A roof panel assembly

Abstract

The present invention discloses a roof panel assembly (10) comprising: at least two roof 5 panels (1,2), each formed with one or more ribs, in which every two roof panels (1,2) are connected by having a rib of an overlaying roof panel (2) stacking on a rib of an underlaying roof panel (1) to form an overlapping section; a fastener (3) for securing the overlapping section; and an elongate cap (4) configured to cover the fastener and at least a portion of the overlapping section, wherein the elongate cap (4) is formed with 10 a resilient structure that clamps the overlapping section.

Description

[0001]

[0002] A ROOF PANEL ASSEMBLY

[0003] FIELD OF INVENTION

[0004] The invention relates to a roof panel assembly. More particularly, the invention relates to an elongate cap for covering the fasteners exposed at the overlapping section of the roof panels.

[0005] BACKGROUND OF THE INVENTION

[0006] In recent years metal roofs have become increasingly popular as they are very strong, very rugged, and long lasting. Corrugated metals are commonly used to cover roofs. The corrugated metal roof is manufactured using a metal sheet coil which is then shaped into preset corrugated pattern of alternating ridges and grooves. The advantage of the corrugated metal roof is its low cost, provides structural strength due to its ridged design, durable, and is long lasting than conventional asphalt roof. However, the corrugated metal roof exposes multiple fasteners used to secure the overlapping sections of the roof sheets. Over the time, the exposed fasteners get loosen and has a potential to become a source for leakage especially water during rains.

[0007] Over the years, various roof panels are developed. For instance, PCT Patent Application Number WO2020128592A1 discloses a fastening component for a clip-on securing system for roofing and cladding. The fastening component comprising at least one full anchor bracket that can be secured to an underlying structure. The full anchor bracket comprising a substantially trapezoidal bracket body comprising a pair of spaced apart bracket legs that taper from a relatively wider lower end of the bracket body to a relatively narrower upper end of the bracket body, the lower end of each bracket leg having outwardly splayed flanges for securing the bracket to the underlying structure. The full anchor bracket further comprising an overlying spring clip extending over the upper end of the bracket body. The tempered spring clip comprising resilient spring arms that extend away from the tapering bracket legs, the resilient spring arms clippingly receive and resilient engage the overlying covering sheet.

[0008] Accordingly, it is desirable to provide an elongate cap that covers the fasteners secured to the overlapping sections of the roof sheets. This invention offers a solution to this problem.

[0009] SUMMARY OF INVENTION

[0010] The present invention discloses a roof panel assembly comprising: at least two roof panels, each formed with one or more ribs, in which every two roof panels are connected by having a rib of an overlaying roof panel stacking on a rib of an underlaying roof panel to form an overlapping section. A fastener for securing the overlapping section. The elongate cap configured to cover the fastener and at least a portion of the overlapping section. The elongate cap is formed with a resilient structure that clamps the overlapping section.

[0011] Preferably, the ribs are each formed with a corrugated profile having multiple folds and a flat peak surface.

[0012] Preferably, the overlaying roof panel has one edge formed with a partial rib or a full rib to be stacked in a stable and complementary manner with the partial rib or the full rib of the underlaying roof panel.

[0013] Preferably, the flat surface of the peak provides a wider area to accommodate the fastener to be fastened through the stacked peaks of the overlapping portion.

[0014] Preferably, the resilient structure of the elongate cap is in the form of an arch.

[0015] Preferably, the arch has two notched ends has a shape with dimensions that allow snap fitting of the notched ends to the corrugated profile of the overlapping section of the ribs.

[0016] Preferably, the elongate cap has the same length as the overlapping section.

[0017] One skilled in the art will readily appreciate that the invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are not intended as limitations on the scope of the invention.

[0018] BRIEF DESCRIPTION OF THE DRAWINGS

[0019] For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the invention, its construction, and operation and many of its advantages would be readily understood and appreciated.

[0020] Fig. 1 is an exploded view of a roof panel assembly.

[0021] Fig. 2 is a side view of the roof panel assembly in accordance to the Fig. 1.

[0022] Fig. 3 a is a diagonal view of a first roof panel profile from left side.

[0023] Fig. 3b is a diagonal view of the first roof panel profile from right side.

[0024] Fig. 3 c is a diagonal view of the first roof panel profile from bottom side.

[0025] Fig. 3d is a diagonal view of the first roof panel profile from top side.

[0026] Fig. 4 is a top planar view of the first roof panel profile.

[0027] Fig. 5 is a bottom planar view of the first roof panel profile.

[0028] Fig. 6 is a left-side planar view of the first roof panel profile.

[0029] Fig. 7 is a right-side planer view of the first roof panel profile.

[0030] Fig. 8 is a planar view of an elongate cap from top, bottom, left side and right side.

[0031] Fig. 9 is a diagonal view of the elongate cap from top, bottom, left side and right side.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] The invention will now be described in greater detail, by way of example, with reference to the drawings.

[0034] Fig. 1 illustrates an exploded view of a roof panel assembly (10) comprises at least two roof panels (1, 2), a fastener (3) and an elongate cap (4). The roof panels (1,2) can be installed either on a solid substrate or on an open frame structure such as metal purlins or wood support beams. Preferably, the roof panels (1,2) have a ribbed profile and hence, the roof panels (1,2) are ribbed roof panels, where each roof panel (1,2) is formed with one or more ribs as shown in Fig. 3a to Fig. 3d and Fig. 4 to Fig. 7. The ribs are formed with pre-defined space between them along the length and width of each roof panel (1,2). Between two ribs includes at least one narrower rib formed along the length and width of each roof panel (1,2). The roof panels (1,2) are formed with a partial rib on one edge and a full rib on other edge.

[0035] While installing the roof, one portion of the one roof panel (1,2) is stacked on the other portion of the roof panel (1,2). The roof panel (2) placed on top of the other panel (1) is known as the overlaying roof panel (2), whereas the roof panel (1) being under the overlaying roof panel (2) is the underlaying roof panel (1). Preferably, one edge of the overlaying roof panel (2) is formed with a partial rib or a full rib that is stacked in a stable and complementary manner on the partial rib or the full rib formed on the edge of the underlaying roof panel (1). Preferably, the rib is formed with a corrugated profile having multiple folds and a flat peak surface. The full rib includes a peak being a flat surface, also referred to as the “flat peak surface” herein, and a purlin bearing leg structure extending from one end of the flat peak surface. The full rib also includes inwardly bent indentation structure formed on its either side and the at least two folds with space formed on its flat peak surface. While the half rib includes the flat peak surface which is slightly curved but does not have the purlin bearing leg structure and the folds formed on the flat peak surface. The half rib also includes the inward bent indentation formed on its one side. The flat peak surface provides a wider area to accommodate the fastener (3) to be fastened through the stacked peaks of the overlapping portion.

[0036] As shown in Fig. 2 every two roof panels (1,2) are connected by having the rib of an overlaying roof panel (2) stacked on to the rib of an underlaying roof panel (1) to form an overlapping section. The fastener (3) is secured to the overlapping section. Preferably, the fastener (3) is a screw drilled through the overlapping section of the two roof panels (1,2). The roof panel (1,2) with edge having the half rib is stacked on to the roof panel (1,2) with the edge having the full rib and vice versa to form the overlapping section. Preferably, the roof panel (1,2) with the edge having the half rib is stacked on the roof panel (1,2) with the edge having the full rib forming the overlapping section and the fastener (3) is arranged secured through the overlapping section. The fastener

[0037] (3) passes through the flat surface of the half rib and the in between the folds formed on the flat peak surface of the full rib. The folds formed on the flat peak surface of the full rib prevents the flat peak surface of the half rib from bending when secured by the fastener (3) and thereby, enables to secure the fastener in position without any free movement. As shown in the Fig. 1 and Fig. 2, the elongate cap (4) is arranged to cover the fasteners and at least the portion of the overlapping section. The profile structure of the elongate cap (4) is clearly shown in Fig. 8 and Fig. 9. Preferably, the elongate cap

[0038] (4) is formed with a resilient structure that clamps onto the overlapping section. More preferably, it is the clamping portion of the elongate cap (4) that is resilient and is made of an elastic material. Preferably, the length of the elongate cap (4) is same as the length of the overlapping section. The resilient structure of the elongate cap (4) is in the form of an arch. Preferably, the arch has two notched ends having a shape with dimensions that allow snap fitting of the notched ends to the corrugated profile of the overlapping section of the ribs of the roof panels (1,2). The notched ends are at least part of the clamping portion of the elongate cap (4). One of notched end of the elongate cap (4) gets snap clamped on to the inward bent indentation of the half rib and the other notched end of the elongate cap (4) gets snap clamped on to the inward bent indentation of the full rib. Thereby, the elongate cap (4) covers the exposed fasteners (3) and may prevent the fastener from loosening due to the snap fit effect. Further, the arch structure of the elongate cap (4) is intact and strong enough to prevent any structural deformity which may be caused by workers walking or stamping on it.

[0039] The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.

Claims

CLAIMS1. A roof panel assembly (10) comprising: at least two roof panels (1,2), each formed with one or more ribs, in which every two roof panels (1,2) are connected by having a rib of an overlaying roof panel (2) stacking on a rib of an underlaying roof panel (1) to form an overlapping section; a fastener (3) for securing the overlapping section; and an elongate cap (4) configured to cover the fastener and at least a portion of the overlapping section.

2. The roof panel assembly (10) according to claim 1 , wherein the elongate cap (4) is formed with a resilient structure that clamps the overlapping section.

3. The roof panel assembly (10) according to claim 1 or 2, wherein the ribs are each formed with a corrugated profile having multiple folds and a flat peak surface.

4. The roof panel assembly (10) according to any one of the preceding claims, wherein the overlaying roof panel (2) has one edge formed with a partial rib or a full rib to be stacked in a stable and complementary manner with the partial rib or the full rib of the underlaying roof panel (1).

5. The roof panel assembly (10) according to claim 3, wherein the flat surface of the peak provides a wider area to accommodate the fastener (3) to be fastened through the stacked peaks of the overlapping portion.

6. The roof panel assembly (10) according to claim 2, wherein the resilient structure of the elongate cap (4) is in the form of an arch.

7. The roof panel assembly (10) according to claim 6, wherein the arch has two notched ends has a shape with dimensions that allow snap fitting of the notched ends to the cormgated profile of the overlapping section of the ribs.

8. The roof panel assembly (10) according to any one of the preceding claims, wherein the elongate cap (4) has the same length as the overlapping section.

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