Purlin construction for roof structures

Abstract

An elongated purlin for use in roof structures including an elongated solid continuous strip of metal, the strip of metal having multiple bends parallel with the longitudinal axis to form and define an elongated mounting wall, an elongated upright wall extending from the mounting wall, a first cross piece extending horizontally outwardly in opposite directions from the plane of the upright wall, a second cross piece integrally attached to the first cross piece and extending horizontally outwardly in opposite directions from the plane of the upright wall, and each of the first and second cross pieces having bent double layer construction. The first and second cross pieces are spaced apart to define channels designed to receive an edge of a solar panel or roof section engaged therein.

1 . An elongated purlin for use in roof structures comprising:
 an elongated solid continuous strip of metal with a longitudinal axis, the strip of metal having multiple bends parallel with the longitudinal axis to form and define:   an elongated mounting wall designed to be mounted to and supported on roof beams;   an elongated upright wall integrally affixed to and extending from the mounting wall and extending in a plane;   a first cross piece integrally attached to the upright wall with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the upright wall, each of the first portion and the second portion of the first cross piece formed with bent double layer construction;   a second cross piece integrally attached to the first cross piece with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the plane of the upright wall, each of the first portion and the second portion of the second cross piece formed with bent double layer construction; and   the first cross piece and the second cross piece being spaced apart to define first and second horizontal channels opening outwardly in opposite directions from the plane of the upright wall, the first horizontal channel being defined between the first portion of the first cross piece and the first portion of the second cross piece and the second horizontal channel being defined between the second portion of the first cross piece and the second portion of the second cross piece, and each of the first and second channels being designed to receive an edge of a solar panel or roof section engaged therein.   
     
     
         2 . An elongated purlin as claimed in  claim 1  wherein the elongated upright wall between the elongated mounting wall and the first cross piece is continuous with no breaks or openings therein. 
     
     
         3 . An elongated purlin as claimed in  claim 1  wherein the elongated solid continuous strip of metal has a length at least equal to a desired length of the elongated purlin and a width approximately 19.00 inches to 21.00 inches. 
     
     
         4 . An elongated purlin as claimed in  claim 1  wherein the first portion and the second portion of the first cross piece extend horizontally outwardly a greater distance than the first portion and the second portion of the second cross piece. 
     
     
         5 . An elongated purlin as claimed in  claim 4  wherein the first cross piece extends horizontally outwardly in opposite directions from the plane of the upright wall a distance greater than 1 inch. 
     
     
         6 . An elongated purlin as claimed in  claim 4  wherein the second cross piece extends horizontally outwardly in opposite directions from the plane of the upright wall a distance less than 1 inch. 
     
     
         7 . An elongated end cap purlin for use in roof structures comprising:
 an elongated solid continuous strip of metal with a longitudinal axis, the strip of metal having multiple bends parallel with the longitudinal axis to form and define:   an elongated mounting wall designed to be mounted to and supported on roof beams;   an elongated upright wall integrally affixed to and extending from the mounting wall and extending in a plane, the mounting wall extending from the upright wall in a direction;   a first cross piece integrally attached to the upright wall and extending horizontally outwardly from the upright wall in a direction parallel with the direction of the mounting wall, the first cross piece formed with bent double layer construction;   a second cross piece integrally attached to the first cross piece and extending horizontally outwardly from the plane of the upright wall in a direction parallel with the direction of the mounting wall, the second cross piece formed with bent double layer construction; and   the first cross piece and the second cross piece being spaced apart to define a horizontal channel therebetween opening outwardly from the plane of the upright wall, and the second channel being designed to receive an edge of a solar panel or roof section engaged therein.   
     
     
         8 . A solar panel mounting system for use in roof structures comprising:
 a plurality of elongated purlins with each purlin comprising an elongated solid continuous strip of metal with a longitudinal axis, the strip of metal having multiple bends parallel with the longitudinal axis to form and define:   an elongated mounting wall designed to be mounted to and supported on roof beams;   an elongated upright wall integrally affixed to and extending from the mounting wall and extending in a plane;   a first cross piece integrally attached to the upright wall with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the upright wall, each of the first portion and the second portion of the first cross piece formed with bent double layer construction;   a second cross piece integrally attached to the first cross piece with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the plane of the upright wall, each of the first portion and the second portion of the second cross piece formed with bent double layer construction; and   the first cross piece and the second cross piece being spaced apart to define first and second horizontal channels opening outwardly in opposite directions from the plane of the upright wall, the first horizontal channel being defined between the first portion of the first cross piece and the first portion of the second cross piece and the second horizontal channel being defined between the second portion of the first cross piece and the second portion of the second cross piece, and each of the first and second channels being designed to receive an edge of a solar panel or roof section engaged therein;   a plurality of elongated end cap purlins, each end cap purlin comprising:   an elongated solid continuous strip of metal with a longitudinal axis, the strip of metal having multiple bends parallel with the longitudinal axis to form and define:   an elongated mounting wall designed to be mounted to and supported on roof beams;   an elongated upright wall integrally affixed to and extending from the mounting wall and extending in a plane, the mounting wall extending from the upright wall in a direction;   a first cross piece integrally attached to the upright wall and extending horizontally outwardly from the upright wall in a direction parallel with the direction of the mounting wall, the first cross piece formed with bent double layer construction;   a second cross piece integrally attached to the first cross piece and extending horizontally outwardly from the plane of the upright wall in a direction parallel with the direction of the mounting wall, the second cross piece formed with bent double layer construction; and   the first cross piece and the second cross piece being spaced apart to define a horizontal channel therebetween opening outwardly from the plane of the upright wall, and the second channel being designed to receive an edge of a solar panel or roof section engaged therein; and   a plurality of solar panels;   the plurality of elongated purlins and the plurality of elongated end cap purlins attached to roof beams to define a flat roof and the plurality of solar panels engaged in each of the first and second horizontal channels of the plurality of elongated purlins and the horizontal channel of each of the plurality of elongated end cap purlins to form a continuous flat roof.   
     
     
         9 . A method of fabricating an elongated purlin for use in roof structures comprising the steps of:
 providing an elongated solid continuous strip of metal with a longitudinal axis, bending the strip of metal parallel with the longitudinal axis with multiple bends not necessarily in the order listed below;   bending the strip of metal parallel with the longitudinal axis to form an elongated mounting wall designed to be mounted to and supported on roof beams;   bending the strip of metal parallel with the longitudinal axis to form an elongated upright wall integrally affixed to and extending from the mounting wall and extending in a plane;   bending the strip of metal parallel with the longitudinal axis to form a first cross piece integrally attached to the upright wall with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the upright wall, each of the first portion and the second portion of the first cross piece formed with bent double layer construction;   bending the strip of metal parallel with the longitudinal axis to form a second cross piece integrally attached to the first cross piece with a first portion and a second portion extending horizontally outwardly in opposite directions from the plane of the upright wall to form a T-shape with the plane of the upright wall, each of the first portion and the second portion of the second cross piece formed with bent double layer construction; and   bending the strip of metal parallel with the longitudinal axis to form the first cross piece and the second cross piece in a spaced apart relationship to define first and second horizontal channels opening outwardly in opposite directions from the plane of the upright wall, the first horizontal channel being defined between the first portion of the first cross piece and the first portion of the second cross piece and the second horizontal channel being defined between the second portion of the first cross piece and the second portion of the second cross piece, and each of the first and second channels being designed to receive an edge of a solar panel or roof section engaged therein.   
     
     
         10 . A method as claimed in  claim 9  wherein the steps of bending the strip of metal parallel with the longitudinal axis to form the first cross piece and bending the strip of metal parallel with the longitudinal axis to form the second cross piece includes forming the first cross piece to extend horizontally outwardly a greater distance than the second cross piece. 
     
     
         11 . A method as claimed in  claim 9  wherein the step of bending the strip of metal parallel with the longitudinal axis to form the first cross piece includes extending the first cross piece horizontally outwardly in opposite directions from the plane of the upright wall a distance greater than 1 inch. 
     
     
         12 . A method as claimed in  claim 9  wherein the step of bending the strip of metal parallel with the longitudinal axis to form the second cross piece includes extending the second cross piece horizontally outwardly in opposite directions from the plane of the upright wall a distance less than 1 inch.