Patent Grant
9637927
Various systems are known for supporting loads on roofs, and for installing skylights and/or smoke vents onto, into roofs.
A significant motivation for use of skylights is that the daylighting which enters the building through the skylight lenses can reduce or eliminate the need for use of electrical light fixtures during the daylight hours. Further, conventionally-known control systems can monitor the light intensity at desired, selected locations inside the building and automatically turn on selected ones of the electrical light fixtures as needed in order to maintain a desired level of light intensity at the selected locations inside the building, or selectively dim, or turn off, such light fixtures when a desired level of light intensity is being delivered through the skylights.
The benefits of using skylights to obtain daylighting include lower energy costs, less use of fossil fuels for generating electricity, and potentially less worker stress or fatigue. A significant problem associated with use of conventionally-available skylight lens assemblies is that conventionally-available skylight lens assemblies are known to have high probability of leaking during rain events.
Commonly used skylighting systems have translucent or transparent covers, also known as lenses, mounted on a support structure, commonly known as a “curb”, which is mounted to building support members inside the building and wherein such support structure extends through an opening in the roof. Ambient daylight passes through the lens and thence through the roof opening and into the building.
Thus, conventional skylight and smoke vent installations use a curb structure beneath the exterior roofing panels and inside the building enclosure, and extending through the roof structure, in order to provide a support which extends through the roof, past the roof panels, and which supports the skylight lens assembly. Conventional skylight curbs, thus, are generally in the form of a preassembled box-like structure. Such box-like structure is mounted to building framing members inside the building enclosure, and extends through a respective opening in the roof, and past the respective elongate metal roof panels. The skylight assembly thus mounts inside the building enclosure, and extends through an opening in a corresponding roof structure. Fitting skylight assemblies into such roof opening presents problems, both for the installer and for the user. A primary problem is that mentioned above, namely that all known types of installations of conventional skylight support structures have a tendency to leak water when subjected to rain.
In light of the leakage issues, there is a need for a more effective way to support skylights and smoke vents, thus to bring daylighting into buildings, as well as a more effective way to support a variety of other loads, on roofs.
To achieve desired levels of daylighting, conventional skylight installations use multiple roof openings spaced regularly about the length and width of a given roof surface through which daylighting is to be received. Each skylight lens is installed over a separate such opening.
Skylight assemblies of the invention are mounted on the ribs defined by metal roof panels of standing seam metal roofs. The skylight assemblies are raised above elongate centralized panel flats which extend the lengths of the panels, whereby rib elements at the sides of adjacent such roof panels are joined to each other in elongate joinders, referred to herein as the ribs.
The opening for a conventional skylight cuts across multiple such ribs in order to provide a wide enough opening to receive conventionally-available commercial-grade skylight assemblies. The conventional skylight assembly, itself, includes a curb which is mounted inside the building and extends, from inside the building, through the roof opening and about the perimeter of the opening, thus to support the skylight lens above the flats of the roof panels, as well as above the ribs. Flashing, and conventional pliable tube construction sealants are applied about the perimeter of the roof opening, between the roof panels and the flashing, including at the cut ribs. Typically, substantially all of such sealant is applied in the panel flats, which means that such sealant is a primary barrier to water leakage about substantially the entire perimeter of the skylight curb.
One of the causes of roof leaks around the perimeter of conventional roof curbs which attach primarily through the panel flat at the water line is due to foot traffic, such as heel loads or other dynamic loads imposed by workers wheeling gas cylinders or other heavy equipment on the roof panel e.g. with dollies. This type of dynamic loading can cause high levels of stress and/or flexing of the adjacent roof panels, adjacent the edges of the curb. Such joints between the roof panels and the curb typically rely solely on flashing and tube sealant to provide seals between the curb and the roof panels, most notably in the panel flats. Leaks are also commonly attributed to areas around fastener locations, as the panels flex under load, causing stress between the sealant and the respective curb and/or roof panels; whereby the sealant deforms such that, with repeated flexing of the sealant over time, passages develop through the sealant, which allows for the flow of water through such passages and into the building.
Such curbs, each extending through a separate roof opening, each sealed largely in the panel flats, create multiple opportunities for water to enter the interior of the building. Such opportunities include, without limitation,
The traditional curb constructions and methods of attachment in most cases thus require that a complex support structure be installed below the metal roof panels and supported from building framing structure, such as purlins, located inside the building enclosure, which allows disparate/discordant movement of the metal roof panels and the skylight assembly relative to each other, as associated with thermal expansion and contraction of the metal roof e.g. in response to differences in temperature changes outside the building relative to contemporaneous temperatures inside the building.
In addition, conventional curb-mounted skylight structures tend to collect condensation on inside surfaces of the heated space in the building.
In some known structures, water is diverted to only one side of the structure. In the case of heavy rains, it may, in some instances, be desirable to provide a support structure to divert water to both sides of the structure in order to effect faster water run-off.
In some instances, it would be desirable to provide a thermal break and/or a vapor barrier up alongside the rib and upstanding elements of the support structure in order to attenuate water vapor condensation on inside surfaces of the support structure.
In some instances, it would be desirable to provide a support structure having a combination of a thermal barrier and a vapor barrier up alongside the rib, and alongside upstanding elements of the support structure, in order to attenuate water vapor condensation on inside surfaces of the support structure, as well as to attenuate thermal conduction through the support structure.
Thus, it would be desirable to provide a skylight system which provides a desired level of daylighting in a commercial and/or industrial building while substantially reducing the incidence/frequency of leaks occurring about such skylights, as well as reducing or eliminating the incidence/frequency of condensate accumulation inside the building in the areas of such skylights.
It would also be desirable to provide a smoke vent system while substantially reducing the incidence/frequency of leaks occurring about such smoke vents, as well as reducing or eliminating the incidence/frequency of condensate accumulation inside the building in the areas of such smoke vents.
It would further be desirable to provide a support system, suitable for supporting any of a variety of roof loads, up to the load-bearing capacity of the metal panel roof while substantially controlling the tendency of the roof to leak about such support systems, as well as reducing or eliminating the incidence/frequency of condensate accumulation in the areas of such support systems.
It would be further desirable to provide thermal break structure which interrupts the path of travel of thermal energy otherwise entering the building through the skylight or smoke vent structure.
The invention provides a construction system for installing loads, such as skylight assemblies and/or smoke vent assemblies, or other loads, on the major rib elevations of a building's metal panel roof system such that substantially all of the load is conveyed through a load support structure, thence through side rails mounted on roof panel ribs, thence through the ribs and to underlying building support structure, thereby utilizing the beam strengths of the standing seams of the rib elements of the roof panels as the primary support structure supporting such loads, such that all, or nearly all, of the overlying load is conveyed, through the ribs, to the underlying building support structure.
As used herein “beam strength” refers to the capability of a structural element to resist a bending force, as “beam strength” is defined at www.wikipedia.org. Within this context, the standing seams on the ribs, in a standing seam metal panel roof, acting in a capacity as beam web structure, provide beam-like strength in supporting/resisting the weight of overlying vertical loads imposed on the roof.
In addition, the invention can provide improved control of thermal losses, and corresponding condensation on inside surfaces of the load support structure inside the climate-controlled building envelope, by providing thermal insulation and thermal break structures, about the opening in the roof.
Further, some embodiments of the invention provide structure diverting up-slope water to both left and right opposing sides of the load support structure.
In a first family of embodiments, the invention comprehends an upper diverter having opposing left and rights sides, and being configured to be mounted on a sloping metal panel roof of a building, the upper diverter comprising a lower flange having a first left end disposed toward a left side of the upper diverter, and an opposing first right end disposed toward a right side of the upper diverter, and a first length between the first left end and the first right end; and an upstanding end panel having an upper edge and a lower edge, a second left end corresponding to the left end of the lower flange, and an opposing second right end corresponding to the right end of the lower flange, and a second length between the second left end and the second right end and extending in generally a same direction as the first length of the lower flange, the end panel comprising an upper web having a third length extending in generally the same direction as the first and second lengths, between left and right ends of the upper web, the upper web further having an upper edge and a lower edge, and left and right diversion panels defining left and right diversion surfaces extending between, and being joined with, the lower flange and the upper web, each of the left and right diversion panels extending, in the direction of the length of the upper web, beyond respective ones of the left and right ends of the upper edge of the upper web.
In some embodiments, the apparatus comprises a plurality of closure members which, when assembled to such roof in cooperation with each other, define the support structure, and extend up from the roof, and wherein one of the closure members comprises such an upper diverter.
In some embodiments, the apparatus further comprises a panel stiffener plate adapted and configured to underlie the lower flange and to optionally provide primary support to a downwardly-directed load applied to the lower flange.
In some embodiments, the apparatus further comprises a panel stiffener plate adapted and configured to underlie the lower flange and to provide primary support to a downwardly-directed load applied to the lower flange, the panel stiffener plate being substantially longer than the lower flange, and sufficiently long to extend from one of the opposing ends of the lower flange across a next adjacent one of the panel flats to a next adjacent rib, the panel stiffener plate having upstanding legs configured to interface with an upstanding panel of such next adjacent rib, the apparatus further comprising mounting structure adapted to mount the panel stiffener to the next adjacent rib.
In some embodiments, the panel stiffener plate is sufficiently long to extend across a next adjacent one of the panel flats from each of the opposing ends of the lower flange, to next adjacent ribs.
In some embodiments, the apparatus is configured to be mounted to the metal roof of the building, and further comprises a panel stiffener having first, second and third width elements extending sequentially across an overall width of the panel stiffener, the second width element having a width dimension at least equal to the width of the lower flange proximate the ends of the upper web, the first and third width elements extending from opposing sides of the second width element and each having upstanding legs, on opposing ends thereof, the apparatus further comprising mounting structure adapted to secure the panel stiffener to upstanding rib elements of the ribs.
In some embodiments, the upper diverter is configured to extend across the width of at least one of the metal roof panels, the support structure further comprises first and second rail structures configured to be mounted on the ribs of respective ones of the metal roof panels such that the ribs provide primary vertical roof support for the support structure, with the first and second rail structures forming joinders with the upper diverter, the support structure further comprising a lower closure configured to extend between respective ones of the rail structures across the width of the respective metal roof panel at a lower end of the support structure.
In a second set of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides and defining a panel flat area, a given panel flat having a width, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels, in combination with a support structure configured to support a load from the sloping roof system, the support structure having a support structure width extending across the panel flat area of at least one of the metal roof panels, and a support structure length extending along the lengths of the metal roof panels, the support structure extending about at least a portion of the panel flat of the respective metal roof panels, the support structure comprising an upper diverter as described herein, the support structure further comprising a first rail structure comprising one or more first rails arranged end to end with respect to each other, and a second rail structure comprising one or more second rails arranged end to end with respect to each other, the first and second rail structures extending from a relatively upper portion of the support structure, at a relatively upper portion of the roof, toward a relatively lower portion of the support structure at a relatively lower portion of the roof system, and a lower closure closing the support structure at the lower portion of the support structure.
In some embodiments, the first and second rail structures are mounted on first and second ones of the ribs of the roof system, the lower edge of the end panel of the upper diverter defining first and second downwardly-directed slopes extending in opposing directions from proximate a mid-point of the length of the end panel, thereby to direct water, flowing by gravity, laterally in opposing directions along the length of the end panel.
In some embodiments, the combination further comprises a first cut-away gap section defining a first path through a first rib at the left side of the upper diverter and a second cut-away gap section defining a second path through a second rib at the right side of the upper diverter, both cut-away gap sections traversing the respective ribs at elevations of the respective panel flats, the lower flange of the upper diverter and a lower portion of the upstanding end panel extending along the respective paths through the respective gaps in the respective ribs, whereby water encountering the support structure at the upper diverter flows laterally, in opposing directions along the paths, toward and through the respective cut-away rib gap sections and onto the panel flats of the next adjacent metal roof panels on the opposing sides of the support structure.
In a third family of embodiments, the invention comprehends an upper diverter having opposing left and right sides, and being configured to be mounted on a sloping roof of a building, the upper diverter comprising a lower flange having a first left end disposed toward a left side of the upper diverter, and an opposing first right end disposed toward a right side of the upper diverter, and a first length between the first left end and the first right end; and an upstanding end panel having an upper edge and a lower edge, a second left end corresponding to the left end of the lower flange, and an opposing second right end corresponding to the right end of the lower flange, and a second length between the second left end and the second right end and extending in generally a same direction as the first length of the lower flange, the end panel comprising an upper web having a third length extending in generally the same direction as the first and second lengths between left and right ends of the upper web, an upper edge and a lower edge, the upper edge of the upper web having a left end and a right end, and first and second diversion panels having left and right diversion surfaces extending between, and being joined with, the lower flange and the upper web, each of the left and right ends of a lower portion of the upper web extending, in the direction of the length of the upper web, beyond respective ones of the left and right ends of the upper edge of the upper web.
In a fourth family of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides and defining a panel flat area, a given panel flat having a width, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels, in combination with a support structure configured to support a load from the sloping roof system, the support structure having a support structure width extending across the panel flat area of at least one of the metal roof panels, and a support structure length extending along the lengths of the metal roof panels, the support structure comprising a two-way upper diverter as described herein, the support structure further comprising a first rail structure on a first side of the support structure, and a second rail structure on a second opposing side of the support structure, the first and second rail structures extending from a relatively upper portion of the support structure, at a relatively upper portion of the roof system, toward a relatively lower portion of the support structure, at a relatively lower portion of the roof system, and a lower closure closing the support structure at the lower portion of the support structure.
In some embodiments, the first and second rails are mounted on first and second ones of the ribs of the roof system, the lower edge of the end panel of the upper diverter defining downwardly-directed slopes extending across the width direction of the support structure and toward opposing sides of the support structure, thereby to direct water, flowing by gravity, laterally in opposing directions across one or more of the metal roof panels at the upper diverter.
In some embodiments, the combination further comprises first and second cut-away gap sections defining first and second paths through the ribs at first and second sides of the support structure adjacent the upper diverter, at elevations of the respective panel flats, the lower flange of the upper diverter, and portions of the end panel, extending along the paths through the cut-away gap sections in the respective ribs and to the panel flats of the adjacent metal roof panels, and the lower portions of the end panels terminating at the respective ribs, whereby water encountering the support structure at the upper diverter flows laterally across the at least one panel flat, along the paths through the respective cut-away rib gap sections and onto the panel flats of the next adjacent metal roof panels on opposing sides of the support structure.
In a fifth family of embodiments, the invention comprehends an upper diverter, configured to be mounted on a sloping roof of a building, the upper diverter having a first length and opposing first and second ends, and comprising a lower flange having a second length extending along the first length; and an upstanding end panel forming a joinder with the lower flange at a lower edge of the end panel, the joinder extending generally along the second length of the lower flange, the upstanding end panel having opposing first and second sides and extending upwardly from the joinder with the lower flange to an upper edge of the upstanding end panel, the upper edge of the upstanding end panel having a third end corresponding to the first end of the upper diverter and a fourth end corresponding to the second end of the upper diverter, at least portions of the upstanding end panel, at the first and second ends of the upper diverter, extending beyond the third and fourth ends of the upper edge of the upstanding end panel.
In some embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides and defining a panel flat area, a given panel flat having a width, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels, in combination with a support structure configured to support a load from the sloping roof system, the support structure having a support structure width extending across the panel flat area of at least one of said metal roof panels, and a support structure length extending along the lengths of said metal roof panels, the support structure comprising a two-way upper diverter as described herein, the support structure further comprising a first rail structure forming a first side of the support structure, and a second rail structure forming a 35 second side of the support structure, the first and second rail structures extending from a relatively upper portion of the support structure, at a relatively upper portion of the roof system, toward a relatively lower portion of the support structure, at a relatively lower portion of the roof system, and a lower closure closing the support structure at the lower portion of the support structure.
In some embodiments the first and second rails are mounted on first and second ones of the ribs of the roof system, the lower edge of the upstanding end panel of the upper diverter defining first and second downwardly-directed slopes extending in opposing directions across the width of the support structure and toward opposing sides of the support structure, thereby to direct water, flowing by gravity, laterally in opposing directions across one or more of the metal roof panels at the upper diverter.
In some embodiments, the combination further comprises a first cut-away gap section defining a first path through a first rib at the left side of the upper diverter and a second cut-away gap section defining a second path through a second rib at the right side of the upper diverter, both cut-away gap sections traversing the respective ribs at elevations of the respective panel flats, the lower flange of the upper diverter and a portion of the upstanding end panel extending along the respective paths through the respective cut-away gap sections in the respective ribs and to the panel flats of the adjacent metal roof panels, and the lower portions of the end panels terminating at the ribs, whereby water encountering the support structure at the upper diverter flows laterally across the at least one panel flat, in opposing directions along the paths through the respective cut-away rib gap sections and onto the panel flats of the next adjacent metal roof panels on the opposing sides of the support structure.
In a sixth family of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides, a given panel flat having a width, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels; in combination with a support structure configured to support a load from the sloping roof system, the support structure comprising a plurality of closure members, including an upper diverter, the upper diverter comprising a lower flange having a flange length extending across the width of a given roof panel, and an upstanding end panel, having a mid-section, and left and right sides, the end panel being joined with the lower flange at a lower edge of the end panel, the joinder extending generally along the length of the lower flange, lower portions of the end panel extending through first and second cut-away sections of respective ribs adjacent the upper diverter, and covering exposed open profiles of such ribs in the cut-away sections, and terminating at or proximate edges of such cut-away sections of the ribs which are remote from the mid-section of the end panel.
In some embodiments, the lower flange extends through the first and second cut-away sections of the respective ribs and onto the panel flats of next-adjacent roof panels.
In a seventh family of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels; in combination with a support structure configured to support a load from the sloping roof system, the support structure comprising a plurality of closure members, including an upper diverter, the upper diverter comprising a lower flange having a flange length extending across the width of a given roof panel, and an upstanding end panel, having a mid-section, and left and right sides, the end panel being joined with the lower flange at a lower edge of the end panel, the joinder extending generally along the length of the lower flange, lower portions of the end panel extending through first and second cut-away sections of respective ones of the ribs adjacent the upper diverter, and not extending across the panel flats of the next adjacent roof panels.
In some embodiments, the lower flange extends through the first and second cut-away sections of the respective ribs and onto the panel flats of the next adjacent roof panels.
In an eighth family of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels; in combination with a support structure configured to support a load from the sloping roof system, the support structure comprising a plurality of closure members, including an upper diverter and a panel stiffener plate, the upper diverter comprising a lower flange having a flange length extending across the width of a given roof panel at, and in facing relationship with, a top surface of a respective panel flat, and an upstanding end panel extending upwardly from the lower flange, the panel stiffener plate underlying the lower flange and underlying the respective panel flat, the panel stiffener plate extending at least one of up-slope or down-slope of the lower flange, the panel stiffener plate having first and second end portions, each extending up under, and in generally parallel relationship with, and being mounted to, a panel of a respective rib.
In some embodiments, the end portions of the panel stiffener plate are mounted to the rib panels with mechanical fasteners such as, without limitation, rivets or screws.
In some embodiments, the panel stiffener plate is adapted and configured to provide primary support to a downwardly-directed load applied to the lower flange.
In some embodiments, each stiffener plate end portion has a depending mid-section, a separate depending up-slope section, and a separate depending down-slope section, each of the up-slope and down-slope sections extending up under, and in generally parallel relationship with, and being mounted to, a panel of the respective rib.
In a ninth family of embodiments, the invention comprehends a sloping roof system comprising a plurality of metal roof panels, each having a width, and opposing sides, and a roof panel length, and a panel flat extending across the roof panel width, between the opposing sides, a given panel flat having a width, the metal roof panels being arranged side by side, adjacent each other, edge portions of adjacent ones of the metal roof panels defining elevated ribs on opposing sides of the respective metal roof panels; in combination with a support structure configured to support a load from the sloping roof system, the support structure comprising a plurality of closure members, including an upper diverter and a panel stiffener plate, the upper diverter comprising a lower flange having a flange length extending across the width of a given roof panel at, and in facing relationship with, a top surface of a respective panel flat, and an upstanding end panel extending upwardly from the lower flange, the panel stiffener plate underlying the lower flange and underlying the respective panel flat, the panel stiffener plate further extending under a respective rib and across the panel flat of a roof panel next adjacent the upper diverter.
In some embodiments, the panel stiffener plate extends under the ribs and under the panel flats of roof panels next adjacent the upper diverter on opposing ends of the upper diverter.
A more complete understanding of the present invention and the attendant features and advantages thereof may be had by reference to the following detailed description when considered in combination with the accompanying drawings wherein the FIGURES depict various components and compositions of support structures of the invention.
The invention is not limited in its application to the details of construction, or to the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various other ways. Also, it is to be understood that the terminology and phraseology employed herein is for purpose of description and illustration and should not be regarded as limiting. Like reference numerals are used to indicate like components.
The products and methods of the present invention provide a load support structure, for use in installing and supporting various exterior roof loads, including structures which close off openings in metal panel roofs. For purposes of simplicity, “support structure” is used interchangeably herein to refer to various types of structures which are mounted on ribs of raised-elevation metal panel roof structures, such that substantially all of the load passes through the support structure and through the ribs on which the support structure is mounted, to the underlying building framing inside the building. The support structure typically surrounds an opening in the roof, including extending across the flat of a roof panel. Skylight assemblies and smoke vents are non-limiting examples of covers which are mounted on such support structures and which extend over, and which close off, such roof openings. Air handling operations such as vents, air intakes, and air or other gaseous exchanges to and/or from the interior of the building are non-limiting examples of operations where conduits extend through the roof opening. In the case of roof ventilation, examples include simple ventilation openings, such as, for example and without limitation, roof fans and smoke vents, which are used to allow the escape of smoke through the roof during a fire. The only limitation regarding the loads to be supported is that the magnitude of a load must be within the load-bearing capacity of the roof panel or panels to which the load is mounted.
The number of skylights or other roof loads can vary from one load, to as many loads as the building roof can support, limited only by the amount of support which the respective roof panels, namely the ribs to which the load is attached, can provide.
The invention provides structures and installation processes, as closure systems which utilize the beam-like bending resistance of the standing seams, in the roof panel ribs, as a primary support, supporting e.g. a downwardly-directed load on the roof.
Support structures of the invention do not need to be mounted directly to the building framing inside the climate-controlled building enclosure for the purpose of being themselves supported, and thereby supporting, an installed skylight system or other load. Neither does the skylight system of the invention require a separate curb construction surrounding each skylight lens assembly to separately support or mount or attach each skylight lens assembly to the roof. Rather, a support structure of the invention, which supports such skylights, is overlaid onto, and mounted to, the roof panels, thus exposing the support structure to the same ambient weather conditions as the weather conditions which the surrounding roof panels experience. Accordingly, the support structure experiences approximately the same, or a similar, rate of thermal expansion and contraction as is experienced by the respective roof panel or panels to which the support structure is mounted. This is accomplished through direct attachment of the support structure of the invention, which supports e.g. a skylight assembly or other load, to the underlying metal roof panels. According to such roof mounting, and such ambient weather exposure, expansion and contraction of the support structure of the invention generally coincides, at least in direction, with concurrent expansion and contraction of the metal roof panels.
Referring now to the drawings, a given metal roof panel generally extends from the peak of the roof to the respective eave. Skylight systems of the invention contemplate the installation of two or more adjacent skylight assemblies in an end to end relationship along the major rib structure of a given such metal roof panel on the building, over a single aperture in the roof, whereby the individual skylight assemblies are installed in strips over a continuous, uninterrupted opening in the metal roof, the opening extending along a line which extends from at or near the roof ridge to a location at or near a corresponding eave.
In the alternative, a single skylight assembly can be installed over each, or any, such roof opening.
Skylight systems of the invention can be applied to various types of ribbed roof profiles.
A skylight/ventilation support structure is illustrative of support structures of the invention which close off roof-penetrating openings. Such support structure can comprise a rail and closure structure which surrounds an opening in the roof, and which is adapted to be mounted on, and supported by, the prominent standing elevations, standing rib structures, or other upstanding elements of conventional such roof panels, where the standing structures of the roof panels provide the support for the so-mounted support structures. Namely, structure which is mounted to the roof panels above the panel flats, e.g. at seams/joints/ribs where adjoining metal roof panels are joined to each other, provides the support for supporting respective loads. A such rail and closure support structure may be secured to the conventional metal roof panels across a single panel flat, by fasteners located above the respective panel flat, and surrounds a roof opening formed largely in the intervening flat region of one or more metal roof panels.
Skylight lens assembly 130, which is part of the closure system for closing off the aperture, generally comprises a skylight lens frame 132 mounted to the load support structure and extending about the perimeter of a given load support structure, in combination with a light-transmitting skylight lens 134 mounted to frame 132. An exemplary such skylight lens is that taught in U.S. Pat. No. 7,395,636 Blomberg and available from Sunoptics Prismatic Skylights, Sacramento, Calif.
Still referring to
Referring now to
As illustrated in
Where space 239 faces away from upstanding web 238 of the side rail, as at the left side of
Gap plug 243 is relatively short, for example about 1.5 inches to about 2.5 inches long, and has a width/height cross-section, shown in
Gap plug 243 is made of a relatively solid, yet resilient, e.g. EPDM (ethylene propylene diene monomer) rubber, which provides relatively solid e.g. relatively non-pliable mass in space 239 between the folded-over standing seam and upstanding web 238 of the rail, and relatively pliable, putty-like, tape mastic and tube caulk or the like are used to fill the relatively smaller spaces which remain after the gap plug has been inserted in the respective gap/space. Upper flange 240, at the top of the rail, is adapted to support skylight frame 132, seen in
Referring back to
Rail and closure structure 140 is representative of the perimeter portion of support structure 100. Rails 142, 144 fit closely along the contours of ribs 32. Upper diverter 146 and lower closure 150 have contours which match the cross-panel contours of the respective ribs 32 as well as matching the respective panel flats 14, 114. The various mating surfaces of structure 140 and roof 110 can be sealed in various ways known to the roofing art, including caulk or tape mastic. Plastic or rubber fittings or inserts such as plugs 243, and plugs 460, discussed hereinafter, can be used to fill larger openings at the rails and ribs.
As illustrated, the uncompressed, rest cross-section of rod 260 in cavity 264 is somewhat greater than the slot-shaped opening 268 between inside panel 244 and upstanding web 238. Thus retainer rod 260 is deformable, and the cross-section of the rod is compressed as the rod is being forced through opening 268. After passing through opening 268, rod 260 expands against web 238, upper flange 240, and panel 244 of the cavity while remaining sufficiently compressed to urge vapor barrier layer 250 against web 238, upper flange 240, and panel 244 of the cavity whereby vapor barrier layer 250 is assuredly retained in cavity 264 over the entire length of the rail or rails. A highly resilient, yet firm, polypropylene or ethylene propylene copolymer foam is suitable for rod 260. A suitable such rod, known as a “backer rod” is available from Bay Industries, Green Bay, Wis. Such backer rod can be manually compressed sufficiently to effect the insertion of the foam through opening 268 and into cavity 264.
In alternative embodiments, rod 260 can comprise a less compressible material, whereupon any or all of the cavity structure elements, namely upstanding web 238, upper flange 240 and inside panel 244 are specified to be sufficiently resiliently deflectable that a worker can deflect inside panel 244 away from upstanding web 238, thus increasing the dimension of slot-shaped opening 268 enough to allow the rod to be manually pushed through the slot.
Such rod for the alternative embodiments can be any material which can effectively engage and hold the vapor barrier sheet when force is applied to the surface of the rod. Non-limiting examples of such materials are various non-foamed, or slightly-foamed, relatively higher density rubber-like materials, such as EPDM rubbers, styrene butadiene styrene rubbers, and the like. Various plastics such as PVC and various ones of the polyolefins, such as polyethylene, polypropylene, or the like, can also be used, either unfoamed or modestly foamed having densities greater than about 10 pounds per cubic foot, optionally greater than 12 pounds per cubic foot, optionally greater than 20 pounds per cubic foot, up to the unfoamed densities of the respective materials. In some instances, a wood rod/dowel is acceptable for rod 260.
In any embodiment, the installer deflects panel 244 progressively along the length of slot opening 268 while correspondingly inserting respective progressive portions of the length of rod 260 into the cavity or compresses the rod while correspondingly inserting the progressive portion of the length of the rod into the cavity, or both compresses the rod and deflects panel 244 while inserting the progressive length of the rod into the cavity. As the installer releases a respective portion of inside panel 244 or rod 260, in the process of inserting a respective portion of the rod 260 into the cavity, the respective cavity structure or rod resiliently returns toward its rest position, closing slot 268 and/or expanding the rod to its rest position, which brings inside panel 244 into a holding engagement with the rod whereby the force being exerted between rod 260 and panel 244 in attempting to return to respective unstressed configurations applies an effective frictional holding force against vapor barrier 250.
Thus, the function of capturing the vapor barrier layer can be achieved either by temporarily compressing the rod enough that the rod can be inserted through slot 268 or by temporarily enlarging slot 268 enough that the rod can be pushed through the enlarged slot, or both compressing the rod and enlarging slot 268. Accordingly, the vapor barrier can be captured by rod 260 by any of the following exemplary methods:
In each instance, whether compressing rod or the resiliently deflecting inside panel 244, or both, the diameter/cross-section of the rod must be ultimately sufficiently small that the rod can be inserted through slot 268 into cavity 264, while being sufficiently large that a latent force exists between the rod and inside panel 244 after installation of the rod is completed/finished.
Thus, in the first instance, the resilient rod applies a constant outwardly-directed force against the vapor barrier layer, which is transmitted through the vapor barrier layer, to inner flange 244. And in the second instance, the resiliency of inside panel 244, once released, applies a constant inwardly-directed force against the vapor barrier layer, which is transmitted through the vapor barrier layer, to rod 260. Or a combination of outwardly-directed force and inwardly-directed force cooperate with each other as the rod holds the vapor barrier layer against the inner surfaces of the cavity.
Upper diverter 146 and lower closure 150 extend across the flat of the metal roof panel adjacent the upper and lower ends of roof opening 249 (
Bridging tape or the like is used to bridge between the side portions and end portions of insulation vapor barrier layer 250 at the “Y” cuts at the ends of support structure 100, such that the vapor barrier layer and tape, collectively, completely separate the interior of skylight cavity 274 from the respective elements of support structure 100 other than inside panel 244.
In
Most standing seam roofs are seamed using various clip assemblies that allow the roof panels to float/move relative to each other, along the major elevations, namely along the joinders between the respective roof panels, such joinders being defined at, for example, elevated ribs 32. By accommodating such floating of the panels relative to each other, the roof panels are free to expand and contract according to e.g. ambient temperature changes relative to any concurrent expansion or contraction of others of the roof panels.
The design of the skylight systems of the invention takes advantage of such floating features of contemporary roof structures, such that when skylight assemblies of the invention are secured to respective rib elevations as illustrated herein, the skylight assemblies, themselves, are supported/carried by the roof panels at ribs 32. Thus, the skylight assemblies, being carried by the roof panels, move with the expansion and contraction of the respective roof panels to which they are mounted.
As seen in
In the process of installing a skylight system of the invention, a short length of one of the ribs 32, to which the closure support structure is to be mounted, is cut away, forming gap 122 in the respective rib, to accommodate drainage of water around the rail and closure structure, at that end of the rail and closure structure which is relatively closer to ridge cap 120. Such gap 122 is typically used with standing seam, architectural standing seam, and snap seam roofs, and can be used with any other roof system which has elevated elongate joinders and/or ribs.
In the retained portions of rib 32, namely along the full length of the skylight as disposed along the length of the respective roof panel, the standing seams 18 provide structural support characteristics which resemble the structural characteristics of the web of an I-beam. Thus, the standing seams, in combination with the other upstanding portions of ribs 32, support side rails 142 and 144 while maintaining the conventional watertight seal at the joinders between roofing panels, along the length of the assembly. Portions of ribs 32, inside the enclosed space of skylight cavity 274, may be removed to enlarge the roof opening, which in turn allows a further increment of additional light from skylight lens 130 to reach through the respective roof opening.
Lower flange 410 of diverter 146 runs along, parallel to, and in general contact with, panel flat 14 of the respective roof panel. Fastener holes 430, illustrated in
Panel stiffener structure 148 is illustrated in
Panel stiffener 148 can also be used to provide lateral support, connecting respective ones of ribs 32 to each other. Panel stiffener 148 is typically steel or other material sufficiently rigid to provide a rigid support to the rail and closure structure at diverter 146 and to transfer the I-beam strength characteristics of the standing seam across gap 122 between the respective lengths of the standing seam.
Rail and closure structure 140 is configured such that the skylight subassembly can be fastened directly to the rails with rivets or other fasteners such as screws and the like as illustrated at 310 in
Looking now to
As illustrated, end panel 412 has a diversion surface 420. Diversion surface 420 is, without limitation, typically a flat surface, and end panel 412 defines first and second obtuse angles with lower flange 410 and with an upper web 415 of end panel 412. As indicated in
Diversion surface 420 can, in the alternative, be either concave or convex whereby the central portion of the width “W1” and/or “W2” of the diversion surface is recessed or protruding, relative to a plane axis extending across the width of the respective roof panel and along the lengths of the lines which represent the joint between the diversion surface and upper web 415, and the joint between diversion surface and the lower flange, while the top and bottom edges of the diversion surface, namely at the respective joints, are typically, though not necessarily, represented by straight lines.
Referring to
At the end of lower flange 410 which is closer to the cut rib is a rib sealing portion 450 of upper web 415, which functions as an end closure of the cut rib 32 on the lower side of gap 122. Rib sealing portion 450 further functions to divert water across gap 122, through the respective rib 32, and onto the flat 14 portion of the adjacent roof panel. Rib sealing portion 450 extends through gap 122 and across the respective otherwise-open end of the rib, thus closing off access to the otherwise-open, down-slope end of the rib. Hard rubber rib plugs 460, along with suitable tape mastic and caulk or other sealants, are inserted into the cut ends of the rib on both the upstream side and the downstream side of gap 122. The upstream-side plug, plus tube sealants, serve as the primary barrier to water entry on the upstream side of gap 122. Sealing panel portion 450 covers the rib plug 460 on the down-slope side of gap 122, and serves as the primary barrier to water entry on the downstream side of gap 122, with plug 460, in combination with the tube sealant, serving as a back-up barrier.
The cross-section profiles of plugs 460 approximate the cross-section profiles of the cavities inside the respective rib 32. Thus plugs 460, when coated with tape mastic and tube caulk, provide a water-tight closure in the upstream side of the cut rib, and a back-up water-tight closure in the downstream side of the cut rib. Accordingly, water which approaches upper diverter 146, from up-slope on the roof, is diverted by diversion surface 420 and flange 410 and secondarily by web 415, toward sealing portion 450, thence through gap 122 in the rib, away from the high end of closure support structure 100 and onto the flat portion of the next laterally adjacent roof panel. Accordingly, so long as the flow channel through gap 122 remains open, water which approaches the skylight assembly from above upper diverter 146 is directed to gap 122, and flows through gap 122, and away from, and around, the respective skylight assembly.
As illustrated in e.g.
In some embodiments, not shown, the diverter can be the mirror image of the diverter as illustrated. Thus, lateral leg 147 extends through a gap 122 on the left end of the diverter, at the left side of the support structure, as viewed from up-slope of the diverter. Correspondingly, the right end of the diverter is closed off by rib mating surface 440, which engages a rib at the right end of the diverter, at the right side of the support structure. Thus, a diverter which discharges water on a single side of the support structure, as in
Selection of the discharge side is generally not important where the respective roof panel is horizontal across a width of the roof panel perpendicular to the sides of the roof panel, thus between the corresponding ribs. However, in some instances, the roof is pitched down, typically gently down, across the width of the roof panel, whereby the upper diverter is selected such that lateral leg 147 is on the down-slope side of the width of the roof panel.
Referring to
Upper cap 500 is an elongate inverted, generally U-shaped structure. A first downwardly-extending leg 524 has a series of apertures spaced along the length of the cap. Screws 526 or other fasteners extend through leg 524 and through closure web 520, thus mounting cap 500 to bottom portion 510 of the lower closure.
Cap 500 extends, generally horizontally, from leg 524 inwardly and across the top of closure web 520, along upper flange 536 to inside panel 537. Inside panel 537 extends down from bearing panel 536 at an included angle, between upper flange 536 and inside panel 537, of about 75 degrees, to a lower edge 538 of the inside panel.
Thus, the upper cap of the lower closure, in combination with the upper region of closure web 520, defines a cavity 542 which has a cavity cross-section corresponding with the cross-sections of cavities 264 of rails 142, 144. As with cavities 264 of the side rails, foam retaining rod 260 has been compressed in order to force the rod through slot 544, capturing vapor barrier layer 250 between the retaining rod and the surfaces which define cavity 542. The vapor barrier layer has been lifted into opening 249 in the roof. Vapor barrier layer 250 traverses cavity 542 along a path similar to the path through cavities 264. Thus, vapor barrier layer 250 enters cavity 542 against the inner surface of closure web 520, extends up and over/about rod 260 in the cavity, against flange 536 and panel 537, and back out of cavity 542 to a terminal end of the vapor barrier layer outside cavity 542. The tension on vapor barrier layer 250 holds edge portion 256 of the batting against bottom portion 510 of the lower closure.
The uncompressed, rest cross-section of rod 260 in cavity 542 is somewhat greater than the cross-section of slot-shaped opening 544 between inside panel 537 and closure web 520, whereby rod 260 is compressed while being inserted through slot-shaped opening 544 and into cavity 542. After passing through opening 544, rod 260 expands against panels 520 and 537, and optionally flange 536, of the cavity while remaining sufficiently compressed to urge facing sheet 250 against panels 520 and 537 optionally against flange 536, whereby facing sheet 250 is assuredly retained in cavity 542.
In the alternative, and as with the cavities in rails 142, 144, rod 260 can comprise a less compressible material, whereupon the cavity structure such as, without limitation, inside panel 537 is specified to be relatively more resiliently deflectable. Panel 537 and/or panel 536, or panel 524, is e.g. sufficiently resiliently deflectable that slot 544 can be expanded enough to receive rod 260 with substantially no reduction in the cross-sectional area of rod 260. The properties of such panel or panels are such that such panel or panels can be temporarily deflected far enough that rod 260 can be pushed into cavity 542 by an installer, and sufficiently resilient that a so-deflected panel returns, or attempts to return, to its unstressed state with enough force and/or movement to securely hold rod 260 in place in the cavity.
Such less-compressible rod can be any material which can effectively engage and hold the vapor barrier sheet when force is applied to the surface of the rod. Non-limiting examples of such materials are various non-foamed, or slightly-foamed, relatively higher density rubber-like materials, such as EPDM rubbers, styrene butadiene rubbers, and the like. Various plastics such as PVC and various ones of the polyolefins, such as polyethylene, polypropylene, or the like, can also be used, either unfoamed or modestly foamed having densities greater than about 10 pounds per cubic foot, optionally greater than 12 pounds per cubic foot, optionally greater than 20 pounds per cubic foot, up to the unfoamed densities of the respective materials. In some instances, a wood rod/dowel is acceptable for rod 260.
In any embodiment, the installer deflects panel 537 progressively along the length of the slot-shaped opening 544 while correspondingly inserting respective progressive portions of the length of rod 260 into the cavity, or compresses the rod while correspondingly inserting progressive portions of the length of the rod into the cavity, or both compresses the rod and deflects panel 537 while inserting progressive portions of the rod into the cavity. As the installer releases a respective portion of inside panel 537 or rod 260, in the process of inserting a respective portion of the rod 260 into the cavity, the respective cavity structure or rod resiliently returns toward its rest position, which brings inside panel 537 into a holding engagement with the rod, whereby the force being exerted between rod 260 and panel 537 in attempting to return to respective former configurations applies an effective frictional holding force against vapor barrier 250.
In each instance, the compressible rod, or the resiliently deflectable inside panel 537, or both, the diameter/cross-section of the rod must be sufficiently small that the rod can be inserted through slot 544 into cavity 542, while being sufficiently large that a latent force exists between the rod and inside panel 537 after installation of the rod is complete/finished.
Thus, in the first instance, the resilient rod applies a constant outwardly-directed force against the vapor barrier layer, which is transmitted through the vapor barrier layer, to inside panel 537 and is resisted by inside panel 537. And in the second instance, the resiliency of inside panel 537, once released, applies a constant inwardly-directed force against the vapor barrier layer, which is transmitted through the vapor barrier layer, to rod 260. Or a combination of outwardly-directed forces and inwardly-directed forces cooperate with each other as the rod holds the vapor barrier layer against the inner surface of the cavity.
As with screws 300 which mount the skylight assembly to side rails 142, 144, upper diverter 146, and lower closure 150, screws 526 extend through cap 500, through closure web 520, and terminate in rod 260, whereby rod 260 insulates the inside of the roof opening from temperature differentials transmitted by screws 526, thereby to avoid the fasteners being a source of condensation inside space 274 below the skylight lens.
Upper cap 500 of the lower closure extends inwardly, toward opening 249, of closure web 520 at a common elevation with upper flanges 240 of the side rails. Collectively, the upper flanges of side rails 142, 144, lower closure 150, and upper diverter 146 form a consistent-height top surface of the rail and closure structure, which receives the skylight lens subassembly.
Closure 150 includes rib mating flanges 540 and 550, as extensions of lower flange 522, to provide tight fits along ribs 32.
A salient feature of support structures 100, relative to conventional curb-mounted skylights, is the reduction in the number of roof penetrations, namely roof openings, required to provide daylight lighting to the interior of a building, as multiple skylight assemblies can be mounted along the length of a single elongate opening in the roof, whereby fewer, though longer, openings can be made in the roof. Namely, a single opening in the roof can extend along substantially the full length of a roof panel, if desired, rather than cutting multiple smaller openings along that same length, and wherein the single opening can provide for an equal or greater quantity of ambient light being brought into the building through a smaller number of roof openings.
Another salient feature of support structures 100, relative to conventional curb-mounted skylights, is the fact that the full lengths of the entireties of the sides, namely the side rails, are above the panel flats, namely above the typical high water elevations of the respective metal roof panels.
Yet another salient feature of support structures 100, relative to conventional curb-mounted skylights, is the provision of lateral leg 147 of the upper diverter, which diverts water laterally away from the upper end of the support structure while maintaining the integrity of the rib at full height at the upper diverter, on the opposing side of the support structure.
Support structures of the invention are particularly useful for continuous runs of e.g. skylights, where individual skylights are arranged end to end between the ridge and the eave of a roof.
As only one non-limiting example, skylights can be produced in units about 10 feet long, and so connected end to end for as long a strip assembly as is desired or necessary to achieve the desired level of light transmission into the building, with each skylight unit being supported by the primary rib elevations of the panel roof. The lengths of the rib elevations extend along the entire lengths of the side rails of the rail and closure structure, whether one skylight assembly is used, or a number of skylight assemblies are used end to end. No water can enter over the tops of the side rails of the rail mounting system. No water can enter the top end or bottom end of such strip of skylights.
The standing rib elevations are shown underlying and in continuous supporting contact with the side rails, providing continuous underlying support to the rails along the entireties of the lengths of the rails, and respectively along the entireties of the lengths of the skylight assemblies.
In the process of installing the closure support structure, the upper diverter is installed first, after cutting a small portion of opening 249 near the diverter location. Then, after the upper diverter is installed, the remainder of the roof opening is cut in the respective roof panel and the rails are installed. The lower closure is then installed, which completes the process of defining the perimeter bearing surfaces for the support structure, which are to support the perimeter of the collective set of skylight assemblies which overlie opening 249. Insulation 248, as appropriate, is then drawn up through the opening and secured in the cavities in the rails, in the diverter, and in the lower closure. The skylight assemblies are then mounted on the respective bearing surfaces and the ends of the respective skylight assemblies are joined to each other; and the skylight assemblies are secured to the rails. Tube sealant and tape mastic are applied, as appropriate, at the respective stages of the process to achieve leak-free joinders between the respective elements of the closure assembly.
Skylight assemblies of the invention can be connected end to end for as long a distance as necessary to completely cover/overlie a roof opening, as each skylight assembly unit is supported by the ribs 32 of the respective roof panel through respective rails 142, 144. The full collective lengths of the respective rails, regardless of the number of skylight assemblies which are used to close off a given opening in the roof, can extend longitudinally along the standing rib elevations. And except for the skylight assemblies on either end of a run of skylights, the entirety of the weight of the skylight assembly passes through the respective rib and thence to the underlying building support structure. Minor portions of the weight of the skylight assembly may pass through the panel flat at the upper and lower ends of the rail and closure structure.
Water cannot enter over the tops of the rails because of the sealant at 330 at the rails, at diverter 146, and at closure 150. Water cannot enter at the upper diverter at the uppermost skylight assembly because of the seal properties provided by the upper diverter, by panel stiffener structure 148, and by the respective sealants, as well as because the diversion of water away from the upper end of the strip of skylights through gap 122 prevents any substantial quantity of water from standing on a panel 10 against upper diverter 146 for any extended period of time. Water cannot enter at the lower end of the strip of skylights because of the seal properties provided by the lower closure and by the sealants between the lower closure and the respective roof panel. Water cannot enter between the ends of the skylight subassemblies because of the tortuous path through the interface between ends 622 and 630 in combination with the sealants applied at such end-to-end interface.
Each diversion panel stands generally upright while, without limitation, defining a first obtuse angle with lower flange 410 and a second obtuse angle with upper web 415, whereby an imaginary extension of upper web 415 defines a generally perpendicular angle with lower flange 410. As illustrated, diversion panels 420A, 420B meet at an upright dividing line 422 in and panel 412, midway between rails 142, 144. Each diversion panel 420A, 420B thus has a relatively greater width illustrated as width “W1”, and thus generally a greater height, at a generally central location midway between rails 142, 144; and a generally decreasing width, illustrated by width “W2”, and generally lesser height, both width and height approaching nil dimensions, as the respective diversion panels approach rib gaps 122A, 122B (
In addition, panel stiffener 148A extends entirely across the widths of the panel flats of the next adjacent roof panels, extending to the uncut ribs at the opposing sides of such next adjacent panel flats. Respective portions of the lengths of the panel flats of the next adjacent roof panels thus overlie the respective lengths of panel stiffener 148A such that the panel stiffener generally interfaces with the panel flats of the next adjacent roof panels.
Legs 533 on panel stiffener 148A extend upwardly at the uncut next adjacent ribs on the next adjacent roof panels, matching the upstanding direction of at least one upwardly-extending panel of the respective rib 32. Self-drilling screws, or rivets, or other fasteners 534 extend through holes 430, through the respective facing portion of the roof panel, and into panel stiffener 148A. Panel stiffener 148A acts as a nut for the respective screws 534, whereby the screws/fasteners can firmly secure the lower flange to the roof panel. Additional screws/fasteners 534 also secure panel stiffener 148A to the next adjacent ribs 32 at upstanding legs 533. Panel stiffener 148A thus provides vertical support to upper diverter 146D adjacent opening 249, and also provides lateral support to lower flange 410 through the attachments of legs 533 to the next adjacent, uncut ribs across the panel flats from upper diverter 146D. Still further, panel stiffener 148A provides a foundation for bringing together lower flange 410, panel flat 14, and the panel stiffener in face-to-face relationships where the lower flange, the panel flat 14, and the panel stiffener are sufficiently tightly drawn to each other that a waterproof seal is provided, preventing water leakage into the enclosed space at the opening, or directly into the building, at the lower flange.
Referring now to
Rails 142, 144, upper diverter 146, 148D, and lower closure 150 are typically made of metal. Given the thermal conductivity of metals commonly used in building structures, such metal elements of support structures 100 have the potential capability to conduct cold and/or heat through the support structure elements, to the inner surfaces of the support structure. Such conduction affects the thermal space heating and/or space cooling needs of the interior of the respective building. In addition, the conduction of cold, from the outside environment to the interior of the building potentially lowers the temperature of the inside surfaces of support structure 100. Such conduction of cold may lower the temperatures of such inside surfaces enough to cause moisture from the air inside the building to condense onto such cooled inside surfaces, which can result in dripping of such condensed moisture onto building contents below. Such condensation can thus be deleterious to the building structure and/or to the contents of the building.
While the thermal insulation illustrated, such as in
Cold which passes through web 238 by conduction is stopped either by insulation batt material 252 or by leg 660 of the thermal break. Cold conducted through upper flange 240, optionally through inside panel 244, is stopped by the respective legs 662, 664, and/or 666. Cold which reaches the joinder between upper flange 240 and inside panel 244 is stopped by the upper edge of leg 666.
While thermal space heating efficiency is a consideration, the primary issue being addressed by thermal break structure 650 is to maintain the temperature of all surfaces of the controlled-temperature space at the opening sufficiently warm as to prevent condensation of moisture on the exposed surfaces of the support structure. Thus even though un-foamed plastic extrusions, as used for thermal break structures 650, are not generally considered to be effective thermal insulators, compared to fiberglass batt material or foamed plastics, the thermal properties of many polymer compositions are sufficient to block enough of the thermal conduction that condensation can be avoided.
Addressing space heating loss relative to the embodiment of
Addressing condensation prevention, the thermal protection provided by insulation 248 and rod 260 is in excess of that needed to prevent condensation while being effective to control thermal temperature-control requirements. Given the inventors' recognition that condensation is a potential issue at corner 668, by conduction of cold through upper flange 240, thermal protection against such condensation is provided by configuring thermal break 650 to cover the inside surface of inside panel 244, facing opening 249, at corner 668, and by engineering the thermal properties of thermal break 650 so as to prevent condensation at the temperature differential and humidities expected to exist in the particular skylight or other application of the invention.
The inventors contemplate that the dead air space in the serrations adds to the thermal efficiency of the thermal break. In some embodiments, the serrations are spaced from the top and bottom of inside panel 244 in recognition of stresses which may be concentrated at such locations, combined with respective strength requirements at such locations.
Considering the embodiments illustrated in
Referring to
Insulation 248 extends up through opening 249 in the roof and lies against rib 32 up to the top of the rib at standing seam 18. Vapor barrier layer 250 of the insulation extends over the top of the standing seam and down between the standing seam and upstanding web 238 of the rail. The vapor barrier layer is held in place over the standing seam by a plurality of resilient spring clips 676 mounted over the vapor barrier and onto the standing seam, respective such clips being spaced along the length of the rail. A variety of clips and/or clamps, or similar devices can be used in place of the clip illustrated.
The vapor barrier can be installed using at least two different methods. In the first method, shown in
At the lower closure, a lower leg of angle bracket 672 overlies the upper surface of the lower flange as illustrated in
As illustrated in
Returning to
The outwardly extending portion 260P of the rod extends to, and interfaces with, an upper portion of insulation 248. Thus, the combination of insulation 248 and rod 260 provides thermal break properties extending upwardly between opening 249 and the inner surface of upper flange 240. Thermal break structure 650 provides at least a portion of the thermal break properties between the inner and outer surfaces of the upper flange.
Thus, rail 144 has an upstanding web 238, upper flange 240, inside panel 244, and lower shoulder 242. Inside panel 244 extends from upper flange 240 at an optional acute angle β of about 75 degrees; although in this embodiment up to a perpendicular angle β is acceptable. Rivets 310 are spaced along the length of the rail, mounting the rail to underlying rib 32 above panel flat 14. External thermal break 650 covers inside panel 244 and upper flange 240. Short extensions of the thermal break extend down web 238 and around the distal end of inside panel 244.
Insulation 248 extends up through opening 249 in the roof and lies against rib 32 up to the top of the rib at standing seam 18, Vapor barrier layer 250 of the insulation extends over the top of the standing seam and down between the standing seam and upstanding web 238 of the rail. The vapor barrier layer is held in place over the standing seam by a plurality of resilient spring clips 676 mounted over the vapor barrier and onto the standing seam, respective such clips being spaced along the length of the rail.
A length of deformable, compressible fiberglass batt material 248C, typically having no vapor barrier layer, is inserted into cavity 264. Batt material 248C is resiliently compressible, and is compressed as the batt material is being inserted through opening 268 into cavity 264. Batt material 248C, is inserted into cavity 264 far enough that, once the compressed batt material is released in the cavity, and the batt material expands against the cavity walls, the expanded batt material reaches, and interfaces with, at least web 238 and inside panel 244, optionally with upper flange 240. With the cross-section of the batt material thus extending across the full width of the cavity between web 238 and inside panel 244, the frictional engagement of the batt material against the inner surfaces of web 238 and inside panel 244, along the tapering, narrowing cross-section of cavity 264, top to bottom, optionally in combination with engagement of the batt material with the up-turned end of thermal break 650 at the inside surface of inside panel 244, and the relatively narrow width of opening 268 between panel 244 and vapor barrier 250, retains batt material 248C in cavity 264, even though a portion 248CP of the batt material extends outwardly through cavity opening 268.
The outwardly extending portion of the batt material extends to, and interfaces with, an upper portion of insulation 248 at vapor barrier 250. Thus, the combination of insulation 248 and batt material 248C provides thermal break properties extending upwardly between opening 249 and the inner surface of upper flange 240. Thermal break structure 650 provides the thermal break properties between the inner and outer surfaces of the upper flange and inside panel 244.
The rail assembly embodiment of
With the insulation thus held in place, and typically after the upper diverter has been assembled to the respective roof panels, rail 144 is mounted to the shoulder of the respective rib, using rivets 310 as illustrated. Thermal break 650 can be installed either before or after the rail has been mounted to the rib. With the rail so mounted to the rib, and with thermal break 650 mounted to the rail, insulation batt material 248C is inserted into cavity 264 such that the batt material extends down from opening 268 to the top of vapor barrier layer 250, again as shown in
Vapor barrier 250 extends up through opening 249 in the roof and lies against rib 32 up to the top of the rib at standing seam 18. As in the embodiment of
A length of generally rigid, optionally deformable, foam board 678 is shown having been inserted into cavity 264. A typical foam board is expanded bead polystyrene foam having a density of about 2 pounds per cubic foot (pcf) to about 20 pcf, optionally about 4 pcf to about 8 pcf. Such foam is modestly resiliently compressible and generally returns to its uncompressed configuration so long as its elastic limit has not been exceeded, and so long as the foam has not been permanently damaged such as by tearing or cutting.
Foam board 678 has a notch 680 which extends along the full length of the board, where foam material has been removed in order that the board can mount over, and correspondingly receive, the combination of standing seam 18, vapor barrier 250, and resilient spring dips 676.
In the embodiment illustrated, foam board 678 generally fills cavity 264, typically being in face-to-face contact with web 238, flange 240, inner panel 244, the top and a side of spring dip 676, and vapor barrier layer 250 at the top of shoulder 16. When the foam board is inserted into cavity 264, the foam may be slightly compressed at one or more of the contact interface with the lower surface of upper flange 240, the contact interface with the upper surfaces of clips 676, the contact interface with the cavity-facing surface of inner layer 244, and the contact interface with vapor barrier layer 250 at the top of shoulder 16.
The recited minor levels of compression experienced by foam board 678 at such interfaces when the foam board is inserted into cavity 264 can create enough friction between the foam board and the other facing members to retain the foam board in cavity 264.
The compressibility, deformability of the foam board is such that the board can be deformed enough to allow the board to be manually inserted through opening 268, into cavity 264. Where the foam board has limited resilient compressibility, such as with expanded bead polystyrene foam, opening 268 is expansive as shown, extending almost the full height of web 238, whereby only a small downward length of inner panel 244 is available to retain the top of board against displacement from cavity 264. In such instance, the amount of deformation as the board is inserted into cavity 264 is relatively minimal.
Where the board is more compressible, deformable, such as tolerating a resilient compressive reduction of e.g. at least about 25 percent in any given dimension, and readily recovering from such compressive reduction in dimension, then the dimension of opening 268, between the end of flange 244 and the top of rib 32, is reduced accordingly, and is more like the opening illustrated in
Whatever the resilient compressibility of the foam board, opening 268 is sized accordingly, in order to both enable the user to insert the board as desired into cavity 264, and to retain the board in the cavity after the board has been so inserted.
Turning attention now to insulation layer 248 in
The rail assembly embodiment of
After the edge portion of the insulation batt material has thus been stuffed up into cavity 682, the vapor barrier layer is extended up through the aperture/opening, over and about the standing seam, and secured in place by clips 676. With the vapor barrier thus held in place, and typically after the upper diverter has been assembled to the respective roof panels, rail 144 is mounted to the shoulder of the respective rib, using rivets 310 as illustrated. A thermal break 650 can be installed on the rail as in e.g.
With the rail so mounted to the rib, and with thermal break 650, if any, mounted to the rail, foam insulation board 678 is inserted into cavity 264 such that the foam board extends down from opening 268 to the top of the respective shoulder 16 of the rib elevation. Thus, the combination of batt material 252 of layer 248 and foam board 678 in cavity 264 collectively provide an upwardly-extending thermal barrier from the inner surface of flange 240 to and through the bottom of the rib cut at aperture 249, interrupted only by vapor barrier layer 250 and the horizontally-extending portion of rib shoulder 16.
Inserting foam board 678 into cavity 264 may involve a modest amount of manual compression of board 678 such that the board material expands against the cavity walls whereby the expanded foam material reaches, and interfaces with enough of the surface elements of cavity 264, optionally including upper flange 240, inner flange 244, the tops of clips 676, and/or the vapor barrier layer at the top of shoulder 16, whereby certain ones of such interfaces provide frictional engagement with board 678, thereby to retain foam board 678 in the cavity, even though a portion of the foam board extends downwardly through cavity opening 268.
The downwardly extending portion of the foam board extends to, and interfaces with, the upwardly-facing surface of vapor barrier 250.
As an alternative, or supplemental, method of installing foam board 678, two-sided adhesive tape 684 can be mounted to the surface or surfaces of web 238 and/or flange 240 which face into cavity 264. After the tape has been so mounted to such cavity wall surfaces, the board is inserted into the cavity and urged against the exposed surfaces of the tape. In some instances, especially where the foam board fits closely and with some compression against the wall surfaces of cavity 264, the tape supplements the frictional engagement of the board with the wall surfaces, whereby the board is held in cavity 264 by a combination of friction and tape adhesion.
In other instances, foam board 678 is cut to more loosely fit into cavity 264 whereby, while inner panel 244 and the top of shoulder 16 assist in positioning the board in the cavity, the two-sided tape is the primary structure which assures that the board will be retained inside cavity 264.
Now addressing all of the embodiments illustrated, the weight of a load received on rails 142, 144 is transferred directly from the rails, to ribs 32 of the respective underlying roof panels, optionally along the full lengths of the support structure; and only a minor portion, such as less than 10%, if any, of that weight is borne by the panel flat, and only at the upper and lower ends of the support structure. Thus, the weight conveyed by the rails, or conveyed by the rail and closure structure, is borne by those elements of the roof panels which are most capable of bearing weight without substantial deflection of the roof panels under load, namely most, if not all, of the weight is carried by the ribs.
A wide variety of roof-mounted loads, in addition to skylights and smoke vents, is contemplated to be mounted on rails 142, 144, so long as the weight of such roof-mounted loads does not exceed the allowable load on the ribs. Where the load does not overlie an opening of substantial size in the roof, such as where a roof-mounted load is e.g. an air conditioner or electrical panel, the upper diverter and the lower closure can be omitted. Where the upper diverter and lower closure are omitted, nominally 100% of the load passes through rails 142, 144 to ribs 32, thence through the ribs defined by the roof panels, and thence to the building structural members. While the rails can extend onto an intervening panel flat, such is not the typical case. Rather, the rails are typically confined to the ribs, with the load spanning the panel flat above the ribs whereby rain water freely flows down the panel flat between the rails, optionally under the load.
The primary reason why the disclosed rail and closure structures can surround an opening without water leakage is that a great portion of the perimeter of the support structure, namely that which is defined by side rails 142, 144, is above the panel flat, namely above the normal high water line on the roof panel; and all associated roof penetrations, such as screws 310 which mount the rails to the ribs, are above the water line. With little or no standing water at the joinders between the rails and the roof panels, or at any fasteners, even if the sealant fails at a joinder, no substantial quantity of water routinely enters such failed joinder because of the heights of such joinders above the water line.
Rail and closure structures of the invention close off a roof opening from unplanned leakage of e.g. air or water through such roof opening. The rail and closure structure 140 extends about the perimeter/sides of the roof opening and extends from the roofing panel upwardly to the top opening in the rail and closure structure. A closure member, e.g. skylight subassembly, overlies the top opening in the rail and closure structure and thus closes off the top opening to complete the closure of the roof opening.
Support structure 100 thus is defined at least in part by rail and closure structure 140 about the perimeter of the roof opening, and the closure member, such as skylight assembly 130, or the like, overlies the top of the rail closure structure and thus closes off the top of the closure support structure over the roof opening.
Rail and closure structure 140 has been illustrated in detail with respect to one or more variations of the standing seam roofs illustrated in
While the figures depict a skylight, the rail structure, with or without end closures, can be used to mount a wide variety of loads on such roof, including various types of skylights, smoke vents, air conditioning, other vents, air intakes, air and other gaseous exhausts, electrical panels or switching gear, and/or other roof loads, including roof-penetrating structures, all of which can be supported on rail structures of the invention, and the rails passing the load to and through ribs 32 of the metal panel roof, thence directly or indirectly to underlying building framing members inside the controlled-environment space inside the building.
Although the invention has been described with respect to various embodiments, this invention is also capable of a wide variety of further and other embodiments within the spirit and scope of the appended claims.
Those skilled in the art will now see that certain modifications can be made to the apparatus and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims.
To the extent the following claims use means plus function language, it is not meant to include there, or in the instant specification, anything not structurally equivalent to what is shown in the embodiments disclosed in the specification.
This application claims priority under 35 U.S.C. 120, as a non-provisional patent application, to Provisional Application 61/860,122 filed Jul. 30, 2013, and also to Provisional Application 61/842,775 filed Jul. 3, 2013. This application also claims priority under 35 U.S.C. 120, as a Continuation-in-Part patent application to non-Provisional application Ser. No. 13/894,158 filed May 14, 2013, which is a Continuation application of non-Provisional application Ser. No. 13/066,487 filed Apr. 14, 2011, all of which are incorporated by reference in their entireties.
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| Child | 14316743 | US |
