Hip, ridge, and valley construction clip

Abstract

A clip to be used with at least one track in a roofing assembly, the clip including a planar surface and at least one pair of flanges extending away from the planar surface in an orthogonal manner to define a right angle between each flange and the planar surface. Each flange defines an attachment surface for a corresponding track and extends away from a lower boundary of the planar surface in an orthogonal manner to define a right angle between each flange of the upper pair of flanges and the planar surface. The clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12. Moreover, the planar surface may include a G-90 coating and the clip can be manufactured from a material selected from a group including 16 gauge steel, wood, polymer and an alloy.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/802,140, filed May 22, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a hip, ridge and valley construction clip used to facilitate creation of roof assemblies for residential and commercial structures.

2. Description of the Related Art

Typically, present day home and commercial construction techniques do not always lend themselves to a truss support system. While truss support systems continue to be used in roofing systems having relatively simple or conventional designs, many new building structures call for custom roofing systems. Therefore, such custom roofing systems include roof designs that require what is commonly referred to as a rafter frame. Builders or roofing contractors often approach such rafter frames with reluctance in terms of devising a methodology and assembly for constructing the roofing system, particularly when the roofing system requires the use of light gauge steel.

In conventional wooden roof framing, builders or roofing contractors commonly use a ridge beam. When the ridge beams are required to be used with light gauge steel, the rafters of the roofing system must be cut on an angle of the roof, which requires an inordinate number of clips.

As a result, there is a need in the construction industry, and particularly in the roofing industry, for a clip that saves time and material, and as a result, provides significant cost savings to roof framers, builders, and building owners. Moreover, light gauge steel framing becomes a more economically viable and effective construction option.

SUMMARY OF THE INVENTION

It is an aspect of the present invention to provide a hip, ridge and valley clip (hereinafter, simply referred to as an “HRV clip” or a “clip”) that is configured to make it easier to construct rafter roof frames from light gauge steel. The clip is primarily intended to be used by the light gauge steel industry for residential housing and small commercial construction markets. The clip is to be used to create assemblies, such as, hip assemblies, ridge assemblies and valley assemblies in the construction of light gauge steel roofing systems.

According to one feature of the present invention, the clip is manufactured from galvanized steel sheets of a light gauge, e.g., 16 gauge, having a G-90 coating on at least one, and preferably both sides. A template or pattern is formed for each clip and is used as a guide during the production process. The clip is produced by shearing the metal sheet into the correct pattern and then subjecting the sheared metal sheet into the appropriate pattern using a suitable piece of manufacturing equipment, e.g., a break press.

Preferably, the metal sheet is a substantially square piece of metal after having been sheared during the production process. The larger sized clips are typically modified to have tapered edges so as to allow the break press to fold the sheet to finalize the clip production process. It should be noted that breaking the metal sheet to form the clip creates flanges that are bent approximately 90 degrees in a direction toward the rear face of the clip. The flanges serve as attachment faces to which the tracks of the roofing system are attached to create a roof assembly.

Another feature of the present invention is that the clip can be designed to fit the pitch of any roof, such that the larger the roof, the larger the size of the clip. In other words, the dimensions of the clip of the present invention are proportional relative to the pitch of the roof such that the size, and even material choice, of the clip may be adjusted accordingly.

Preferably, the clip is inserted between a pair of tracks to create an assembly that can be used for any one of hips, ridges or valleys. As described above, conventional wood framing requires the use of a ridge beam, wherein when the ridge beams are used with light gauge steel, the rafters must be cut to the angle of the roof, which requires not only the step of cutting the rafter, but also requires a rather high number of clips. The clip of the present invention eliminates not only the costly and time consuming step of cutting the rafter to the precise angle of the roof pitch, but also substantially reduces the number of clips that must be used in the roofing assembly.

Once the clip is positioned between the pair of tracks to create an assembly, the assembly is set in place within the roofing system and the rafters are placed inside the track and connected to a top portion and bottom portion of the flange for each corresponding track using, preferably, mechanical fasteners. No additional clips are required, but most importantly, the rafters do not have to be cut before attaching the rafters to the clip and tack assembly. Accordingly, the clip of the present invention provides or creates the pitch needed by the builder so that the builder may use the materials, e.g., rafters, tracks, and the like, as provided by the manufacturer without any further modifications made to the materials in the field. As such, the clip of the present invention saves the builder a significant amount of time spent on erecting or constructing the roof.

The clip of the present invention provides several advantages that would readily be understood to one of ordinary skill in the art to which the invention pertains. For example, once positioned inside or between the pair of tracks, the clip and tracks create or define an assembly that can be manufactured to any length. Furthermore, unlike the long beams used in conventional roof framing systems, the weight of the clip and tracks assembly is very lightweight and can easily be handled by the builders in the field. Moreover, as stated above, the inventive clip can be used with any roof pitch. As a result, the assembly using the inventive clip and pair of tracks saves the builder significant sums of time and money by eliminating the need to cut the rafters to the precise angle and the number of clips needed.

The above and other aspects, features and advantages of the invention will become apparent from the following description of preferred embodiments taken in conjunction with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is front view of a sheet of material on which a pattern is provided to form the inventive clip according to an embodiment of the present invention;

FIG. 2 is front view of the sheet of material from FIG. 1 after the upper left and right flanges have been bent away from a first surface of the sheet;

FIG. 3 is front view of the sheet of material from FIG. 2 after the lower left and right flanges have been bent away from a first surface of the sheet;

FIG. 4 is front view of the sheet of material from FIG. 3 after tracks have been attached to the surfaces of the lower left and right flanges after the flanges have been bent away from a first surface of the sheet;

FIGS. 5a-c illustrate another embodiment of the inventive clip, which is designed for a roof having a 6/12 pitch;

FIGS. 6a-c illustrate another embodiment of the inventive hip and valley clip, which is designed for a roof having a 6/12 pitch;

FIGS. 7a-c illustrate another embodiment of the inventive clip, which is designed for a roof having a 7/12 pitch;

FIGS. 8a-c illustrate another embodiment of the inventive hip and valley clip, which is designed for a roof having a 7/12 pitch;

FIGS. 9a-c illustrate another embodiment of the inventive clip, which is designed for a roof having a 8/12 pitch;

FIGS. 10a-c illustrate another embodiment of the inventive hip and valley clip, which is designed for a roof having a 8/12 pitch; and

FIGS. 11-14 illustrate alternate embodiments of the inventive clip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a description of a preferred embodiment of the present invention will be discussed. The hip, ridge and valley clip 1 (hereinafter interchangeably referred to as the “HRV clip” or simply the “clip”) is formed from a sheet of material 10, which is preferably metal, but can also be any suitable material possessing sufficient strength and other properties to be used in a roofing system. Such material as polymer, wood, alloy, and other materials that are now known or later developed are to be considered within the scope of the present invention. Put simply, the type of material chosen from which the clip 1 is to be manufactured should be left to the engineer, architect, designer or builder of the roofing system based on the requirements and needs of the roofing system.

It should be noted that if the material is steel, preferably the steel is a light gauge steel, and even more preferably, is a 16 gauge steel. Moreover, at least one, and preferably both, surface(s) of the sheet of material is provided with a G-90 coating.

A pattern or boundary 11(11a and 11b) is provided on a first surface 2 of the material 10 which defines a pentagon shape and segments the first surface 2 into four flanges 12 through 15 and a center region 16. The pattern 11 segments the first surface 2 into upper left and right flanges 12 and 13, respectively, lower left and right flanges 14 and 15, respectively, and the center region 16. The upper left and right flanges 12 and 13 are each defined by a corresponding upper boundary 11a of the center face 16, while the lower left and right flanges 14 and 15 are each defined by a corresponding lower boundary 11b of the center face 16.

To arrive at the clip 1, the material 10 is first sheared from a larger sheet of material (not shown) such that a relatively square shaped piece of material 10 remains. The pattern 11 is then provided on the first surface 2 of the material 10 so as to segment the first surface 2 into four flanges 12 through 15 and a center region 16. A break press (not shown) is then used to bend the material 10 along the pattern 11 so as to define each flange 12 through 15 and the center region 16.

For example, as shown in FIG. 2, the break press bends the material 10 along the upper boundary 11a of the center face 16 such that the upper left and right flanges 12 and 13, respectively, are extending away from first surface 2. The upper left and right flanges 12 and 13 should extend away from the first surface 2 by at least 90 degrees, and preferably extend away from the first surface 2 exactly 90 degrees to form a right angle with the center region 16. As such, when viewing the first surface 2 as seen in FIG. 2, the flanges 12 and 13 should not be visible to the observer as they are extending into the sheet of paper.

The break press (not shown) is then used to bend the material 10 along the pattern 11 so as to define each lower left and right flange 14 and 15. For example, as shown in FIG. 3, the break press bends the material 10 along the lower boundary 11 b of the center face 16 such that the lower left and right flanges 14 and 15, respectively, are extending away from first surface 2. The lower left and right flanges 14 and 15 should extend away from the first surface 2 by at least 90 degrees, and preferably extend away from the first surface 2 exactly 90 degrees to form a right angle with the center region 16. As such, when viewing the first surface 2 as seen in FIG. 3, the flanges 14 and 15 should not be visible to the observer as they are extending into the sheet of paper. Moreover, the resulting clip 1 will preferably have a pentagon shape defined by the two upper boundary lines 11a, 11a, the two lower boundary lines 11b, 11b, and a third boundary 11c formed between the two lower boundary lines 11b, 11b.

The flanges 12 through 15 are configured to receive a track thereon so as to form a roof assembly into which a plurality of rafters (not shown) may be inserted. For example, looking at FIG. 4, a track TR1 is placed against the lower left flange 14 and attached thereto by a fastener (not shown), which can be any well known or later developed fastener, such as a bolt, screw, nail, and the like. It is also within the scope of the invention for the track TR1 to be affixed to the lower left flange 14 using an adhesive or other such industrial strength adhesive, as well as any known or later developed welding technique. Similarly, another track TR2 is placed against the lower right flange 15 and similarly attached or affixed thereto. At least one rafter (not shown), and most likely a plurality of rafters, are then inserted into the open end of each track TR1 and TR2, so as to provide an assembly component of a roofing system.

The preferred embodiment of the clip 1 anticipates the use of 6 inch rafters within the open end of each track TR1 and TR2. However, modifications may be made to the clip 1 to change the pitch of the roof. For example, if the material used for the rafters exceeds 6 inches, then the dimensions of the clip 1 may also change accordingly. In other words, the dimensions of the clip 1 are all proportional to the pitch of the roof, such that the overall size of the material 10 used will change accordingly.

The inventive clip 1 of the instant application is intended to be used with any known roof pitch. For example, FIG. 5a illustrates another embodiment of the inventive clip wherein a clip 21 is used for roof that is on a 6/12 pitch. A difference between the clip 21 of FIG. 5a and the clip 1 of FIGS. 1-4 is the size of the clip 21 results in smaller upper left and right flanges 22 and 23, being formed, and larger lower left and right flanges 24 and 25. Moreover, each of the lower left and right flanges 24 and 25 includes a tapered edge 24a and 25a, respectively, to facilitate being bent by the break press or machine. FIG. 5b shows a lower left perspective view of the clip 21 while FIG. 5c shows an upper left perspective view of the clip 21.

In another example, FIG. 6a illustrates another embodiment of the inventive clip wherein a 6/12 hip and valley clip 31 is used for roof that is on a 6/12 pitch. A difference between the clip 31 and the clip 1 of FIGS. 1-4 is the size of the upper left and right flanges of the clip 31 are smaller than the upper left and right flanges 12 and 13 of the clip 1. Also, a difference between the clip 31 of FIG. 6a and the clip 21 of FIGS. 5a-c is that the lower left and right flanges 34 and 35 of the clip 31 do not include tapered edges. FIG. 6b shows a lower left perspective view of the clip 31 while FIG. 6c shows an upper right perspective view of the clip 31.

In yet another example, FIG. 7a illustrates another embodiment of the inventive clip wherein a clip 41 is used for roof that is on a 7/12 pitch. A difference between the clip 21 of FIG. 5a and the clip of FIGS. 7a-c is the pitch. Also, the size of the clip 41 can also possible be different or the same relative to the clip 21 in FIGS. 5a-c. Moreover, each of the lower left and right flanges 44 and 45 includes a tapered edge 44a and 45a, respectively, to facilitate being bent by the break press or machine. FIG. 7b shows a lower left perspective view of the clip 41 while FIG. 7c shows an upper right perspective view of the clip 41 wherein the upper left and right flanges 42 and 43 are shown.

Similarly, in yet another example, FIG. 8a illustrates another embodiment of the inventive clip wherein a 7/12 hip and valley clip 51 is used for roof that is on a 7/12 pitch. A difference between the clip 51 and the clip 31 of FIGS. 6a-c is the pitch. Also, the size of the clip 51 may be different or the same as the size of the clip 31 in FIGS. 6a-c. Moreover, as in FIG. 6a, the lower left and right flanges 54 and 55 of the clip 51 include relatively smaller tapered surfaces 54a and 55a, respectively, compared with the tapered surfaces 44a and 45a of the clip 41. FIG. 8b shows a lower left perspective view of the clip 51 while FIG. 8c shows an upper right perspective view of the clip 51 wherein the upper left and right flanges 52 and 53 are shown.

FIG. 9a illustrates another embodiment of the inventive clip 61 wherein the clip 61 is used for a roof that has an 8/12 pitch. Similarly, FIG. 10a illustrates yet another embodiment of the inventive clip 71 wherein a, 8/12 hip and valley clip 71 is used for a roof that has an 8/12 pitch. Like the clips 21 and 41, the lower left and right flanges 64 and 65, and 74 and 75, of the clips 61 and 71, respectively, include tapered surfaces 64a and 65a, and 74a and 75a, respectively. As in the clips 21 and 41, each of the lower left and right flanges 64 and 65 and 74 and 75m of the clips 61 and 71, respectively, includes a tapered edge 64a and 65a, and 74a and 75a, respectively, to facilitate being bent by the break press or machine. FIGS. 9b and 10 show a lower left perspective views of the clips 61 and 71, respectively, while FIGS. 9c and 10c show an upper right perspective view of the clips 61 and 71, respectively.

Although not illustrated herein, it is also within the scope of the invention for the hip and valley clips 51 and 71 shown in FIGS. 8a-c and 10a-c to be manufactured for roofs having a pitch of 9/12, 10/12 and 11/12. Such clips for the9/12, 10/12 and 11/12 pitch roofs will generally have the same structural configuration as the clips 51 and 71, with proper allowances for the size of the tapered edges and flanges to vary due to the different pitch for which each clip is manufactured.

FIGS. 11-14 show clips 81, 91, 101 and 111, respectively, that are manufactured for roofs having a 9/12, 10/12, 11/12 and 12/12 pitch, respectively. The upper left and right flanges (82 and 83, 92 and 93, 102 and 103, and 112 and 113, respectively) include flanges 82a, 83a, 92a, 93a, 102a, 103a, 112a and 113a, respectively. Similarly, the lower left and right flanges (84 and 85, 94 and 95, 104 and 105, and 114 and 115, respectively) include flanges 84a and 85a, 94a and 95a, 104a and 105a, and 114a and 115a, respectively. The only difference between each of the clips 81, 91, 101 and 111 is the size of their corresponding flanges, which is driven by the different roof pitch for which they are constructed. Although not illustrated, the flanges 82 through 84 for the clip 81, the flanges 92 through 94 for the clip 91, the flanges 102 through 104 for the clip 101, and the flanges 112 through 114 for the clip 111 are all bent away from the first surface 2 in a manner similar to the previously described clips, and such discussion is therefore omitted herefrom to avoid redundancy. Likewise, the tracks TR1 and TR2 are attached to the face of the lower left and right flanges for each of the clips 81, 91, 101 and 111 as described above.

As noted above, each of the aforementioned clips are preferably manufactured from galvanized steel sheets of a light gauge, e.g., 16 gauge, having a G-90 coating on at least one, and preferably both sides. The flanges of each clip described herein serve as attachment faces to which the tracks TR1 and TR2 of the roofing system are attached to create a roof assembly. More importantly, and as illustrated by the different embodiments shown and described above, is the fact that the inventive clip can be designed to fit the pitch of any roof, such that the larger the roof, the larger the size of the clip. In other words, the dimensions of the clip of the present invention are proportional relative to the pitch of the roof. As a result, the inventive clip eliminates not only the costly and time consuming step of cutting the rafter to the precise angle of the roof pitch, but also substantially reduces the number of clips that must be used in the roofing assembly. Accordingly, the clip of the present invention provides or creates the pitch needed by the builder so that the builder may use the materials, e.g., rafters, tracks, and the like, as provided by the manufacturer without any further modifications made to the materials in the field. As such, the clip of the present invention saves the builder a significant amount of time spent on erecting or constructing the roof.

While there has been described herein what are at present considered to be preferred embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the spirit and scope or the present invention.

Claims

1. A clip to be used with at least one track in a roofing assembly, the clip comprising:

a planar surface; and

at least one pair of flanges extending away from the planar surface in an orthogonal manner to define a right angle between each flange and the planar surface,

wherein each flange defines an attachment surface for a corresponding track.

2. The clip according to claim 1, wherein each flange includes a tapered edge.

3. The clip according to claim 1, wherein the planar surface has a pentagon shaped geometric configuration.

4. The clip according to claim 3, wherein the at least one pair of flanges define a lower pair of flanges, each flange of the lower pair of flanges extending from a lower boundary of the planar surface.

5. The clip according to claim 4, wherein the planar surface further comprises an upper boundary, and wherein an upper pair of flanges extends away from the upper boundary of the planar surface in an orthogonal manner to define a right angle between each flange of the upper pair of flanges and the planar surface.

6. The clip according to claim 5, wherein each flange of the upper pair of flanges includes a tapered edge.

7. The clip according to claim 1, wherein the clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.

8. The clip according to claim 2, wherein the clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.

9. The clip according to claim 5, wherein the clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.

10. The clip according to claim 6, wherein the clip is sized to form a roof assembly having a pitch selected from any one of 6/12, 7/12, 8/12, 9/12, 10/12, 11/12 and 12/12.

11. The clip according to claim 1, wherein the planar surface includes a G-90 coating and the clip is manufactured from one of 16 gauge steel, wood, polymer and an alloy.

12. The clip according to claim 2, wherein the planar surface includes a G-90 coating and the clip is manufactured from one of 16 gauge steel, wood, polymer and an alloy.

13. The clip according to claim 5, wherein the planar surface includes a G-90 coating and the clip is manufactured from one of 16 gauge steel, wood, polymer and an alloy.

14. The clip according to claim 6, wherein the planar surface includes a G-90 coating and the clip is manufactured from one of 16 gauge steel, wood, polymer and an alloy.