Lantern crown assembly

Abstract

The lantern crown assembly, particularly for interconnecting roof beams of a conservatory or orangery, comprises a number of end pieces 12 each for connection to a respective support beam, and a centr

Description

FIELD OF THE INVENTION This invention relates to a lantern crown assembly. A “lantern crown assembly” is the structure at the peak of the roof of a conservatory, orangery or other building, at which a number of beams of the roof structure meet and are interconnected, the beams supporting the glass or other panels of the roof. The present description relates primarily to a lantern crown assembly at which four beams meet but it will be understood that the invention is also applicable to lantern crown assemblies at which other numbers of beams meet. In this specification, directional and orientational terms such as “top”, “horizontal” and “vertical” for example, refer to the components in their normal orientation of use unless otherwise specified. For ease of understanding, a part of the roof 1 of a conservatory is represented in Fig.1. There are four beams 2 supporting four triangular-shaped glazing units 3. The four beams 2 meet at the peak 4 of the roof 1. Fig.2 shows a part of the structure of Fig.1 in more detail, with the glazing units 3 removed. Fig.3 shows the same part of the structure with the glazing carriers 5 and crown cover cap 6 removed to reveal the lantern crown assembly 10. The beams 2 which are shown in Figs. 1 and 2 comprise a structural support beam 7 and the glazing carrier 5. The support beams 7, which are usually called “hips”, are shown in Fig.3 and provide the structural strength for the roof. In typical fashion the hips 7 are extruded profiles, in this example of aluminium but in some cases plastics such as PVC. The top end of each of the hips 7 is secured to the lantern crown assembly 10 by respective fasteners, the fastener 8 of one of the hips 7 being visible in Fig.3. The glazing carriers 5 carry the weather seals for the glazing and separate the glazing units 3. The glazing carriers 5 are typically plastics extrusions and are mounted to a channel at the top of each of the hips 7. Fig.2 also shows the (plastics) clip-on trims 9 which are mounted to the glazing carriers 5 to cover the gaps between neighbouring glazing units 3. A (plastics) crown cover cap 6 is also shown, which covers the region where the four glazing carriers 5 meet at the peak or crown of the roof 1. The structure which is described above is conventional; the distinction of the present invention is the lantern crown assembly 10 by which the four hips 7 are secured at the peak of the roof 1. It is a particular benefit of the present invention that the hips 7, glazing carriers 5, clip-on trims 9 and crown cover cap 6 can be known components so that installers can continue to use much of the existing componentry. It will be understood that a roof structure such as that shown in Figs. 1-3 with four beams 2 meeting at the peak of the roof 1 is not the only structural form used for conservatories, orangeries and the like. Another known structure is often called a pitched skylight and has a horizontal ridge beam at the peak of the roof and two lantern crown assemblies connected to each end of the ridge beam. Two hips are in turn connected to each of the lantern crown assemblies. Other known structures have six or eight hips meeting at a lantern crown assembly. Whilst the following description relates primarily to the lantern crown assembly 10 of the structure shown in Figs. 1-3 having four hips 7, it will be understood that the assembly could readily be modified to cater for different roof structures without departing from the invention. A known lantern crown assembly comprises a plurality of end pieces and a central connector or boss. Each end piece is configured for connection to one of the hips and also to the central connector whereby the hips are securely interconnected at the peak of the roof. It will be clear from the above description that the lantern crown assembly is an important component in the roof structure. By interconnecting the hips which support most of the weight of the glazing units, the lantern crown assembly itself provides a major part of the structural strength of the roof. The lantern crown assembly also ensures the proper alignment and orientation of the hips at their top ends. The proper alignment and orientation of the hips is in turn critical to ensuring that the glazing units fit properly and the weather seals can properly prevent the ingress of moisture. In the known lantern crown assembly the end pieces which are connected to the respective hips are each fastened to the central connector by one or two bolts. The central connector is drilled and tapped to receive the bolts and enable the connection of the end pieces. The correct positioning and alignment of the drilling and tapping operations is necessary to ensure that the bolts fit correctly and the end pieces (and consequently the hips) are properly positioned and aligned. The central connector is typically machined at the manufacturing location where appropriate jigs and fittings are available for all of the separate machining operations. The end pieces are usually assembled to the central connector at the manufacturing location so that an assembled lantern crown assembly is provided to the installer at the site of use. The assembly includes the insertion of a large number of bolts which requires significant assembly time. SUMMARY OF THE INVENTION It is an object of the present invention to reduce the number of machining operations which are required for the central connector, and thereby to reduce the manufacturing complexity and the likelihood of errors during manufacture. It is another object of the present invention to avoid the bolted connection between the end pieces and the central connector, and thereby to reduce the assembly time. It is another object of the present invention to seek to commonise many of the components of the lantern crown assembly whereby to reduce the manufacturing complexity and minimise the cost of stockholding. According to the present invention there is provided a lantern crown assembly comprising a central connector and a number of end pieces, each end piece being configured for connection to a hip of a roof structure, each end piece being connected to the central connector by a dovetail connection. The provision of a dovetail connection avoids the requirement for a bolted connection and it will be understood that the male and female elements of the dovetails can be cast or moulded and can avoid the requirement for machining. Preferably, the central connector carries the male dovetail element and the end piece carries the female dovetail element. Preferably also, the central connector has multiple dovetail elements whereby a single central connector can be connected to multiple end pieces and thereby to multiple hips. Desirably, the dovetail elements are tapered. Thus, in addition to the dovetail elements cooperating in the horizontal orientation, the (horizontal) cross-sectional form of the dovetail elements tapers along the vertical axis, and in particular narrows from the top to the bottom of the central connector. Accordingly, and somewhat similarly to the central keystone in an arched bridge, the weight of the central connector, in combination with the weight of the hips and supported glazing units, act to increase the connection between the central connector and the end pieces. Preferably, the central connector has a single drilled and tapped hole by which to secure the end pieces. Accordingly, the components of the lantern crown assembly can be held together by a single securing bolt whereby the machining requirements and the assembly time are significantly reduced over the known lantern crown assemblies. Preferably also, the end pieces have a part-hole to receive the single securing bolt. Desirably the part-holes of neighbouring end pieces are aligned in the assembled lantern crown assembly whereby the part-holes together form a complete hole for the securing bolt. Desirably, the complete hole is aligned with the drilled and tapped hole of the central connector. The securing bolt can therefore be passed through the aligned part-holes and into the drilled and tapped hole of the central connector in order to secure the end pieces to the central connector. Desirably, each of the end pieces is identical. The end pieces can therefore all be made with common tooling which reduces the manufacturing cost and also reduces the cost of stocking the parts ready for use. For example, in a lantern crown assembly having four end pieces, all four of the end pieces can be identical. The end pieces can also be identical in roof structures having six or eight hips, provided those hips are equally spaced around the central connector. Preferably, the central connector has a covering piece, which covering piece can cover recesses and / or openings in the lantern crown assembly, which recesses and / or openings might otherwise have acted as water traps. Preferably also, the covering piece covers the dovetail connections in the assembled lantern crown assembly. Desirably, the covering element is a substantially flat plate. Desirably also the substantially flat plate is integral part of the central connector. Preferably, the lantern crown assembly has a fixing hole to which a part of the overlying roof structure can be secured. Preferably also, the fixing hole is provided in the central connector. Desirably, a connector element is mounted to the central connector, the connector element having a first end and a second end, a first recess at the first end and a second recess at the second end. In the assembled lantern crown assembly the first recess is threaded to receive a bolt by which the end pieces are secured to the central connector, and the second recess is provides the fixing hole. BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention will now be described in more detail, by way of example, with reference to the accompanying drawings, in which: Fig.1 shows a roof structure having a lantern crown assembly according to the present invention; Fig.2 shows a part of the roof structure of Fig. 1; Fig.3 shows a part of the hips and lantern crown assembly of the roof structure of Fig.1; Fig.4. shows a perspective view of the central connector of a first embodiment of lantern crown assembly according to the invention; Fig.5 shows a vertical cross section through the central connector of Fig.4; Fig.6 shows an underside view of the central connector of Fig.4; Fig.7 shows a perspective view of one of the four end pieces of the lantern crown assembly according to the invention; Fig.8 shows a side view of the end piece of Fig.7, in the direction towards its dovetail element; Fig.9 shows an array of four of the end pieces of Fig.7 in plan view; Fig.10 shows the parts of the lantern crown assembly during manufacture; Fig.11 shows a vertical cross-section through the end piece of Fig.7; Fig.12 shows a side view of the end piece of Fig.7, towards its hip connectors; Fig.13 shows the assembled first embodiment of lantern crown assembly; Fig.14 shows a connector element of the central connector of a second embodiment of lantern crown assembly according to the invention; Fig.15 shows the central connector of the second embodiment; Fig.16 shows the second embodiment of lantern crown assembly during assembly; Fig.17 shows the assembled second embodiment of lantern crown assembly; Fig.18 shows an exploded view of a third embodiment of lantern crown assembly according to the invention; Fig. 19 shows a sectional view of the assembled third embodiment of lantern crown assembly; Fig.20 shows an underside view of the assembled third embodiment of lantern crown assembly; and Fig.21 shows a cross-section through the assembled third embodiment of lantern crown assembly. DETAILED DESCRIPTION A description of the roof structure of Figs. 1-3 is set out above and will not be repeated. As stated, many of the components of the roof structure 1 are identical to a known roof structure and the only difference can be the lantern crown assembly 10, 110 by which the hips 7 are interconnected as described below. Since the hips 7 are formed as extrusions it is not practical to interconnect them directly to each other, nor directly to a central boss or connector. Instead, and in common with the known roof structures, a respective end piece 12 is secured to the top end of each of the hips 7 and the end pieces are in turn connected to a central connector 14,114. The end pieces 12 according to the present invention are shown in Figs. 7-14 and these end pieces are common to both embodiments of the lantern crown assembly. The central connector 14 of the first embodiment is shown in Figs. 4-6 and the central connector 114 of the second embodiment is shown in Figs. 15-17. The end pieces 12 and the central connector 14,114 are metallic and are made by diecasting. Whilst it might be possible for some applications to make these components in plastics that is not generally preferred because plastics are not likely to have the structural strength required in most applications. Figs. 11 and 12 show the aligned bolt holes 16 by which a hip 7 can be secured to and end piece 12. Thus, the bolt 8 which is seen in Fig.3 passes through a hole formed near to the top end of the hip 7 and into the aligned holes 16. The holes 16 are formed in projections 18 which are spaced apart by a distance corresponding to the separation of the webs of the profile of the hip 7, which webs are visible in Figs.2 and 3. As best seen in Fig.4, the central connector 14 of the first embodiment has a (horizontal) cross-sectional form somewhat like a Maltese cross, with four male dovetail elements 20. As best seen in Fig.5, the central connector 14 tapers inwardly (i.e. narrows) from its top end to its bottom end, with a relatively shallow draft angle a. Accordingly, the horizontal cross section of the central connector 14, and the horizontal cross section of each of the dovetail elements 20, becomes smaller from the top to the bottom of the central connector 14. The shallow draft angle a can also be seen in the underside view of Fig.6. A perspective view of an end piece 12 is shown in Fig.7. The structure of the end piece 12 is made somewhat more complex by the optional voids 22 which are included in this embodiment to save weight and also facilitate the diecasting process. The relevant parts of the end piece 12 are the projections 18 and holes 16 as previously described, and also the female dovetail element 24. It will be understood that the female dovetail element 24 is sized to securely accommodate one of the four male dovetail elements 20 of the central connector 14. Fig.9 shows four of the end pieces 12 prior to assembly. It will be seen that each end piece 12 comprises a quadrant and it will be understood that the end pieces 12 can all be moved together from the position of Fig.9 until they engage their neighbours and form a continuous structure as in Fig. 13. Each end piece 12 has a lateral projection 26 which locates in a recess 28 of the neighbouring end piece, to provide additional structural stability. Fig.10 shows all of the components of the lantern crown assembly 10 during manufacture. When the end pieces 12 are all brought together, the central connector 14 can be moved downwardly from the position shown, and one of the male dovetail elements 20 can enter into each of the female dovetail elements 24 and hold the end pieces together. The tapering form of the dovetail elements 20, 24 causes the end pieces 12 to become more securely held together as the central connector 14 is moved downwardly. As seen in Figs.4 and 5, the central connector has a bore 30 which is hexagonal. The bore 30 can accommodate a securing nut 32 which is shown in Fig.10 and the hexagonal form of the bore 30 prevents the securing nut 32 from rotating. As seen in Figs. 5 and 6, the bottom end of the bore 30 has a bolt hole 34. As seen in Figs. 7-9 and 11, each of the end pieces 12 has a part-hole (and in particular a quarter-hole) 36. When the end pieces 12 are moved together the quarter-holes 36 form a complete hole which is aligned with the bolt hole 34, allowing a securing bolt 38 to pass through the quarter-holes 36 and bolt hole 34 to engage the securing nut 32. It will be understood that the head of the securing bolt 38 (and fitted washer if provided) engages the bottom surface of each of the end pieces 12. As the securing bolt 38 is tightened the central connector 14 is forced downwardly as drawn in Fig.10 relative to the end pieces 12, further increasing the connection between the respective dovetail elements 20, 24 and thereby between the central connector 14 and the end pieces 12 and resulting in a rigid lantern crown assembly 10. It is preferably arranged that the male dovetail elements 20 do not quite reach the bottom of their respective female dovetail elements 24 when the securing bolt 38 is fully tightened, in order to ensure that manufacturing tolerances do not act to prevent the securing bolt from fully tightening and securing the lantern crown assembly. Figs. 14-17 show the parts of a second embodiment of crown lantern assembly 110. As stated above, the end pieces 12 which connect to the central connector 114 are identical to the end pieces described above and will not be described further. The second embodiment is distinguished from the first embodiment firstly in that the central connector 114 has a covering piece 140. As seen in Fig.17, in the assembled lantern crown assembly the covering piece 140 overlies and obscures the bore 130 of the central connector 114 and also overlies and obscures the dovetail elements 120, which parts could otherwise provide water traps. The second embodiment is distinguished secondly by a connector element 142. The connector element 142 has a first end and a second end, which are the lower and upper ends respectively as viewed and in use. The first end has a threaded recess to receive the securing bolt 38 and thereby replaces the fixing nut 32 of the first embodiment. The periphery of the connector element 142 adjacent to the first end has a hexagonal form and cooperates with the hexagonal form (not seen) at the bottom end of the bore 130 to prevent rotation of the connector element 142 relative to the central connector 114. The connector element 142 is fitted into the bore 130 of the central connector though its open top end as seen in Fig.16. The connector element has an enlarged head which overlies a part of the covering piece 140 adjacent to the bore 130. It will be understood that in the assembled lantern crown assembly the head of the securing bolt 38 (and fitted washer if provided) engages the bottom surface of each of the end pieces 12 as described above. As the securing bolt 38 is tightened the connector element 142, and consequently the central connector 114, are forced downwardly as drawn in Fig.16 relative to the end pieces 12, increasing the connection between the respective dovetail elements thereby between the central connector 114 and the end pieces 12 and resulting in a rigid lantern crown assembly 110. It is again preferably arranged that the male dovetail elements 120 do not quite reach the bottom of their respective female dovetail elements 24 when the securing bolt 38 is fully tightened, in order to ensure that manufacturing tolerances do not act to prevent the securing bolt from fully tightening and securing the lantern crown assembly 110. The second end of the covering piece has a recess 144. As seen in Fig. 17, in the assembled lantern crown assembly the recess 144 is accessible and provides a fixing hole to which a part of the roof structure (such as the cover cap 6 for example) can be fitted and secured. Figs. 18-21 show the parts of a third embodiment of crown lantern assembly 210. The third embodiment is distinguished from the first and second embodiments firstly in that the bolt 238 is a square-headed bolt, the head 248 of which fits into an enclosed recess formed from four quadrants 250, one quadrant being formed in each of the four (identical) end pieces 212. Only one of the quadrants 250 is seen in Fig. 18 but the other three quadrants are identical and all four quadrants are aligned. In the assembled lantern crown assembly 210 the head 248 of the bolt 238 is fully enclosed and therefore not visible in the underside view as seen in Fig.20. As is clear from the sectional views of Figs. 19 and 21, the head 248 is captive and neither a tool or access for a tool is required to prevent the bolt 238 from rotating as the connector element 242 is tightened. A hexagonal head has been added to the connector element 242 to allow it to be tightened to the bolt 238 by a suitable tool. In addition, some of the locating pegs and cooperating recesses of the end pieces 212 have been modified to help with alignment of the end pieces during assembly, and also to reduce or eliminate gaps in the assembled lantern crown assembly. The avoidance of gaps is important to minimise the ingress of paint or other surface 5 coating which is applied to the assembled lantern crown assembly.

Claims

1. A lantern crown assembly having a central connector and a number of end pieces, each end piece being configured for connection to a support beam of a roof structure, each end piece being connected to the central connector by cooperating dovetail elements.

2. A lantern crown assembly according to claim 1 in which the dovetail elements comprise a male dovetail element and a female dovetail element, and in which the central connector has the male dovetail element and the end piece(s) has the female dovetail element.

3. A lantern crown assembly according to claim 1 or claim 2 in which the dovetail elements are tapered.

4. A lantern crown assembly according to any one of claims 1-3 in which the central connector has multiple dovetail elements and each end piece has a single dovetail element.

5. A lantern crown assembly according to claim 4 in which the multiple dovetail elements surround a recess.

6. A lantern crown assembly according to any one of claims 1-5 in which the central connector has a hole configured to receive a fastener for securing the end pieces to the central connector.

7. A lantern crown assembly according to claim 6 when dependent upon claim 5 in which the hole is formed at the bottom of the recess.

8. A lantern crown assembly according to claim 6 or claim 7 in which each end piece has a partial hole configured to receive the fastener.

9. A lantern crown assembly according to claim 8 in which the partial holes of the end pieces together form a complete hole, the complete hole being aligned with the hole of the central connector.

10. A lantern crown assembly according to claim 8 or claim 9 in which each end piece has a recess, the recesses together creating a volume for accommodating a head of the fastener.

11. A lantern crown assembly according to any one of claims 1 -10 in which each of the end pieces is of identical form.

12. A lantern crown assembly according to any one of claims 1-11 having a covering element which covers the dovetail elements.

13. A lantern crown assembly according to claim 12 in which the covering element is an integral part of the central connector.

14. A lantern crown assembly according to any one of claims 1-13 having a fixing hole configured to receive a fastener by which a part of an overlying roof structure can be secured.

15. A lantern crown assembly according to any one of claims 1-14 in which a connector element is mounted to the central connector, the connector element having a first end and a second end, with a first recess at the first end and a second recess at the second end.

17. A lantern crown assembly according to claim 16 in which the first recess is threaded.

18. A lantern crown assembly according to any one of claims 1 -17 having four end pieces.

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