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BACKGROUND OF THE INVENTION
Construction panels are generally formed from sheet aluminum or steel, and
they are frequently webbed on their long sides to provide longitudinal
stiffening. The edges of the panels, or their webs, are often formed or
developed in special configurations so that panels placed side by side may
be interlocked to each other along their edges. Many different
configurations of interlocking means have proposed or placed into use.
Among them are those shown in U.S. Pat. Nos. 1,198,764; 1,429,400;
1,913,342; 2,019,379; 2,302,949; 3,055,461; 3,100,556; 3,131,794;
3,234,697; 3,276,171; 3,394,524; 3,462,906; 3,481,094; 3,606,718;
3,608,267 and 3,969,866.
Roofing panels are a special form of construction panel. It is desirable
that roofing panels be capable of installation on the underside of a
roofing framework from below the framework. This circumstance makes many
panel interlocking systems impractical or inconvenient for roofing panels,
including those which involve rotation of one panel with respect to
another in the course of installation, or telescoping of panel edges
together, or the use of fastening systems which are exposed or which
require access to space above the roofing framework.
Furthermore, it is necessary that a roof formed of roofing panels have
sufficient integral strength when assembled to avoid sagging and uneveness
even though it is attached to the framework at relatively widely spaced
points.
SUMMARY OF THE INVENTION
In accordance with the present invention, an improved roofing panel is
provided which is particularly well adapted for installation on the
underside of a roofing framework from below the framework. The roofing
panels of the invention are preferably roll formed from sheet aluminum or
sheet steel into channel shaped members of desired length having
upstanding webs on their long sides. Special locking means are provided
along the upper edges of the webs to provide for attachment of the panels
to the underside of a roofing framework, and to each other, with the
installation work being done from beneath the roofing level.
The locking means are preferably integrally formed from the material of the
panel webs and thus comprise special developments of the panel edges. The
female locking means is oriented outwardly of the web on which it is
carried, and is generally in the shape of an inverted "L". The base of the
"L", the mounting flange, is generally parallel to the main plane of the
panel and is adapted to abut against the underside of a roofing framework
member, typically an I-beam, so that a fastener such as a self-tapping
screw may be driven through the area of abutment to attach the panel to
the framework. The inverted "L" may thus be aptly termed a mounting and
locking means. The leg of the "L" depends from the mounting flange and
terminates in an inwardly oriented detent rib.
At the point where the mounting flange of the female locking means
intercepts the plane of the web on which it is carried, there is formed,
in accordance with the invention, a narrow scabbard which is oriented
inwardly of the web. In its preferred form, the scabbard is formed
integrally with the web and "L", and is oriented slightly downwardly as
well as inwardly.
The male locking means is proportioned to interlock with the female
mounting and locking means of an adjacent panel. It comprises an inwardly
oriented leg terminating in an inwardly oriented detent rib. In accordance
with the invention, the profile of the male locking means may take one of
two forms, depending upon whether it is desired to be able to apply the
fasteners from below or above the roof level. If the first is the case,
the male locking means comprises a leg which extends first downwardly
along the side of the web, and then inwardly and downwardly at an angle to
terminate in an inwardly oriented detent rib. This configuration provides
room within the locking means when assembled to accommodate the head of a
fastener such as a screw or rivet.
If, on the other hand, a system is desired in which the fasteners are
applied from the top and engage both the female and male locking means,
the leg of the male locking means extends first inwardly and then inwardly
and downwardly to terminate in an inwardly oriented detent rib. The
inwardly extending portion of the leg abuts the mounting flange of the
female lock when two panels are locked together, and the shaft of a
fastener may be driven from above through both of them.
At the point of juncture between the male locking member and the web on
which it is carried there is formed a narrow blade oriented outwardly of
the web. The blade is preferably integrally formed with the web and leg,
and is proportioned to fit into the scabbard of a female locking means
when two adjacent panels are interlocked.
When two panels of the invention are interlocked to form a section of
roofing, the male locking means of one panel is forced upwardly into the
female locking means of the other panel. As the detent ribs of the two
locking means come into contact, the legs of the locking means are
momentarily resiliently deformed until the rib of the male locking means
snaps upwardly past the rib of the female locking means. The snap action
impels the panel carrying the male locking member toward the other panel
to seat the blade in the scabbard. The scabbard-and-blade interconnection
of the panels resists downward force applied by one panel upon the other.
From the foregoing, it can be seen that a principal object of the present
invention is to provide an improved roofing panel which may be readily and
securely assembled and attached to the underside of a roofing framework by
installers working in the main, or entirely, from positions under the
framework.
This object, together with other objects and purposes, may best be
understood by a consideration of the detailed description which follows,
together with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a service station canopy with a roof formed
of panels of the invention installed therein;
FIG. 2 is an enlarged top perspective view of a portion of a roof
constructed in accordance with the invention, with portions of two
interlocked panels and a portion of a roofing framework being shown;
FIGS. 3 through 6 are sequential fragmentary and elevational views, partly
in section, of adjacent panels of the invention being installed on the
underside of a roofing framework and locked together;
FIG. 7 is a fragmentary end elevational view of a panel of the invention
constructed with an alternate form of male locking means; and
FIG. 8 is a fragmentary end elevational view of a pair of panels locked
together, the male locking means being that of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a canopy 10 of the kind commonly installed over pump
islands at service stations. The canopy structure includes supports 11, a
facia 12 which surrounds and conceals a roofing framework formed of
I-beams. Beneath the roofing framework is mounted roof 13, made up of a
series of panels 14, arranged in side-by-side relationship, and
interlocked together. Canopy 10 represents a typical building structure in
which roofing panels are mounted to the underside of a roofing frame.
From FIG. 2 it can be seen that panel 14 is in the form of a shallow
channel with a substantially planar main surface 15, and upstanding webs
16, 17. A rib 18 may be formed in main surface 15 for aesthetic and
strength-enhancing purposes, if desired, and more than one such rib may be
provided. Also, a bevel may be provided at the intersection of webs 16 and
17 with planar main surface 15.
An integral male locking means designated generally as 19 is formed on the
upper edge of web 16, and an integral female mounting and locking means
designated generally as 20 is formed on the upper edge of web 17.
Positioned next to panel 14 is like panel 14A, whose web 16A and male
locking means 19A can be seen in FIG. 2. Webs 17 and 16A are in abutting
relation, and male locking means 19A is inserted upwardly into and
interlocked with female locking and mounting means 20. The upper planar
portions of female locking and mounting means 20 is adapted for abutment
against the underside of I-beam 21, which is an element of a roofing
framework. A screw fastener 22 connects panel 14 to I-beam 21 in the
region of abutment.
The structure of the male and female locking means may best be understood
from FIG. 3. Female locking and mounting means 20 is preferably integrally
formed as a development of the upper edge of web 17 of panel 14. It is
generally in the shape of an inverted "L", with a substantially planar leg
23 extending outwardly from web 17 in abutment with the underside of
I-beam 21. Fastener 22 connects the leg 23, and thus panel 14, to beam 21.
At the outer end of leg 23 is positioned downwardly extending leg 24,
which terminates in an inwardly oriented detent rib 25.
At the point where leg 23 intercepts the plane of web 17, an integral
inwardly extending narrow scabbard 26 is formed. In addition to extending
inwardly, scabbard 26, or at least the bottom thereof, preferably extends
downwardly at a slight angle from the horizontal, preferably about ten
degrees.
The male locking means 19A is preferably integrally formed as a development
of the upper edge of web 16A, and comprises leg 27 which extends
downwardly and inwardly to a termination in detent rib 28. In the
embodiment shown in FIGS. 2-6, leg 27 has two distinct sections, the first
being a straight downwardly extending section 29, and the second being a
downwardly and inwardly extending section 30. An important advantage of
this arrangement is that clearance space is created for the head of
fastener 22 when the parts are fully interlocked (See FIG. 6).
At the juncture between leg 27 and web 16A there is formed narrow blade 31
which is oriented outwardly of web 16A. As can be seen in FIG. 3, blade 31
is preferably integrally formed by folding of the material of the web.
FIG. 6 shows that blade 31 is proportioned and positioned to fit into
scabbard 26. Like the scabbard, it is preferably angled slightly
downwardly from the horizontal, preferably about ten degrees.
A consideration of FIGS. 3 through 6, together and sequentially, will give
an understanding of the dynamics of the interlock system of the invention.
In FIG. 3, panel 14 is attached to I-beam 21 by means of fastener 22 before
panel 14A is brought into position beside it. Because of the open bottom
of female mounting and locking means 20, ready access may be had to the
underside of leg 23 for tools used to install fastener 22. Panel 14A is
then brought into the position shown in FIG. 3, and is pushed upwardly as
indicated by the arrow in that FIG.
Upward movement of panel 14A brings detent ribs 28 and 25 into contact, as
is shown in FIG. 4. As the panel is pushed upwardly, leg section 30 of the
male locking means and leg 24 of the female locking means flex away from
each other, as indicated by the arcuate arrows in FIG. 4, so the rib 28
can slide past rib 25. During this movement web 16A flexes also, as
indicated by the arcuate arrow in FIG. 4.
FIG. 5 shows the locking means just as detent rib 28 has snapped past
detent rib 25. As is indicated by the arcuate arrows in that FIG., legs 24
and 30 thereupon flex back toward their unstressed positions. At the same
time, blade 31 is lifted to the level of scabbard 26, and the violence of
the snap action just described impels panel 14A to the left as FIG. 5 is
drawn, this movement being indicated by the horizontal arrow in FIG. 5.
Blade 31 thus starts to enter scabbard 26.
FIG. 6 shows the parts at rest, with the interlock completed. Blade 31 is
fully seated in scabbard 26, and detent rib 28 is locked and seated above
detent rib 25. Web 16A is abutted against web 17. Clearance room
sufficient for the head of fastener 22 is provided. It should also be
noted that the weight load of panel 14A is applied to fastener 22 through
leg 23 from both sides and not merely one, in cantilever fashion. Part of
the load is applied at blade 31 and scabbard 26, on the left, and the rest
is applied at the interlock of ribs 25 and 28 on the right.
FIGS. 7 and 8 show another embodiment of the invention in which the male
locking means is given an alternate configuration to specially adapt the
locking and mounting system of the invention to applications where it is
desired to apply the fasteners from above the level of the roof.
In FIGS. 7 and 8 the parts are given the same reference characters as in
the prior FIGS. with the superscripts "B" and "C" added to indicate the
right and left panels respectively. The male locking means of FIGS. 7 and
8 differs from that shown in FIGS. 2-6 in that its leg 27B has a section
29B which extends substantially straight inwardly from web 16B instead of
straight downwardly as did leg section 29 of FIG. 3. Section 29B is thus
in abutment with leg 23C of the female locking and mounting means, so that
fastener 22B may be driven through both of them, as appears in FIG. 8.
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