Roofing rail transportation system

[0001] 1. Field of the Invention

[0002] The present invention relates to transportation systems, and more particularly to a device for transporting various roofing materials along the rooftop of a building for installation onto the rooftop.

[0003] 2. Description of the Prior Art

[0004] It is well known that constructing a rooftop requires the placement of several layers of different roofing materials upon the building purlins. These roofing materials consist of one or more layers of insulation material, which are then covered by tile or, on many commercial buildings, sheets of metal roofing. These metal sheets are generally provided in large sections, and are bulky and difficult to manage. The sheets must be lifted onto the rooftop, transported or manually carried across the purlins to their respective destinations, and installed. Furthermore, the tradespersons handling these layers must often work upon the exposed purlins while carrying these materials. Even on non-windy days, this poses significant safety risks to the tradesperson and to those below.

[0005] The traditional process for transporting, handling and ultimately installing such materials is time-consuming. Depending upon the material to be installed, this may require the cooperation of several tradespersons to lift and move each sheet. First, several sheets of a particular roofing material are bundled together and hoisted onto the rooftop. Tradespersons on the roof must then unbundle each sheet, carry it across the exposed purlins to its destination, and install it. They must then return to the bundle to repeat the process. This task is further complicated by the fact that the distance from the bundle to the placement location increases as the work progresses, requiring more time and effort to transport each individual sheet to its ultimate destination. The work continues until the final sheet of material is installed at the opposite end of the rooftop.

[0006] A variety of devices have been developed to transport these materials upon the rooftops, many of which involve transportation devices movably mounted upon the purlins. For example, U.S. Pat. No. 4,068,446 discloses a movable platform that travels along the purlins by internal means of locomotion. This platform is large enough to support several tradespersons, and allow them to work from atop the platform. A fence surrounds the platform to prevent the tradespersons from falling. Outrigger arms, a winch assembly, and an insulation roller system increase the functionality of this device. Furthermore, the device may travel from the purlin onto a completed roof panel via rails placed onto the panel.

[0007] U.S. Pat. No. 6,216,416 discloses a dual sectional working platform, also traveling upon the purlins. One section serves as the materials handling area, where various roofing materials are installed onto the purlins. The other section serves as a support platform for the tradespersons while they install the materials. A series of rollers along one side of the platform allow tradespersons to move roofing materials from one end of the platform to the other. The platform itself is moved via a winch connecting the platform to the far end of the roof, this winch is manually turned to move the platform.

[0008] U.S. Pat. No. 5,749,434 discloses a device for transporting roofing materials specifically along pitched rooftops. The device consists of various roller assemblies movably mounted onto the purlins, with pipes connecting the assemblies to form a single platform. The roofing materials are placed onto the platform, and held in place by stop pieces installed at the ends of the platform. This device is then dragged behind the tradespersons as they install the roofing materials.

[0009] Unfortunately, none of the above described devices are particularly suited for simple and lightweight travel upon sections of completed rooftops. Most of the above described inventions are designed to travel solely upon the building purlins. Thus, their movements and directions are limited by the particular placement of the purlins, and further limited to those sections of the rooftop where the purlins remain exposed. The '446 invention does provide one particular method claim which allows that invention to move onto a section of completed rooftop. However, any such extended movement is generally impractical given the size and weight of the invention, since prolonged use of the invention in such a manner risks damage to the rooftop from the sheer weight and bulk of the invention.

[0010] This reveals another inherent problem with many of the above described inventions, namely that they are generally large and heavy. Most of them contain locomotive means, and various other features that assist in the actual placement and installation of the roofing materials. Those inventions must furthermore be sturdy and large enough to support the weight and movement of several tradespersons upon the devices themselves, in addition to the weight of the roofing materials. Such features are beneficial, but they also increase the size and weight of the inventions. They also increase the costs of purchasing and deploying the devices, as well as maintaining them over time. A final drawback is that those inventions are not readily expandable, they are limited to carrying only certain dimensions of roofing material, and may not be sufficiently large to carry certain other materials.

[0011] It is therefore desirable to provide a lightweight and expandable device for use in transporting various roofing materials upon sections of completed roofing, such that they may then be installed onto their proper locations.

[0012] The present invention provides a simple, relatively lightweight and expandable device for use in transporting roofing materials upon sections of completed roofing. The tool of the present invention is in the form of several portable rail carriages or cars and various elongated sectional tubes. The rail cars have a generally flat top surface, allowing them to hold the various roofing materials, with slight upward curvatures at the surface ends to prevent the materials from sliding off the cars. Each rail car also contains four wheels, two located at each end of the car, having edges that are generally concavely shaped.

[0013] Pairs of tubes constitute the other part of this invention. The first end of each tube is generally smaller in diameter than the remainder of the tube. The second end contains a hollow cavity. The tubes are cylindrical, with a convex surface curvature that corresponds to the concave curvature of the edges of the rail car wheels. This permits each rail car to rest securely upon, and travel smoothly along, the tubes. Two tubes are deployed in a parallel manner to form a single pair of rails. A brace is inserted between the tubes to ensure that they maintain their parallel relationship. The rails may be extended by adding additional tubes, specifically by inserting the first end of a tube into the hollow cavity of the second end of another tube.

[0014] In use, the rails are laid parallel upon the installed roofing materials. Rail cars are then placed upon the rails. Two or more rail cars, each traveling upon separate parallel pairs of rails, provide a platform upon which various roofing materials, such as insulation or sheets of metal roofing, may be placed. The size of the platform may be modified to accommodate different dimensions of roofing materials by adding or removing rail cars, or by adding additional parallel pairs of rails and corresponding cars. A tradesperson then moves the platform (the rail cars) along the rails to transport the roofing materials from the unloading area to the ultimate place of installation.

[0015] Accordingly, the present invention provides the tradesperson with a simple, relatively lightweight and expandable device for use in transporting various roofing materials across sections of completed roofing. The rails allow the invention to travel anywhere upon the completed roofing, so that the invention is not limited solely to any particular area of exposed purlins. Unlike most of the previous inventions disclosed above, the rail cars are individually portable and relatively lightweight, since they are designed only to hold the roofing materials. They are also inexpensive, and easily disassembled and stored upon the completion of a project.

[0016] It is therefore a primary object of the present invention to provide a transportation system that is capable of traveling upon previously installed roofing materials via a system of extendable rails that are temporarily installed during roof construction across completed sections of the roof.

[0017] It is also a primary object of the present invention to provide a transportation system having an expandable platform upon which different dimensions of roofing materials may be transported, simply by adding or removing the number of rails and cars that together constitute the roofing materials platform.

[0018] It is also an important object of the present invention to provide a transportation system that is relatively small, lightweight and portable, so as to minimize any weight stress upon the roofing materials, and at the same time, to facilitate the usage and transportation of the device.

[0019] It is also an important object of the present invention to provide a transportation system that is inexpensive to purchase, deploy and maintain, such that greater numbers of tradespersons may readily utilize the invention.

[0020] It is also an important object of the present invention to ensure the safety of tradespersons installing roofing materials upon rooftops, by freeing them of the burdens and dangers that arise from manually transporting various bulky roofing materials from any one place on the rooftop to another place.

[0021] Additional objects of the invention will be apparent from the detailed description and the claims herein.

[0032] Referring to the drawings wherein like refer ence characters refer to the same or corresponding structures throughout the several views, and referring specifically to FIG. 7, it is seen that the invention includes one or more cars or carriages, generally denoted by the numeral 11, resting upon and traveling along a pair of tubular rails, generally denoted by the numeral 12.

[0033] FIG. 1 illustrates the invention within the environment of a partially completed rooftop. Here, the insulation material has already been installed across the purlins 14. Various sheets of metal roofing 15 have also been installed upon the purlins 14, although that process has not yet been completed. Several uninstalled sheets of metal roofing 16 remain upon the car 11. The car rests upon, and travels along, the tubular rails 12 that generally extend to the edge of the installed metal roofing 15. This allows the rail car to travel almost to the edge of the installed metal roofing, decreasing the distance that a tradesperson must carry the uninstalled metal roofing 16 before installing it in its proper location. While the diagram shows the rails 12 lying across the ribs 17 where the different sheets of metal roofing overlap, it is to be appreciated that the rails may be placed in any direction relative to the ribs 17, or alternatively, that they may be placed in any direction upon the insulation material itself.

[0034] FIG. 2 provides a top perspective of the same environment as FIG. 1. By way of example and for illustrative purposes only, and without limiting the appended claims, this diagram reveals numerous rail cars 11 that collectively form a single platform upon which the uninstalled sheets of metal roofing 16 are placed. FIG. 2 also reveals the various pairs of rails 12, laid in a parallel manner, one pair per rail car, which the cars rest upon and travel along. It is apparent that cars 11, and corresponding pairs of rails 12, may be added or removed to accommodate the particular dimensions of various roofing materials.

[0035] FIG. 3 illustrates a typical car or carriage 11 of the present invention. This car 11 is representative of, and contains the same features and characteristics as, all the other cars of the invention. The upper surface 18 of the rail car 11 is generally flat, and may include a slightly upward curvature 21 at each end. This curvature prevents any roofing materials from falling off the car 11 as it travels along rails 12. Car 11 includes wheels 19 that are adapted to move along the tubular rails 12; specifically, the outer annular edges of wheels 19 are concavely shaped such that they fit the surface curvature of the rails 12 upon which they travel. The wheels 19 are attached to the rail car 11 and held in place by a nuts and axel mechanism 20.

[0036] FIG. 4 provides another perspective of a rail car or carriage 11. This diagram reveals that each end of the rail car 11 contains two wheels 19, one wheel per rail. It further reveals the concave curvature 22 of each wheel 19. This curvature corresponds to the convex curvature of the tubular rails 12, such that the wheels rest securely upon, and travel smoothly along, the rails. The diagram also illustrates the close proximity of the wheels 19 to each other. This gives the rail car 11 a narrow width, making it easier for a single tradesperson to carry and deploy the invention.

[0037] FIG. 7 shows both a rail car 11 and rails 12 of the invention. In particular, it illustrates that each wheel 19 of a rail car rests securely upon the rails 12, based upon the above described curvature relationship, such that the rail car 11 may travel smoothly and securely along the rails 12. The diagram further shows the two sectional elongated cylindrical tubes that form the rails 12. These tubes are representative of, and contain the same features and characteristics as, all the other tubes of the invention. The first end 23 of each tube is slightly smaller in diameter than the remainder of the tube. This allows the tradesperson to insert the first end 23 of the tube into the hollow cavity 24 at the second end of another tube, until the annular shoulder 25 rests securely against the second end of the other tube. This permits the tradesperson to extend the rails as necessary, allowing the rail car 11 to travel the entire length of the rooftop. Braces (spacers) 26 are placed between the pairs of tubes at different intervals, maintaining the position of the tubes as parallel to one another. Braces 26 ensure that the pairs of rails 12 are consistently spaced apart from each other along their entire length, so that cars 11 rest securely upon, and travel smoothing along, the rails 12, regardless of their location along the length of the rails.

[0038] FIG. 10 illustrates the tubular rails 12 of the invention. In the preferred embodiment, the tubes are of equal length, although tubes different lengths may be employed in a staggered relationship for added stability and to avoid separation. The tubes face in opposite directions and are offset slightly, such that in the preferred embodiment, the hollow cavity 24 of the first tube of the pair is adjacent to the annular shoulder 25 of the second tube, and vice versa. This particular formation allows the rails to distribute the stress placed upon them, so that the rails do not support the entire weight of the rail cars and their cargo upon any two adjacent points in the rails. This decreases the likelihood that the rails will break under the combined weight above them.

[0039] In use, the uninstalled roofing materials are bundled and hoisted onto the roof area. Tradespersons upon the roof install a single row of roofing material, and place a pair of rails upon the installed roofing material for each rail car. At least two pairs of rails and two corresponding rail cars are generally required. However, the number of rail pairs and corresponding rail cars needed depend upon the dimensions of the roofing materials to be carried. The rail cars are then placed upon the rails to form a platform, and the roofing materials placed onto the platform. The rail cars are then rolled along the rails to the edge of the installed roofing materials. The tradespersons then offload sheets of roofing materials from the platform for installation. As each sheet of roofing material is installed, the tradespersons attach additional tubes to the rails, thereby extending the rails and permitting the platform to be moved to the edge of the installed roof This places the roofing materials within easy reach of the tradespersons, and saves them the time and effort of manually carrying the roofing material from the original location to the place of installation. This process continues until the last row of roofing material is installed. The tradespersons then remove the cars, disassemble the rails and carry the entire device down to the ground.

[0040] It is to be understood that variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the appended claims when read in light of the foregoing specification.