long run form.

8. A method of claim 6 wherein said ribbon is in the form of a channel into with a proximal end region of each of a series of combined soffit and fascia brackets can be inserted in a spaced relationship.

9. A method of claim 6 wherein the ribbon can take the form of any suitable outstand able to engaged into or with the proximal end region of a said bracket.

10. A method of any one of the preceding claims wherein said combined soffit and fascia bracket is of metal.

11. A method of any one of the preceding claims wherein said combined soffit and fascia bracket is of a general channel like form with the exterior of the base of the channel form being formed to receive the suitable said soffit.

- 12 12. A method of any one of the preceding claims wherein the soffit and brackets inter-engage in a male into female, or vice versa, or both, manner at one or more zones across the soffit width.

13. A method of any one of the preceding claims wherein said combined soffit and fascia bracket includes an upstand distally to underlie an upper and lapping region of a said fascia.

14. A method of claim 13 wherein each said bracket includes below said upstand a downward protuberance behind which a lower part of the fascia can be received.

15. A method of any one of the preceding claims wherein said fascia includes a lap to overly inwardly the upstand of said bracket and/or a recessed portion to be inserted behind the lower part of said bracket there to receive therein a distal part of a said soffit.

16. A method of any one of the preceding claims where said soffit is a long run member with shape engaging features longitudinally thereof and/or with one or both edges adapted for association with (a) proximally with a said ribbon and/or distally with a lower part of a said fascia.

17. A method of any one of the preceding claims which involves components, subassemblies, or procedures, substantially as herein described with reference to any one or more of the accompanying drawings.

18. A soffit assembly resulting from such a system of any one of claims 1 to 18.

19. A long run soffit assembly where a long run soffit underlies, but is held to, outstanding brackets that also wholly support a long run fascia, the long run soffit formed of at least two separate sections adjoining each other to create a full panel, wherein an innermost section runs parallel and adjacent the feature or features of the building and an outermost section runs parallel and adjacent a lower edge of the fascia, wherein the long run soffit is at least in part supported by male - female engagement plug fits with the brackets.

20. An assembly of claim 20 wherein each bracket has been nosed into the building or brackets or a ribbon thereof and has been fixed more distally to the building.

21. An assembly of claim 20 or 21 wherein the male - female engagement plug fits are of a shape interfering click fit type manner.

22. A soffit and fascia support bracket having a proximal and distal region adapted for (i) from building or a building anchored ribbon proximal support, (ii) more distal rafter support, (v) distal support to wholly support a fascia and (vi) multiple female receipt from below of male forms of a soffit formed from multiple panels arranged parallel to each other with each panel's elongate axis perpendicular to the - 13 direction from the building or a building anchored ribbon proximal support to the more distal rafter support.