Support Structure for Purlin Roof

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/678,733, filed on Aug. 2, 2024, the content of which is incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

FIELD OF INVENTION

The present general inventive concept pertains to roofs, and more particularly to a portable support structure for providing a temporary work area to a floorless structure such as a series of roof purlins along a partially constructed roof.

BACKGROUND

In roof construction, it is common for support framing of a roof to include one or more “purlins,” which are longitudinal, horizontal, structural members designed to carry and support the sheathing and outer roofing material of a roof and to transfer loads from these materials to the rafters of the roof framing or the walls of the building. In steel construction, purlins typically span parallel to the building eave and support the roof decking or sheeting. The purlins are in turn supported by rafters or walls. Purlins used in steel framed building systems commonly employ Z-shaped cross-sections, such that the purlins allow flexural continuity between spans. However, C-shaped beams (often called “channel sections”), I-shaped beams, U-shaped beams, and other shapes are available for use as purlins in many applications.

In the fabrication of steel framed roofs, it is common for roof frames to be erected comprising a number of steel purlins extending in a parallel-planar, spaced apart configuration with one another, and with empty spaces therebetween, such that the purlins define a general shape of the finished roof. Thereafter, workers may climb on, around, or in between the purlins, and on other portions of the roof frame, in order to attach layers of sheeting material, such as moisture barrier sheeting, insulation, decking, and/or outer roofing material, to the purlins.

Due to the fact that roofs are often constructed at elevated heights, the practice of climbing on and around purlins poses significant risk to worker safety. Workers climbing on and around open roof purlins may accidentally fall, causing injury or death to themselves; or they may drop one or more tools, pieces of work material, etc., resulting in damage or injury to people or objects below. For this reason, numerous jurisdictions require safety equipment, such as harnesses with cords attached to secure locations, be worn at all times while workers climb on and around open roof purlins. However, such safety equipment may limit a worker's movement along the roof structure or may hinder the worker's normal body movements, thereby resulting in decreased performance and/or frustration of the worker. In some instances, workers may choose not to wear the safety equipment, even if doing so means failure to comply with applicable regulations.

In light of the above, there exists a desire to improve safety by providing one or more temporary work surfaces to a floorless structure, such as a series of roof purlins, in order to carry and support workers, materials, etc., while a roof is being constructed.

BRIEF SUMMARY OF THE INVENTION

According to various example embodiments of the present general inventive concept, a support structure for providing a surface along a structure comprising one or more purlins is provided. In various example embodiments, the support structure may comprise a panel having a first end portion and an opposite second end portion, and a retention means defined along the first end portion and configured to slidably receive a portion of one of the one or more purlins therein to secure the panel in overlying relation along the one or more purlins. Various example embodiments of the present general inventive concept may also provide a fastener configured to secure the leading portion of the one of the one or more purlins within the interior void.

The foregoing and/or other aspects and advantages of the present general inventive concept may be achieved by providing a panel in which the retention means is defined by a channel extending along the first end portion of the panel. In various example embodiments, the channel may be defined by a lapped outer edge of the first end portion of the panel. In various embodiments, the channel may have an interior void sized and shaped to conform to a leading portion of one of the one or more purlins. In various embodiments, the support structure may further comprise a fastener wherein a first half of the fastener is defined along the first end portion of the panel and a second half of the fastener is defined along the second end portion of the panel, wherein the first half of the fastener is engageable with a second half of the fastener defined on an adjacent support structure to secure the portion of the purlin within the chanel. In some embodiments, the first half of the fastener may be a through opening defined by the first end portion of the panel. In certain embodiments, the through opening may be a slot. In some embodiments, the second half of the fastener may be a tab. In some embodiments, the tab may extend from the second end portion of the panel perpendicular to an upper surface of the support structure. In some embodiments, the tab may be integrally formed with the second end portion.

In various example embodiments of the present general inventive concept, the first end portion may be removably secured to the panel along a first edge of the panel. In various embodiments, the second end portion may be removably secured to the panel along a second edge of the panel opposite the first edge.

The foregoing and/or other aspects and advantages of the present general inventive concept may be achieved by providing a plurality of locator fasteners extending along the panel between the first and second edge. In various example embodiments of the present general inventive concept, the plurality of locator fasteners may be defined by at least one channel extending along the panel between the first and second edge. In various embodiments, the at least one channel may comprise a first channel extending along a first side of the panel between the first and second edge and a second channel extenidng along a second side of the panel between the first and second edge. In some embodiments, each locator fastener of each channel may align with a locator fastener of the other channel. In some embodiments, a step may be provided removably securable between aligned ones of the locator fastener.

Additional aspects and advantages of the present general inventive concept will be set forth in part in the description, the drawings, and the claims which follow, and, in part, will be obvious from the description, drawings, and claims, or may be learned by practice of the present general inventive concept.

BRIEF DESCRIPTION OF THE FIGURES

The following example embodiments are representative of example techniques and structures designed to carry out the objects of the present general inventive concept, but the present general inventive concept is not limited to these example embodiments. In the accompanying drawings and illustrations, the sizes and relative sizes, shapes, and qualities of lines, entities, and regions may be exaggerated for clarity. A wide variety of additional embodiments will be more readily understood and appreciated through the following detailed description of the example embodiments, with reference to the accompanying drawings in which:

FIG. 1 illustrates a perspective view of a support structure according to one example embodiment of the present general inventive concept;

FIG. 2 illustrates a perspective view of the first end portion of the support structure of FIG. 1;

FIG. 3 illustrates a perspective view of the second end portion of the support structure of FIG. 1;

FIG. 4 illustrates a plurality of support structures according to one example embodiment of the present general inventive concept installed on a roof structure of a building having multple purlins; and

FIG. 5 illustrates a side view of the support structure of FIG. 1, showing an adjustable step installed on the support structure.

DETAILED DESCRIPTION

Reference will now be made to the example embodiments of the present general inventive concept, examples of which are illustrated in the accompanying drawings and illustrations. The example embodiments are described herein in order to explain the present general inventive concept by referring to the figures.

The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the structures and fabrication techniques described herein. Accordingly, various changes, modification, and equivalents of the structures and fabrication techniques described herein will be suggested to those of ordinary skill in the art. The progression of fabrication operations described are merely examples, however, and the sequence type of operations is not limited to that set forth herein and may be changed as is known in the art, with the exception of operations necessarily occurring in a certain order. Also, description of well-known functions and constructions may be simplified and/or omitted for increased clarity and conciseness.

Note that spatially relative terms, such as “up,” “down,” “right,” “left,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over or rotated, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

According to various example embodiments of the present general inventive concept, a support structure is described herein that provides a durable and portable, low-profile work surface for a user to stand, walk, sit, kneel, or lie down on during work along a floorless structure, such as for example, a series of purlin supports extending along a sloped planar configuration. The support structure, or “structure,” includes generally an elongate, rectangular surface having features defined at opposite ends thereof to allow the surface to be secured in spanning relationship between two parallel and spaced-apart purlins. While the example embodiments described herein typically refer to use of the structure along series of purlins, it is understood that these structures may also be used in other types of floorless structures without departing from the spirit and scope of the present general inventive concept.

The attached figures illustrate the general components of a support structure according to example embodiments of the present general inventive concept. In the attached figures, a structure 10 includes a substantially elongate, rectangular central panel 12, a first end portion 14 provided along a first end edge 15 of the panel 12, and an opposite second end portion 16 provided along a second end edge 17 of the panel 12. In the illustrated embodiment, each of the first and second end portions 14, 16 is defined by a panel which is removably secured along a respective one of the first and second end edges 15, 17 of the central panel 12 via a plurality of fasteners 19. Thus, in this embodiment, the first and second end portions 14, 16 may each be fabricated of one or more first materials, such as for example metal, polymer, or the like, while the central panel 12 may be fabricated from one or more different materials, such as for example wood, laminate, etc. However, those skilled in the art will recognize other configurations which may be employed to provide the first end portion 14 along the first end edge 15 of the panel 12 and the second end portion 16 along the second end edge 17 of the panel 12 without departing from the spirit and scope of the present general inventive concept. For example, in various embodiments, the panel 12 may be integrally formed from a unitary material with either or both of the first end portion 14 and second end portion 16. For ease of reference, in the illustrated embodiment, first and second side edges 18, 20, of the central panel 12 are defined extending from respective opposite ends of the end portions 14, 16, thus defining a perimeter of the central panel 12.

In the illustrated embodiment, the first end portion 14 defines a retention means for capturing an upper flange 22 of a purlin 24 and removably securing the first end edge 14 along the upper flange 22. For example, in the illustrated embodiment, an outer edge the first end portion 14 is lapped beneath itself to define an elongated hook-shaped channel 26 extending along the length of the first end portion 14, beneath an upper surface of the structure 10. The channel 26 defines a central void 28 which is sized and shaped generally to receive a portion of the upper flange 22 of a purlin 24, such that the portions of the first end portion 14 forming the channel 26 substantially surround and conform to a leading edge of the upper flange 22 of the purlin 24. Thus, the channel 26 extending along the first end portion 14 may be hooked around the leading edge of the upper flange 22 of a purlin 24, whereupon the structure 10 may lay along an upper surface of the purlin 24 and extend toward one or more adjacent purlins.

In the illustrated embodiment, the above-discussed portion of the retention means is provided via the hook-shaped channel 26 extending along the first end portion 14 of the panel 12. However, those skilled in the art will recognize other shapes and mechanisms which may be used to releasably secure the first end portion 14 along the upper flange 22 of the purlin 24, and such additional shapes and mechanisms may be used without departing from the spirit and scope of the present general inventive concept. For example, in various embodiments, one or more hooks may be provided secured along the first end portion 14, with each of the hooks being configured to receive and retain the leading edge of the upper flange 22 of the purlin 24. In other embodiments, a series of tabs, stops, dogs, or the like may be provided extending substantially perpendicularly downward from the structure 10 along the first end portion 14. In such embodiments, the panel 12 may be placed along an upper surface of the purlin 24 with the first end portion 14 extending slightly beyond an “upper” side of the purlin 24, such that the tabs, stops, dogs, etc., overhang the leading edge of the purlin and the remainder of the structure 10 extends outwardly from an opposite “lower” side of the purlin 24. Thus, the first end portion 14 is retained substantially along the leading edge of the purlin and the structure 10 is limited from sliding translational movement along the downward slope of the roof.

Referring again to the figures, in various embodiments, one half of a two-part fastener is defined along the first end portion 14, and a second half of a two-part fastener is defined along the second end portion 16. Thus, when multiple support structures 10 are provided in adjacent and overlying relationship to one another along adjacent purlins 24 of a roof structure, the overlying first and second end portions 14, 16 of the adjacent structures 10 may secure to one another to limit movement of the structures 10 in relation to one another.

By way of example, and with reference to FIGS. 1-3, a plurality of slots 30 are defined along a central region of the first end portion 14, and a plurality of tabs 32 are defined along a central region of the second end portion 16. Each slot 30 is located, sized, and shaped to receive and mate with a corresponding tab 32 of an adjacent and overlying structure 10. With reference to FIG. 4, with the above-discussed slots 30 and tabs 32 provided, a first structure 10a may be positioned with the channel 26a thereof in engagement with a lower purlin 24a along a roof structure. In this configuration the remainder of the first structure 10a extends downward along the slope of the roof, away from an adjacent upper purlin 24b. A second structure 10b may be positioned with the channel 26b thereof in engagement with the adjacent upper purlin 24b, and the remainder of the second structure 10b may thus extend downward along the slope of the roof, toward the lower purlin 24a and the first structure 10a. In this arrangement, the second end portion 16b of the second structure 10b may be positioned in overlying relationship to the first end portion 14a of the first structure 10a. In this configuration, the fastener second half defined along the second end edge 16b of the second structure 10b, i.e., the tabs 32b, may mate with and secure to the fastener first half defined along the first end portion 14a of the first structure 10a, i.e., the slots 30a. It will be recognized that each slot 30a is located a distance away from the outer edge of the first end portion 14a of the first structure 10a such that, when a tab 32b of the adjacent and overlying second structure 10b is received within a slot 30a of the first structure 10a, the tab 32b prevents the first structure 10a from being slid sufficiently along the associated purlin 24a to allow the channel 26a of the first structure 10a to disengage with the associated received purlin 24a. Hence, the mating of the tabs 32b of the second structure 10b with the slots 30a of the first structure 10a serves to “lock” the first structure 10a to the associated purlin 24a. Thus, the second structure 10b may serve to “lock” the first structure 10a in engagement with the purlin 24a received within the channel 26a of the first structure 10a and prevent the release of the first structure 10a from the associated purlin 24a prior to removal of the second structure 10b.

In several embodiments, each tab 32 is defined by a portion of the second end portion 16 that is partially cut away and folded to extend perpendicular beneath the upper surface of the structure 10. For example, in one embodiment, a plurality of cuts 36 are provided extending from an outer edge 38 of the second end portion 16 along a length dimension of the structure 10, parallel to the first and second side edges 18, 20 of the central panel 12. The cuts 36 cooperate with the outer edge 38 of the second end portion 16 to define a partial perimeter of the tabs 32, with a single edge of each tab 32 being intergrally formed with the second end portion 16. In another embodiment, each tab 32 is defined by a rectangular partial cutout defined along a central portion of the second end portion 16, such that the cutouts of the tabs do not extend to the outer edge 38 of the second end portion 16. In other embodiments, one or more separate pieces may be provided which define the tabs 32 and which project from the second end portion 16 to extend into the slots 30 of an adjacent structure 10. However, it will be recognized that numerous additional shapes and mechanisms may be provided to accomplish the first and second halves of the fastener without departing from the spirit and scope of the present general inventive concept. Furthermore, in still other embodiments, different types of two-part fasteners may be utilized.

In various embodiments, one or more positional locator fasteners may be provided along the first and second side edges 18, 20, which may be configured to receive one or more steps, rails, handholds, or the like, to allow for easier and more convenient movement along the structure 10. For example, in the illustrated embodiment, first and second channels 40, 42 are provided, with each channel 40, 42 being a mirror-image of the other, and each channel 40, 42 extending along a corresponding one of the first and second side edges 18, 20. Each channel 40, 42 defines a plurality of locator fasteners, such as the illustrated through openings 44, pins, tabs, or the like, disposed in a spaced apart configuration along the length thereof. In various embodiments, each locator fastener of each channel 40, 42 aligns horizontally, that is, in an orientation parallel to a long dimension of a purlin received by the channel 26 of the first end portion 14, with an locator fastener of the other channel 40, 42. Thus, one or more additional features, such as for example the above-discussed steps, rails, handholds, or the like, may be provided extending between corresponding aligned pairs of locator fasteners along the channels 40, 42, such that the feature may be configured to extend substantially parallel along the long dimension of the purlin. For example, in one embodiment, an adjustable step 34 is provided which is fastenable to corresponding left and right locator fasteners 44 along the first and second side edges 18, 20. In this configuration, the step 34 may provide a convenient, and relatively flat, horizontal surface upon which a worker may stand or gain a foothold to assist in movement or duration upon the structure 10, or upon which tools or materials may be rested.

From the foregoing description, it will be recognized that a support structure has been described that provides a convenient, transportable, temporary work surface for a user to stand, walk, sit, kneel, or lie down on, or to store building materials or tools on, during work along a floorless structure, such as for example, a series of purlin supports extending along a roof structure. Numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the present general inventive concept. For example, regardless of the content of any portion of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated.

It is noted that the simplified diagrams and drawings included in the present application do not illustrate all the various connections and assemblies of the various components, however, those skilled in the art will understand how to implement such connections and assemblies, based on the illustrated components, figures, and descriptions provided herein, using sound engineering judgment. Numerous variations, modification, and additional embodiments are possible, and, accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the present general inventive concept.

While the present general inventive concept has been illustrated by description of several example embodiments, and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the general inventive concept to such descriptions and illustrations. Instead, the descriptions, drawings, and claims herein are to be regarded as illustrative in nature, and not as restrictive, and additional embodiments will readily appear to those skilled in the art upon reading the above description and drawings. Additional modifications will readily appear to those skilled in the art. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.