A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
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The present invention relates generally to roof curb systems and methods. More particularly, this invention pertains to systems and methods for securing multiple roof accessories to roofs with roof curbs.
Prior art curb mounted roof accessories (e.g., skylights and smoke vents) are attached to roofs in singular fashion on individual roof curbs because attachment to one another violates the fastening requirements specified by most unit manufacturers. For architects that seek linear arrangements of multiple units to achieve a strip of natural daylight into a space or a reduction in the quantity of roof penetrations, attachment of the roof accessories or units to roof curbs is compromised because fastening clearances are eliminated by the abutment of unit frames. The existing plate and baton method of attachment is cumbersome as meticulous welding often warps thin metal frames of the roof accessories at critical water-tight points compromising the durability and weather-tightness of the units as designed by the manufacturer. Therefore, such installations are prone to leaking and must be thoroughly sealed with mastic or caulk, which degrades relatively quickly.
Aspects of the invention provide linking devices for roof accessories (e.g., skylights and smoke vents) installed on roofs with roof curb systems. They may be largely metallic and are designed to provide a weather tight seal between a pair of roof accessories while negating uplift imposed by external forces (e.g., high winds) on roof curb mounted skylights and/or smoke vents arranged in multiple, connected unit configurations. The accessories are linearly linked through a unique gutter assembly that is attached to a pair of roof curbs and includes a clamping member (e.g., uplift channel or cap) to provide uniform clamping that withstands uplift pressures. No modifications are needed to unit frames (i.e., accessory frames) and the ability of traditional roof curb mounted skylights and/or smoke vents to resist uplift is restored.
In one aspect, a gutter channel assembly for mounting roof accessories to a roof having a pair of longitudinally extending roof curbs includes a gutter and and uplift channel. The gutter is configured to extend laterally between the pair of roof curbs of the roof and to receive a longitudinal end of each roof accessory of a pair of roof accessories when the gutter channel assembly is installed on the roof. The uplift channel is configured to secure to the gutter and extend at least partially over the longitudinal ends of the pair of roof accessories received in the gutter when the gutter channel assembly is installed on the roof.
In another aspect, a method of installing a gutter channel assembly on a roof having a pair of longitudinally extending roof curbs include securing opposing lateral ends of the gutter of the gutter channel assembly to the pair of roof curbs. Longitudinal ends of a pair of roof accessories are placed between a pair of opposing sides of the gutter. A hole through an uplift channel is then placed over a threaded rod extending upwardly from the gutter such that longitudinal ends of the uplift channel extend at least partially over the longitudinal ends of the roof accessories received in the gutter. A nut of the gutter channel assembly is screwed onto the threaded rod to secure the uplift channel to the gutter channel and the roof accessories within the gutter.
Reference will now be made in detail to optional embodiments of the invention, examples of which are illustrated in accompanying drawings. Whenever possible, the same reference numbers are used in the drawing and in the description referring to the same or like parts.
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
To facilitate the understanding of the embodiments described herein, a number of terms are defined below. The terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but rather include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as set forth in the claims.
As described herein, an upright position is considered to be the position of apparatus components while in proper operation or in a natural resting position as described herein. Vertical, horizontal, above, below, side, top, bottom and other orientation terms are described with respect to this upright position during operation unless otherwise specified. The upright position of the gutter channel assembly and roof accessories is determined when the system is installed on a generally horizontal pair of roof curbs to hold down adjacent skylights or smoke vents as shown in
The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may. Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without operator input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.
Skylight: a translucent panel that is mounted to the roof of a building for allowing daylight into the building and/or night sky viewing.
Smoke Vent: a vent that is mounted to the roof of a building and designed to open in response to an excessive heat trigger for the purpose of smoke evacuation in the event of a fire in the building.
Roof Curb: a raised weather-tight roof top mounting apparatus for the purpose of liaising roof mounted equipment through an opening in the roof.
Gutter: a low area with walls forming a trough that is used to direct water.
Uplift: an upward force exerted on an object that has the potential to raise it relative to its surroundings.
Referring now to
In one embodiment, a gutter channel assembly 100 is used for mounting roof accessories 202 roof having a pair of longitudinally extending roof curbs 300. The gutter channel assembly 100 includes a gutter 102 and an uplift channel 104.
The gutter 102 is configured to extend laterally between the pair of roof curbs 300 of the roof and to receive a longitudinal end 202 of each roof accessory 200 of a pair of roof accessories when the gutter channel assembly 100 is installed on the roof. In one embodiment, the gutter channel assembly 100 further includes at least one threaded rod 106 extending upwardly from the gutter 102 when the gutter 102 is installed on the roof. In one embodiment, the gutter 102 includes an inner wall 402 (see
In one embodiment, the inner wall 402 of the gutter 102 includes a bottom 420, a first side 422, a second side 424, a first rail 423, and a second rail 425. The bottom 420 extends laterally and generally horizontal between the roof curbs 300 when the gutter channel assembly 100 is installed on a generally horizontal roof. The first side 422 extends generally upward from a first longitudinal edge 430 of the bottom 420 when the gutter channel assembly 100 is installed on the roof. The first rail 423 extends longitudinally outward and generally horizontally from a top edge 431 of the first side 422 when the gutter channel assembly 100 is installed on the roof. An outward edge 432 of the first rail 423 forms a first longitudinal end 404 of the gutter 102. The second side 424 extends generally upward from a second longitudinal edge 440 of the bottom 420 opposite the first longitudinal edge 430 of the bottom 420 when the gutter channel is simply 100 is installed on the roof. The second rail 425 extends longitudinally outward and generally horizontally from a top edge 441 of the second side 424 when the gutter channel assembly 100 is installed on the roof. An outward edge 442 of the second rail 425 forms a second longitudinal end 484 of the gutter 102 opposite the first longitudinal end 404 of the gutter 102. In one embodiment, the gutter 102 further includes the first longitudinal end 404 extending downward from the outer longitudinal edge 432 of the first rail 423 when the gutter channel assembly 100 is installed on the roof in one embodiment, the gutter 102 further includes the second longitudinal end 484 extending downward from the outer longitudinal edge 442 of the second rail 425 when the gutter channel simply 100 is installed on the roof. In one embodiment, the bottom 420, first side 422, first rail 423, first longitudinal end 404, second side 424, second longitudinal end 484, and second rail 425 are all integrally formed such as by stamping and folding sheet-metal. In one embodiment, the distance between the first side 422 of the inner wall 402 of the gutter 102 and the second side 424 of the inner wall 402 of the gutter 102 and a longitudinal depth of the first rail 423 and second rail 425 are selected to allow the gutter 102 to receive the rim 202 of the first roof accessory 200 and the rim 202 of the second roof accessory 200 such that the uplift channel 104 secures the rim 202 of the first accessory 200 and the rim 202 of the second accessory 200 into the gutter 102 when the gutter channel assembly 100 is installed on the roof.
In one embodiment, the outer wall 502 of the gutter 102 includes a bottom 520, a first side 524, and a second side 526. The bottom 520 extends laterally and generally horizontal when the gutter channel assembly is installed on a generally horizontal roof. The first side 524 extends generally upward from a first longitudinal edge 525 of the bottom 520 when the gutter channel assembly 100 is installed on the roof. The first side 524 of the inner wall 502 is attached to the first longitudinal end 404 of the inner wall 402 when the gutter channel assembly 100 is installed on the roof. The second side 526 extends generally upward from a second longitudinal edge 527 of the bottom 520 when the gutter channel simply 100 is installed on the roof. The second side 526 of the inner wall 502 is attached to the second longitudinal end 484 of the inner wall 402 when the gutter channel assembly 100 is installed on the roof. In one embodiment, the first side 524 is attached to the first longitudinal end 404 and the second side 526 is attached to the second longitudinal end 484 via spot welding or riveting.
In one embodiment, the gutter 102 further includes a first lateral end wall 410 and a second lateral end wall 411. The first lateral end wall 410 is attached to a first lateral end of the bottom 420, first side 422, second side 424, first rail 423, and second rail 425. The first lateral end wall 410 extends down at least as far as the bottom 420 when the gutter 102 is in a horizontal and upright position (i.e., installed on the roof). The second lateral end wall 411 is attached to a second lateral end opposite the first lateral end of the bottom 420 first side 422, second side 424, first rail 423, and second rail 425. The second lateral end wall 411 extends down at least as far as the bottom 420 when the gutter 102 is installed on the roof. The first lateral in wall 410 and second lateral end wall 411 are configured to contact the roof curbs 300 when installed on the roof and allow the gutter 1 or 2 to secure to the roof curbs 300 via fasteners or adhesives. The gutter 102 is configured to channel water laterally over the roof curbs 300 and first lateral end wall 410 and second lateral end wall 411 when the gutter 102 is installed on the roof.
In one embodiment, the gutter channel assembly 100 further includes a section of C channel 702 having a plurality of holes there through. The gutter channel assembly 100 further includes a plurality of threaded rods 106 each rod of the plurality of threaded rods 106 extending upwardly through the whole of the plurality of holes in the C channel 702 when the gutter channel assembly 100 is installed on the roof. An open side of the C channel 702 is secured to the gutter 102 when the gutter assembly 100 is installed on the roof. In one embodiment, the open end of the C channel 72 is welded to the bottom 420 of the inner wall 402 of the gutter 102. In one embodiment, the gutter channel assembly 100 further includes a plurality of nuts 704, each nut threaded onto a rod 106 of the plurality of threaded rods down to the sea channel 702 when the gutter channel simply 100 is installed on the roof. In one embodiment, the gutter channel assembly 100 further includes at least one nut 110 configured to engage the threaded rod 106 when the gutter channel assembly 100 is installed on the roof such that the nut 110 secures the uplift channel 104 to the gutter 102 and retains the longitudinal ends 202 of each of the roof accessories 200 received in the gutter 102 in the gutter 102.
The uplift channel 104 is configured to secure to the gutter 102 and extend at least partially over the longitudinal ends 202 of the roof accessories 200 received in the gutter 102 when the gutter channel assembly 100 is installed on the roof. In one embodiment, the uplift channel 104 has a whole 108 there through configured to receive the threaded rod 106 of the gutter 102 when the gutter channel assembly 100 is installed on the roof. In one embodiment, the uplift channel 104 is flat, and in another embodiment, the uplift channel is recessed along a lateral centerline of the uplift channel 104.
In the embodiment of
In one embodiment, the gutter uplift channel assembly 100 includes roof curb gutter 102 and uplift channel 104 which attach to one another with an offset to accommodate specific skylight and/or smoke vent frame dimensions which may vary among unit manufacturers. The roof curb gutter 102 and uplift channel 104 may be made of metal, vinyl, or some other material such as a polymer. The roof curb gutter 102 is attached to roof curbs 300 and extends laterally between the roof curbs 300. The skylights and/or smoke vents 200 being placed adjacent one another in a row or column are set onto the roof curb gutter 102 such that any water shed from the end 202 of the skylight and/or smoke vent 200 is directed into the gutter 102 and laterally outward past the roof curbs 300 that the roof curb gutter 102 extends between. The uplift channel 104 applies downward force to the frames (of the adjacent skylights and/or smoke vents) to maintain the ends 202 of the adjacent skylights and/or smoke vents 200 in the roof curb gutter 102 and resist uplift in high wind situations. In one embodiment, at least one (e.g., a pair of) threaded rods 106 extend upwardly from the gutter 102, and through corresponding hole(s) 108 in the uplift channel 104. A nut 110 (e.g., wing nut) secures the uplift channel 104 to the threaded rods 106 (e.g., bolts) and thus to the roof curb gutter 102.
In one embodiment, the uplift channel 104 is a formed hat channel shape specifically designed with clearances to allow consistent alignment with the skylight and/or smoke vent frames 202 to the roof curb 300 through the applied downward force when fastened to the roof curb gutter 102 via the one or more threaded rods (e.g., bolts) 106. The recessed center section of the uplift channel 104 with pre-punched holes 108 coordinating with the gutter 102 through bolts 106 is dimensioned to provide the applicable strength for uniform pressures to be applied via the through bolt attachment depicted within
In one embodiment, the roof curb gutter 102 portion of the assembly 100 is designed to nest and attach via the pre-punched holes to the modified roof curb wall 300 that adjoins the skylights and/or smoke vents 200. The roof curb gutter 102 seals appropriately to the roof curb 300 and roofing material (e.g., sidewalls) dependent on the construction roofing type with applicable construction sealants, and fastens via structural screws, rivets, or welds with its longitudinal positioning based on the skylight and/or smoke vent 200 unit length to provide the bearing point for the adjacent unit (i.e., roof accessory) frames.
In one embodiment, the through bolt 106 attachment is integrated to the roof curb gutter 102. A threaded bolt 106 is fastened to a top of the gutter 102 bottom 420 trough via mechanical attachment to provide adequate support to resist uplift forces. The gutter 102 is not limited solely to this curb wall application, installation procedure, or attachment method.
Referring to
This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
It will be understood that the particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention may be employed in various embodiments without departing from the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
All of the compositions and/or methods disclosed and claimed herein may be made and/or executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of the embodiments included herein, it will be apparent to those of ordinary skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims.
Thus, although there have been described particular embodiments of the present invention of a new and useful SKYLIGHT AND SMOKE VENT GUTTER UPLIFT CHANNEL ASSEMBLY it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
This application claims priority to and is a non-provisional application of U.S. Provisional Patent Application No. 62/896,536 entitled “SKYLIGHT AND SMOKE VENT GUTTER UPLIFT CHANNEL ASSEMBLY” filed on Sep. 5, 2019.
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