Roofing machine

Abstract

This is a roofing machine wherein the vertical rollers are adapted to engage various types of configurations of the purlins of a metal frame building. The machine also uses angle irons mounted on top of a horizontal roller housing and utilizes angles rather than pipes as is done with most prior art devices. Furthermore, the machine clamps the carriage angles to the angle irons in a simpler manner than prior art devices.

Description

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/200,866 filed Dec. 5, 2008.

FIELD OF THE INVENTION

This invention relates to roofing machines and more specifically to an improved roofing machine constructed, in part, of aluminum angle element components and having an improved cast aluminum housing for the horizontal and vertical rollers or wheel components. The vertical roller, in turn, may be supported by the purlin base element as well as to an edge surface thereof.

BACKGROUND OF THE INVENTION

A roofing machine in which bundles of roofing panels are supported for longitudinal movement over the framework of a metal building is known. Such machine includes a surface for supporting the roof panel and is, in turn, provided with horizontal and vertical rollers that contact opposed surfaces of the building's purlins that provide the rolling support for the machine as the machine moves laterally across the building's frame to position the panels where needed for installation by the roofers. A basic version of such a machine having a framework of tubing and with carriage or cart mounted rollers to contact the top surface as well as an edge surface of multiple purlins that, in part, comprise the skeletal frame of the metal building is shown in U.S. Pat. No. 4,048,924 issued Sep. 20, 1977 to Warren G. Wibben. The disclosure of such patent is hereby incorporated into the present application by specific reference thereto.

Generally, the metal roofing panels which eventually form the outer upper surface, i.e., roof of the building, are screwed in place to the longitudinal members (purlins) extending across the laterally disposed rafters of the building which are, in turn, longitudinally spaced along the opposed roof sides and are generally connected to each other along a centerline or ridge line. With flat roofs, the rafters may extend entirely across both roof sides.

SUMMARY OF THE INVENTION

The purlins referred to in such prior patent are of a Z shape configuration. The present invention expands such use to include buildings utilizing Z, C, bar joist and even 2×4 wooden joist configured purlins. In addition, the present invention provides for enhanced stabilizing roller (wheel) contact with such purlins via contact with one of the vertical body or body element faces of such purlins as distinguished by contact with a terminal top edge thereof that may be dimensionally variable due to their inherent structure and/or positioning upon the roof structure and also subject to damage by nicks, binds and folds all of which can lead to uneven movement of a roofing machine as the machine moves over such uneven and/or movable (bendable) surfaces. The machine of the present invention is further enhanced in that the frame of such machine is formed of angled stock components of non-corrodible material such as aluminum rather than steel pipes that enables the roofing machine to be more easily mounted and assembled on the ladder frame in situ, that is, upon the building's roof surface with simpler clamping of the carriage angles to the angle irons.

Other objects, features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:

FIGS. 1a-1c are isometric views of the roofing machine of the present invention mounted on and engaged to the purlins of a metal frame roof and in various stages of completion;

FIG. 1d is an enlarged portion of the ridge or centerline of the building shown in FIGS. 1a-1c showing part of an assembled system of the present invention positioned thereon;

FIG. 2 is an isometric view of one end of one form of the roofing machine shown with parts broken off and supported on a purlin;

FIG. 3 is a top view of an alternate ridge connector;

FIG. 4 is a bottom isometric view of the roofing machine shown in FIG. 2;

FIG. 5a is a side sectional view showing the roofing cart depicted in FIG. 2 riding atop a typical Z-shaped purlin;

FIG. 5b is a side sectional view showing another variation of the roofing cart riding atop a bar joist and decking building;

FIG. 5c is a side sectional view showing another form of the roofing cart on buildings with back to back C-shaped purlins; and

FIG. 5d is a side sectional view of still another form of the invention utilized on buildings with wooden purlins.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

In the drawings is shown a roofing machine or apparatus 10 for handling roofing panels over purlins 12. Purlins are the side-to-side horizontal supports that extend over the roof rafters, when present.

A packet of plastic or metal roof panels 8 is placed on the roofing apparatus 10 of the present invention from a position on the skeletal roof and is wheeled along the length of the purlins 12 unloading one sheet from the packet at a time and screwing such onto the underlying purlins to form an array of sheets along the length of the purlins 12 until the roof is completed. Throughout this process, the working roofers need not carry any panel more than a few feet and need not raise any panel up into the wind (with the attendant dangers of a roofer falling) as was necessary prior to the use of the present roofing apparatus invention. Use of the disclosed apparatus also makes it possible to utilize panels of maximum length thereby reducing the number of seams with the possibility of leaks. The roofing process above described is illustrated in the transitional steps shown in FIGS. 1a, 1b and 1c wherein the basic skeletal roof structure of a building to be roofed with roof panels 8 is shown in FIG. 1a. The same building is shown in FIG. 1b with the roofing system of the present invention in place, and a partially completed roof is shown in FIG. 1c.

Returning to the drawings and FIG. 2, the purlins 12 in this embodiment shown in FIG. 2, are of a Z shape in cross-section and are so designated in the art. Each such purlin 12 has an upper surface 14 running the length of a pitched roof for supporting the lengths of conventional roofing panels such as shown in FIGS. 1a-1c in a slope direction of roof pitch. The upper surface 14 has a free edge 16 that is turned to provide a secondary surface 18.

The roofing apparatus 10 includes a series of roof carts 20 each of which includes a skeletal frame comprising a first right angle beam 22 and a second right angle beam 24 connected by a first housing 26. The first housing 26 comprising a base portion 28 which is generally rectangular in configuration and having a first long side edge 30 and a second long side edge 32. The first and second long side edges 30, 32 are in spaced parallel relation with each other. A first wing element 34 extends downwardly from the first long side edge 30 and a second wing element 36 extends downwardly from the second long side edge 32. A third wing element 35 extends downwardly from the first long side edge 30 in spaced relation to and on the same plane as the first wing element 34 and a fourth wing element 37 extends downwardly from the second long side edge 32 in spaced relation to and on the same plane as the second wing element 36. The first and second wing elements 34, 36 are in spaced parallel relation to each other as are the third and fourth wing elements 35, 37. A first and horizontal roller or wheel 38 that is cylindrical and roller-like in configuration is mounted to the first and second wing elements 34, 36 and is in spaced parallel relation to the base portion 28 for rotational movement along the horizontal axle 39.

The first long side edge 30 has a first rounded appendage or plate 40 extending therefrom. The appendage 40 lies on the same horizontal plane as the base portion 28. The second long side edge 32 has a second rounded appendage 42 extending therefrom, the appendage 42 lying on the same horizontal plane as the base portion 28 and extending in a direction opposite to that of the appendage 40. A second housing 44 is formed comprising an arched seat or roller shield 46 having a first upper edge 48, a second upper edge 50, an open end 54 and a closed end with the closed end being closed off by an upright element or plate 56. A first wing portion 58 extends integrally from the first upper edge 48 in right angle relationship thereto and a second wing portion 59 extends integrally from the second upper edge 50 in right angle relationship thereto. A second and vertical roller or wheel 60 is attached to the second housing 44 by movably engaging a bolt or axle 57 extending coaxially from the first end of the second wheel 60 to an aperture 59 formed centrally in the upright element 56. The sub assembly of the second roller 60 and the second housing 44 is attached to the base portion 28 by engaging two bolts through wing portions 34, 35. Axle 82a is then inserted into an aperture formed in the first appendage 40 and then bolting the first wing portion 58 to the external surface of the first wing element 34 and bolting the second wing portion 59 to the external surface of the fourth wing element 37 in a manner well known in the art.

A subassembly of the first housing 26, second housing 44, first wheel or roller 38 and second wheel or roller 60 is attached in close proximity to the terminal ends of the first right angle beam 22 and a second right angle beam 24 by nuts and bolts creating a roof cart 20 in which the first right angle beam 22 and a second right angle beam 24 are in spaced parallel relation with each other. Attachment means preferably in the form of a pair of C clamps 62 having to opposed jaws are utilized as indicated in FIG. 1 to hold the roof cart 20 to a pair of elongated support elements 64. The upper jaw of the clamp 62 terminates in a vertically threaded boss that accepts a setscrew 63, the lower terminal end of which engages the upper surface of the base portion 28 to adjustably but fixedly join the cart to the elongated support elements 64. Two clamps are utilized at each cart end, and the clamps are preferably aligned with the angles 22, 24 such that a side surface of each upper jaw is adjacent and in contact with respective outer surfaces of the angles 22, 24. In this way, alignment of the carts over the purlins is assured and also provides added contact stability. As shown in FIG. 1d, the clamps are located at each end of the carts 20 and in this way all the carts and the support elements are joined and thus move as a unit longitudinally back and forth along the roof. As shown in FIG. 2, a spaced series of roof carts 20 are attached to the pair of elongated support elements 64. Sheet alignment tabs 66 are bolted to the right angle beams at predetermined positions.

To assemble the roofing apparatus 10 for use, place the carts 20 on the top surfaces 14 of each roof purlin 12. Place the support elements 64 on top of the upper surfaces 14 of the purlins 12 and to the underside of angles 22 and 24 and clamp with the clamps 62 as shown in FIGS. 1d and 2. Connect the support elements 64 at the roof ridge with ridge splice connectors 68 and connect the other support elements 64 with carriage angle connectors 71.

To connect a pair of carts 20 to the support elements 64, position one cart 20 at a time on a purlin 12 with the first wheel 38 resting on the upper surface 14 and the second or bearing wheel 60 abutting the secondary surface 18. The roof carts 20 are clamped firmly in place with the C clamps 62 as shown in FIGS. 1 and 2. This procedure is continued until all involved purlins 12 have roof carts 20 mounted thereon. Sheet stops 70 are secured in place. The sheet stops 70 prevent the loaded roof panels from sliding off the carts 20. The sheet stops 70 are bolted or otherwise attached to the support elements 64, and they are positioned on the support elements 64 depending on the length of the roof panels. As shown in FIG. 1d, carriage angle connectors 71 are flat bar aluminum elements or strips having holes drilled therein to bolt two pieces of the support elements 64 together laterally, when needed.

The roof cart 20 is shown in FIG. 5a as a roof cart 20a for specific use with Z type purlins 12a. The purlins 12a comprise a base element 72a having a first end from which a first angle element 74a extends and having a second end from which a second angle element 76a extends. The first and second angle elements 74a, 76a are in right angle relationship with the base element 72a and in spaced parallel relationship with each other. The first angle element 74a in this embodiment has an upper surface 14a running the length of a pitched roof for supporting the lengths of panels in a slope direction of the roof pitch. The base element 72a includes an inner or distal surface 78a as shown.

The roof cart 20a comprises a first right angle beam 22a and a second right angle beam 24a connected by a first housing 26a. The first housing 26a includes a base portion 28a which is generally rectangular in configuration and having a first long side edge 30a and a second long side edge 32a. The first and second long side edges 30a, 32a are in spaced parallel relation with each other. A first wing element 34a extends outwardly from the first long side edge 30a, and a second wing element 36a extends outwardly from the second long side edge 32a. The roof cart 20a includes similar means of attachment for a second housing 44a in the same manner as the housing 44. A first wheel or roller 38a is movably engaged to the first and second wing elements 34a, 36a and is in spaced parallel relation to the base portion 28a. The first long side edge 30a has a rounded appendage extending therefrom, and this appendage lies on the same horizontal plane as the base portion 28a. The second long side edge 32a also has a rounded appendage extending therefrom. The rounded appendages are similar in all respects to the appendages 40, 42 of the first embodiment. The second housing 44a includes an arched seat having upper edges, an open end and an end closed off by an upright element as described heretofore for the first embodiment. The second housing 44a is attached to the first housing 26a in a manner similar to that utilized for the first embodiment. A spring tensioned axle 80 is engaged to the second housing 44a such that the long hex axle 80 is coaxial with arched seat 46a and has a free terminal end 82a extending beyond the end of the second housing 44a as shown in FIG. 5a. A bearing wheel 60a is movably attached to the terminal end 82a and is of comparatively large diameter.

A subassembly of the first housing 26a, second housing 44a, first wheel 38a and bearing wheel 60a is attached in close proximity to the terminal ends of the first right angle beam 22a and a second right angle beam 24a by nuts and bolts creating a roof cart 20a in which the first right angle beam 22a and a second right angle beam 24a are in spaced parallel relation with each other. C clamps 62 can be utilized to hold the roof cart 20a to a pair of elongated support elements similar in all respects to the support elements 64 of the first embodiment. A series of spaced roof carts 20a can be attached to the pair of elongated support elements in a manner similar to that of the roof carts 20 of the first embodiment.

To assemble the embodiments of the roofing apparatus 10 utilizing the roof cart 20a as an example, the cart 20a is positioned on the ground under each roof purlins. Place a support element similar in all respects to the support elements 64 on top of the upper surface 14a of the purlins 12a as shown in FIG. 5a. The support elements are connected in the same manner as described for the support elements 64. To connect a pair of carts 20a to the support elements, position one cart 20a at a time on a purlin 12a with the first wheel 38a resting on the upper surface 14a and the bearing wheel 84 abutting the inner or distal surface 78 of the base element 72 as shown in FIG. 3. The roof carts 20a are clamped firmly in place with C clamps 62 as previously shown. This procedure is continued until all involved purlins 12a have roof carts 20a mounted thereon. Thus, the roofing apparatus 10 utilizing the roof cart 20a is used in the same manner as the roofing apparatus 10 with cart 20 and as set forth hereinbefore.

Turning to FIG. 5b, a further modified form of the invention is depicted wherein the purlins are of the bar joist type. Such purlins 12b are of a steel angle iron type configuration and include a proximal base element 72b and a distal base element 78b each with first and second elements 74b and 76b respectively to form a general I frame configuration. The first element 74b includes a distal surface 78b adapted, in turn, to engage a modified wheel 84b. Such wheel 84b includes a generally V-shaped outer groove 85b and includes upper and lower peripheral edge surfaces 86b of somewhat rounded configuration. The upper edge surface 86b is adapted to contact the distal edge surface 78b in the same manner as the roller 60 contacts the edge surface 18 of the Z-shaped purlin configuration shown in FIG. 5a. To accommodate such contact and thus the rolling supporting engagement there between as the cart 20b moves longitudinally back and forth across the length of the roof, the second housing 44b is constructed of a shorter height than that of housing 44a. Otherwise, the operation and construction of the FIG. 5b embodiment is the same as that described above with regard to the description of the FIG. 5a embodiment.

Turning now to FIG. 5c, another modification of the device 20c is shown for particular use with respect to C-shaped purlins, e.g., single as shown or back-to-back C-shaped purlins. The cart 20c is particularly similar to cart 20a except that the roller 60a is replaced with a wheel 84c, vertically oriented and of disc-like configuration and is positioned such that the outer peripheral surface of the second wheel 84c engages an inner or distal surface 78c of the purlin 12c. The wheel 84c is mounted for rotation in an extended hex axle 82c. In this way, a more positive engagement of the purlin 12c is achieved that promotes straightening thereof as the cart 20c rolls along the purlins 12c. This is particularly advantageous if the purlins 12c or otherwise are formed of very low gauge metal as is often the case to lower costs and should the free edge of the first angle element 74c be broken, nicked or warped. Otherwise, the structure, configuration and operation of the FIG. 5c embodiment is similar to that of FIG. 5a except for including the letter “C” designation.

Turning now to FIG. 5d, a still further modification of the device 20d is shown for particular use with roofs utilizing wooden purlins 12d, e.g., 2×4 wood lumber. In this embodiment, a modified vertical second wheel 84d of lesser diameter than that of the FIG. 5c device is mounted on shorter hex axle 82d such that the outer peripheral surface thereof contacts an inner distal surface 78d of the purlin 12d and at a position adjacent the top thereof, i.e., adjacent to the position of the main roller 38d, such that the longitudinal back and forth longitudinal movement of the assembly and the carts 20d attached thereto will not inadvertently contact the underlying rafters of the building structure. Otherwise, the structure, configuration and operation of the FIG. 5d embodiment is similar to that of FIG. 5b except for the letter “d” designation applied to the reference numerals.

Turning now to FIG. 3, a modified version of how the angled support elements 64 making up the sides of the frame to which the carts 20 are connected to each other is depicted. In the previous embodiment, the ends of the elements 64 were connected to each other by a connecting strip 68 as by bolts, etc. which necessitated some undesirable bending or angling of the two parts of the framework engaging the purlins on both sides of the building roof with respect to the ridgeline. In order to remedy such, a heavy duty hinge 100 including opposed leaves 102 is welded to the metal steel flat stock comprising the connection strip 68a such that a bend closely approximating the angle of the ridgeline can be achieved with such strip 68. Such strip 68a, as shown in FIG. 3, may be substituted for strip 68.

While there is shown and described herein certain specific structure embodying this invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.

Claims

1. A system for moving bundles of planar roofing panels longitudinally across the length of a building having a skeletal structure including a roof centerline and opposed roof sides and including laterally disposed rafters running the length thereof and on which rafters a series of laterally spaced purlins which longitudinally extend the length of the building rest such that the roofing panels may be more easily positioned for attachment to the purlins so as to form the completed roof outer surface, said system comprising a pair of parallel longitudinally spaced support elements laterally extending across said roof sides, said support elements each having upper and lower generally planar surfaces, said system further including a least a pair of roof carts longitudinally extending between said support elements and laterally spaced from each other, said carts having a first housing having ends which overlap the upper surfaces of said support elements and are releasably but fixedly connected thereto by clamps at two laterally spaced positions at opposite ends of said first housing so as to position each cart at right angles between said support elements.

2. The system of claim 1, each said cart further having means for mounting a first horizontally disposed roller and a second vertically disposed roller or wheel, each of said carts positioned over a purlin such that the horizontal roller engages the top surface of the purlin and the vertical roller or wheel engages a side surface of the purlin.

3. The system of claim 2, said first housing including a pair of laterally spaced L-shaped angle beams attached to and extending above said first housing, said angle beams each having an upper surface which forms the surface upon which the roofing panels are adapted to rest and end portions which extend over and in contact with said elongated support elements.

4. The system of claim 2, said clamps being C clamps each having a lower jaw contacting the lower surface of said support element and an upper jaw contacting the upper surface of said support element.

5. The system of claim 4, the upper jaw of each said C clamps including a vertically threaded boss adapted to receive a setscrew in turn adapted to contact and clamp the upper surface of the support element.

6. The system of claim 3, said support elements each being L-shaped with the foot portion of each positioned uppermost and outwardly directed from each other.

7. The system of claim 4, each of said C clamps being aligned with said angle beams.

8. A roofing apparatus for handling roofing panels over purlins, the purlins having upper and lower surfaces connected by a body plate or base element having proximal and distal surfaces and free edges running the length of a pitched roof for supporting the lengths of panels in a slope direction of roof pitch comprising, means defining a roof cart with an elongated skeletal frame extending orthogonal to the purlins and spaced wheel means riding on each of several adjacent purlins and carrying the skeletal frame, each of the wheel means comprising first and second wheels with the first roller having an essentially horizontal axis and the second wheel or roller having an essentially vertical axis, the first roller riding on the upper surface of a purlin and the second wheel or roller bearing against the purlin, one such wheel means being provided for each of several adjacent purlins of the roofing so as to form a carriage structure and wherein the carriage structure is of a ladder form and comprises two of said wheel means at each rung of the ladder, wherein the improvement comprises the first wheel positioned within a first housing, the second wheel or roller positioned within a second housing, the first housing comprising a first base plate, the first base plate being generally rectangular in configuration and having a base portion, the base portion having a first long side edge and a second long side edge, one of a pair of wing elements extending upward from the first long side edge, the other of the pair of wing elements extending upward from the second long side edge, the wing elements in spaced parallel relation to each other, the first roller movably engaged to the wing elements in spaced parallel relation to the base portion, the second long side edge having a rounded appendage extending therefrom, the appendage lying on the same horizontal plane as the base portion, the second housing comprising an arched seat having a first upper edge, a second upper edge, an arched base, a first open end and a second open end, the arched seat having a longitudinal axis, an upright element extending from the arched base spaced from the first open end, the second housing attached to the base plate of the first housing whereby the second wheel or roller is movably engaged to the appendage and the upright element.

9. The roofing apparatus of claim 8, wherein the purlin supports to are of the Z or C configuration and said second wheel is mounted on a vertical axis and includes peripheral wheel portions adapted to contact a free edge of said purlin upper surface.

10. The roofing apparatus of claim 8, wherein the purlin supports are of the bar joist or wood purlin configuration and said second wheel is adjustably vertically mounted and the peripheral wheel portions thereof are adapted to contact the body plate distal surface.

11. The roofing apparatus of claim 8, wherein the purlin supports are rectangular cross-sectional dimensional lumber having top, inner and outer side surfaces vertically mounted such that the peripheral roller portions contact an outer side surface of the purlin adjacent the top surface thereof.

12. A system for moving bundles of planar roofing panels longitudinally across the length of a building having a skeletal structure including a roof centerline and opposed roof sides and including laterally disposed rafters running the length thereof and on which rafters a series of laterally spaced purlins which longitudinally extend the length of the building rest such that the roofing panels may be more easily positioned for attachment to the purlins so as to form the completed roof outer surface, said system comprising a pair of parallel longitudinally spaced support elements laterally extending across said roof sides, said support elements each having upper and lower generally planar surfaces, said system further including a least a pair of roof carts longitudinally extending between said support elements and laterally spaced from each other, said carts having a first housing having ends which overlap the upper surfaces of said support elements and are releasably but fixedly connected thereto by clamps at two laterally spaced positions at opposite ends of said first housing so as to position each cart at right angles between said support elements and wherein each of said purlins includes an upper surface and a plate surface, each of said roof carts having a first roller horizontally positioned within a first housing and a second roller vertically positioned in a second housing and wherein the first wheel rests on the upper purlin surface and the second wheel or roller contacts portions of said purlin base plate, the first roller positioned within a first housing, the second wheel or roller positioned within a second housing, the first housing comprising a first base plate, the first base plate being generally rectangular in configuration and having a base portion, the base portion having a first long side edge and a second long side edge, one of a pair of wing elements extending upward from the first long side edge, the other of the pair of wing elements extending upward from the second long side edge, the wing elements in spaced parallel relation to each other, the first roller movably engaged to the wing elements in spaced parallel relation to the base portion, the second long side edge having a rounded appendage extending therefrom, the appendage lying to on the same horizontal plane as the base portion, the second housing comprising an arched seat having a first upper edge, a second upper edge, an arched base, a first open end and a second open end, the arched seat having a longitudinal axis, an upright element extending from the arched base spaced from the first open end, the second housing attached to the base plate of the first housing whereby the second wheel is movably engaged to the appendage and the upright element.

13. The roofing apparatus of claim 12, wherein the purlin supports are of the Z or C shape configuration and said second roller or wheel is mounted on a vertical axis and includes peripheral wheel portions adapted to contact a free edge of said purlin upper surface.

14. The roofing apparatus of claim 12, wherein the purlin supports are of the bar joist configuration and said second wheel is adjustably vertically mounted and the peripheral wheel portions adapted to contact the body plate distal surface.

15. The roofing apparatus of claim 12, wherein the purlin supports are rectangular cross-sectional dimensional lumber having top, inner and outer side surfaces vertically mounted such that the peripheral wheel portions contact an outer side surface of the purlin adjacent the top surface thereof.