Patent Grant
9027291
Various systems are known for supporting loads on roofs, and for installing skylights and/or smoke vents onto, into roofs.
Commonly used skylighting systems have translucent or transparent closure members, also known as lenses, mounted on a support structure which extends through an opening in the roof and is mounted to building support members inside the building. 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 complex structure beneath the exterior roofing panels and inside the building enclosure, in order to support a curb which extends through the roof and supports the skylight lens. Conventional skylight curbs, thus, are generally in the form of a preassembled box structure surrounding an opening which extends from the top of the box structure to the bottom of the box structure. Such box structure is mounted to building framing members inside the building enclosure, and extends through a respective opening in the roof, similar in size to the opening which extends through the box structure. The skylight assembly thus mounts inside the building enclosure, and extends through an opening in a separately mounted roof structure. Fitting skylight assemblies into such roof opening, in a separately-mounted roof structure, presents problems. All known conventional 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 daylight 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 daylight is to be received. Each skylight lens is installed over a separate such opening; and the opening for each such skylight assembly, each representing a single lens, extends across multiple elongate metal roof panels.
The opposing sides of conventional metal roof panels, to which skylight assemblies of the invention are mounted, are raised above elongate centralized panel flats which extend the lengths of the panels, whereby the sides of adjacent such roof structures are joined to each other in elongate joints, referred to herein as ribs. The opening for a conventional skylight cuts across multiple such ribs in order to provide a large enough opening to receive conventionally-available commercial-grade skylight assemblies. The 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. Conventional pliable tube construction sealants are applied about the perimeter of the roof opening, between the edges of the roof panels and the sides of the skylight assembly curb, including at the cut ribs. Typically, substantially all of such sealant is applied in the panel flats, which means that such sealant is the 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 on the joints that rely solely on tube sealant to provide seals in the wet areas, namely in the panel flats. Such leaks are common around fastener locations as the panels flex under load and cause the sealant to deform such that, in time, passages develop through the sealant, which allows for the flow of water through such passages.
Such multiple 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. Applicants have discovered that such opportunities include, without limitation,
The traditional curb constructions and methods of attachment in most cases thus require that a complicated support structure be installed below the metal roofing and 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 inside and outside the building.
In addition, conventional curb-mounted skylights tend to accumulate condensation, especially about fasteners which extend from the outside of the building to the inside of the climate-controlled building envelope.
Thus, it would be desirable to provide a skylight system which provides a desired level of daylight in a commercial and/or industrial building while substantially reducing the incidence/frequency of leaks occurring about such skylights, as well as reducing the incidence/frequency of condensate accumulation 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 the incidence/frequency of condensate accumulation in the areas of such smoke vents.
It would further be desirable to provide a support system, suitable for supporting roof loads, up to the load-bearing capacity of the metal roof while substantially controlling the tendency of the roof to leak about such support systems, as well as reducing the incidence/frequency of condensate accumulation in the areas of such closure support systems.
The invention provides a curbless construction system for installing loads, optionally skylights and/or smoke vents, or other loads, on the major rib elevations of a building's metal roof panel system such that substantially all of the load is conveyed 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 rib elements of the roof panels as an integral part of the support structure supporting such loads.
As used herein “beam strength” refers to the capability of a structural element to resist a bending force, as defined at www.wikipedia.org. Within this context, the ribs in a standing seam metal panel roof provide beam strength in resisting vertical loads imposed on the roof.
In addition, the invention further improves control of water leakage and condensation formation inside the climate-controlled building envelope by refining the design of the upper diverter to close off corners where the upper diverter meets the side rails.
In a first family of embodiments, the invention comprehends a sloping metal roof on a building, the sloping metal roof comprising a plurality of elongate metal roof panels arranged side by side, such roof panels having lengths, edges of adjacent such roof panels meeting at elevated rib structure portions thereof, whereby such roof panels thereby define elevated roof panel ribs, having lengths, panel flats being disposed between such elevated roof panel ribs, a load being mounted on such roof, the load being supported by a load support structure, the load support structure comprising first and second rails having lengths extending in a same direction as the lengths of the roof panel ribs, first and second ones of the roof panel ribs underlying, and supporting, the first and second rails, whereby substantially all of the load is conveyed through the ribs to a structural support system of such building, the load extending between the first and second rails across at least one such panel flat.
In some embodiments, a such panel flat between the first and second rails is sufficiently unobstructed proximate the load that rain water can freely flow down such panel flat between the first and second rails.
In some embodiments, end closures are disposed at upper and lower ends of the load support structure, the end closures extending between the first and second rails and closing off access to the respective roof panel between the end closures and the first and second rails.
In some embodiments, the end closures comprise an upper diverter at the up-slope end of the load support structure and a lower closure at the down-slope end of the load support structure.
In some embodiments, a lower edge of an end panel of the upper diverter defines a downwardly-directed slope extending across a width of the respective metal roof panel thereby to direct water, flowing by gravity toward the load support structure, laterally across the respective metal roof panel at the upper diverter.
In a second family of embodiments, the invention comprehends apparatus adapted to be assembled to form a support structure overlying a portion of a sloping metal roof on a building, wherein the support structure defines a wall, the roof of the building comprising a plurality of elongate metal roof panels which collectively define a plurality of upstanding ribs, and panel flats between the ribs, the wall extending up from the roof, the apparatus comprising a first elongate side rail; a second elongate side rail; and an upper diverter, the upper diverter comprising an end panel extending between the first and second side rails and facing up-slope along the roof, diverter ears extending from the end panel and being folded over the first and second side rails on a fold line which is generally perpendicular to the panel flat.
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 various figures depict the components and composition of the support structure of the invention.
FIG. 8A1 is an enlarged end view of a rail mounted on a rib, and illustrating a gap plug in the space between the upstanding web of the rail and the metal roof standing seam, under the turned-over edges of the standing seam.
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 various exterior roof loads, including structures which close off openings in metal roofs. For purposes of simplicity, “support structure” will be used interchangeably to mean various forms of structures which are mounted on ribs of raised elevation metal roof structures, which may surround an opening in the roof, including across the flat of a roof panel, and which support e.g. a closure over the opening, or a conduit which extends through the roof opening. Skylight assemblies and smoke vents are non-limiting examples of closures over such roof openings. Air handling operations such as vents, air intake, and air or other gaseous exchange 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 roof fans, and smoke vents, which are used to allow the escape of smoke through the roof during fires. In the case of exterior loads on the roof, where no substantial roof opening is necessarily involved, there can be mentioned, without limitation, such loads as air conditioners, air handlers, solar panels and other equipment related building utilities, and/or to controlling water or air temperatures inside the building. 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 structure, to as many load structures as the building roof can support, limited only by the amount of support available from the respective roof panels to which the load is attached.
The invention provides structure and installation processes, as a closure system which utilizes the beam-like strength of the standing seams, in the roof panels, as the primary support, supporting e.g. a downwardly-directed load on the roof.
One family of support structures of the invention comprehends a skylight system which does not require support from the building framing inside the climate-controlled building enclosure for the purpose of supporting the skylight installation. 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, the support structure of the invention, which supports such skylights, is overlaid onto, and mounted to, the roof panels, and exposes the support structure to the same ambient weather conditions which are experienced by the surrounding roof panels, whereby the support structure experiences approximately the same thermal expansions and contractions as are experienced by the respective roof panel or panels to which the support structure is mounted. This is accomplished through direct attachment of the support structures of the invention, which support a skylight assembly, 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 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 the roof ridge to a corresponding eave.
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, namely structure which extends above the panel flats, e.g. at seams/joints where adjoining metal roof panels are joined to each other, provides the support for the support structures. A such rail and closure support structure is secured to the conventional metal roof panels, and surrounds a roof opening formed largely in the intervening flat region of a single metal roof panel.
Skylight lens assembly 130, which is part of the closure system for closing off the opening, generally comprises a skylight lens frame 132 mounted to the closure support structure and extending about the perimeter of a given closure support structure, in combination with a 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
Lower closure 150 closes off the roof opening from the outside elements at the lower end of the e.g. skylight or strip of skylights, thus to serve as a barrier to water leakage at the lower end of the opening in the roof.
Referring now to FIGS. 8A and 8A1, a cross section through rib 32, and associated support structures 100 shows securement of support structures 100 to standing rib portions of the standing seam panel roof 110.
As illustrated in FIGS. 8A and 8A1, in each rib joint, the edges of the two roof panels are folded together, one over the other, leaving a space 239 between the bottom edges of the folded over panel edges and the underlying top flat surface 241 of the rib. Where the space 239 faces web 238 of the rail, as at the right side of
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 FIG. 8A1, which loosely fills space 239. The remainder of the space 239, about plug 243, namely between plug 243 and upstanding web 238, and between plug 243 and the standing seam, is filled with e.g. a pliable construction sealant 245. Such sealant is shown in FIG. 8A1 as white space about plug 243. Plug 243 thus provides a solid fill piece at spaces 239 where there is some risk of water entry into the roof opening, and where the space 239 is too large for assurance that a more pliable sealant can prevent such water entry.
A 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. Bearing panel 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 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 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 460 can be used to fill larger openings at the rails and ribs.
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 necessarily 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 panels 238, 240, 244 of the cavity while remaining sufficiently compressed to urge facing sheet 250 against web 238 and panels 240 and 244 of the cavity whereby facing sheet 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.
Upper diverter 146 and lower closure 150, discussed in more detail hereinafter, extend across the flat of the metal roof panel adjacent the upper and lower ends of roof opening 249 to complete the closure of support structure 100 about the perimeter of the skylight opening. The upper diverter and the lower closure have rail upper support structures 237 having cross-sections corresponding to the cross-sections of upper support structures 237 of rails 142. 144. Those upper support structures thus have corresponding flange cavities which are used to capture facing sheet 250 at the upper diverter and lower closure. Thus, the facing sheet is trapped in a cavity at the upper reaches of the rail and closure structure about the entire perimeter of the rail and closure structure. Bridging tape or the like is used to bridge between the side portions and end portions of insulation facing sheet 250 at the “Y” cuts at the ends of support structure 100, such that the facing sheet completely separates 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 joints between the respective roof panels, such joints being defined at, for example, elevated ribs 32. By accommodating such floating of the panels relative to each other, each roof panel is free to expand and contract according to e.g. ambient temperature changes irrespective of any concurrent expansion or contraction of the next-adjacent roof panels. Typically, a roof panel is fixed at the eave and allowed to expand and contract relative to a ridge. In some roofs, the panels are fixed at midspan, whereby the panels expand and contract relative to both the eave and ridge.
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 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 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 joints and/or ribs.
The retained portions of rib 32, namely along the full length of the skylight as disposed along the length of the respective roof panel, provide beam-type structural support, supporting side rails 142 and 144 and maintaining the conventional watertight seal at the joints between roofing panels, along the length of the assembly. Portions of ribs 32, inside cavity 274, may be removed to allow additional light from skylight lens 130 to reach through the respective roof opening.
As part of the installation of upper diverter 146, a stiffening plate structure 148, illustrated in
Stiffening plate 148 can also be used to provide lateral support, connecting adjacent ribs 32 to each other. Stiffening plate 148 is typically steel or other material sufficient to provide a rigid support to the skylight rail and closure structure at diverter 146.
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
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 are spaced along the length of lower flange 410 and extend through lower flange 410 for securing the lower flange to stiffening plate structure 148 in the panel flat, with the roof panel trapped between the lower flange and the stiffening plate structure. As illustrated, end panel 412 has a diversion surface 420. Diversion surface 420 is, without limitation, typically a flat surface defining first and second obtuse angles with lower flange 410 and with an upper web 415 of end panel 412. As indicated in
At the end of lower flange 410, which is closer to the closed rib, is a rib mating surface 440. 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 rib 32 on the lower side of gap 122, and further functions to divert water across the respective rib 32 and onto the flat 14 portion of the roof panel. Rib sealing portion 450 extends through gap 122 and across the respective otherwise-open 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 serves as the primary barrier to water entry on the downstream side of gap 122, with plug 460, in combination with 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 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, and flows through, gap 122 and away from, around, the respective skylight assembly.
Referring to
Upper rail 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 rail, and screws 526 or other fasteners which extend through leg 524 and through closure web 520, thus mounting rail 500 to bottom portion 510.
Rail 500 extends, generally horizontally, from leg 524 inwardly and across the top of closure web 520, along bearing panel 536 to inside panel 537. Inside panel 537 extends down from bearing panel 536 at an included angle, between panels 536 and 537, of about 75 degrees to a lower edge 538.
Thus, the upper rail 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 facing sheet 250 between the retaining rod and the surfaces which define cavity 542. The facing sheet has been raised. Facing sheet 250 traverses cavity 542 along a path similar to the path through cavities 264. Thus, facing sheet 250 enters cavity 542 against the inner surface of closure web 520, extends up and over/about rod 260 in the cavity, against panels 536 and 537, and back out of cavity 542 to a terminal end of the facing sheet outside cavity 542. The tension on facing sheet 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 necessarily compressed while being inserted through slot 544 and into cavity 542. After passing through opening 544, rod 260 expands against panels 524, 536, and 537 of the cavity while remaining sufficiently compressed to urge facing sheet 250 against panels 524, 536, and 537 whereby facing sheet 250 is assuredly retained in cavity 542.
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 rail 500, through closure web 520, and into 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 rail 500 of the lower closure extends inwardly, toward opening 249, of closure web 520 at a common elevation with bearing panels 240 of the side rails. Collectively, the bearing panels 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 e.g. 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 lines 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 skylight installation 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.
A male mating strip 630 extends across opening 249 at the upper ends of a second pair of rails 142, 144, between a rail 142B and the corresponding rail 144, on the other side of the opening in a constant cross-section illustrated in dashed outline in
Female mating strip 622 has a generally horizontally oriented elongate receptacle/slot under the trailing edge of bearing panel 240F. Male mating strip 630 has a generally horizontally oriented elongate protuberance stepped down from bearing panel 240M and extending from the leading edge of bearing panel 240M. A protuberance on the male mating strip is received in the female receptacle, thus to make the joint across opening 249 for receiving the end members of the frame 132 of the relatively upstream and relatively downstream, skylight assemblies in the respective skylight strip assembly. A bead of tube sealant is laid in the female receptacle before the protuberance is mated with the receptacle. Additional tube sealant is applied along the tops of mating strips 622 and 630 where bearing panels 240F and 240M meet.
A thin strip of thermally insulating foam 636 can be applied to the bottom surfaces of mating strips 622 and 630, bridging the joint and secured temporarily to the tops of bearing panels 240F, 240M. Placement of first and second skylight assembly frames 132 on the respective bearing panels 240F, 240M then secures the ends of the foam on the tops of the mating strips.
Mating strips 622 and 630 have been shown with the female slot/receptacle and the male protuberance in horizontal orientations. Similar mating strips can as well be designed wherein the male protuberance extends upwardly from bearing panel 240M; and the female receptacle is defined by a wall which extends upwardly from bearing panel 240F to a top, and then downwardly in defining a downwardly-opening elongate slot. Once again, the female mating strip is typically on the relatively upstream side of the joint and the male mating strip is on the relatively downstream side of the joint.
In the process of installing the closure support structure, the upper diverter is installed first, after cutting a small portion of the opening near the diverter. Then the remainder of the roof opening is cut in the respective roof panel and the rails are installed. The lower closure and mating strips are then installed, which defines the perimeter bearing surfaces for each skylight assembly. The skylight assemblies are then mounted on their perimeter bearing surfaces and secured to the rails. Tube sealant and tape mastic are applied, as appropriate, at the respective stages of the process to achieve leak-free joints between the respective elements of the closure assembly.
The rails, with or without the upper diverter or the lower closure, depending on the presence, or not, of an opening in the roof, can be installed on major rib elevations for any of the aforementioned roof panel profiles relative to the included flat portion of the respective roofing panel, so long as the rib structure can adequately support the contemplated load.
Skylight assemblies of the invention can be connected end to end for as long a distance as necessary to cover 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.
Water cannot enter over the tops of the rails because of the sealant at 330. Water cannot enter at the upper diverter at, the uppermost skylight assembly because of the seal properties provided by the upper diverter, by bearing plate 148, and by the respective sealants, as well as because of the diversion of water away from the upper end of the strip of skylights through gap 122 which 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 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 receptacle slot 632 in combination with the sealants applied at the end-to-end joint.
As indicated above, the weight of a load transferred by rails 142, 144 is transferred directly 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 high end and at the lower end of the support structure. Thus, the weight of the rails, or of the rail and closure assembly, is borne by the strongest elements of the roof panels, namely the ribs.
A wide variety of roof-mounted loads 650, in addition to skylights and smoke vents, are 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. As illustrated in
Further, where the upper diverter and lower closure are omitted, the rails can extend intermittently along the lengths of ribs 32, or shorter lengths of rails 142, 144, such as about 6 inches to about 12 inches length of such rails, can underlie only the left and right sides of upper and lower ends of the load.
The primary reason why the disclosed rail and closure structures do not leak is that a great portion of the perimeter of the closure, 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 joints between the rails and the roof panels, even if the sealant fails at a joint, no substantial quantity of water routinely enters such failed joint because of the heights of such joints above the water line.
As a general statement, rail and closure structures of the invention close off the roof opening from unplanned leakage of e.g. air or water through the 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. The lens 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 skylight lens subassembly 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.
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 is a Continuation application which claims priority under 23 U.S.C. §120 to application Ser. No. 13/066,487, filed Apr. 14, 2011, which claims priority as a Continuation-In-Part application under 23 U.S.C. §120 to application Ser. No. 13/065,172, filed Mar. 14, 2011.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3521414 | Malissa | Jul 1970 | A |
| 3791088 | Sandow et al. | Feb 1974 | A |
| 3828494 | Uhrhane et al. | Aug 1974 | A |
| 3967423 | Hammond | Jul 1976 | A |
| 4117638 | Kidd, Jr. et al. | Oct 1978 | A |
| 4123883 | Barber, Jr. et al. | Nov 1978 | A |
| 4155206 | Player | May 1979 | A |
| D259812 | Smith | Jul 1981 | S |
| 4296581 | Heckelsberg | Oct 1981 | A |
| 4470230 | Weisner | Sep 1984 | A |
| 4520604 | Halsey et al. | Jun 1985 | A |
| 4543753 | Sonneborn et al. | Oct 1985 | A |
| 4559753 | Brueske | Dec 1985 | A |
| 4621466 | Sonneborn et al. | Nov 1986 | A |
| 4649680 | Weisner et al. | Mar 1987 | A |
| 4703596 | Sandow | Nov 1987 | A |
| 4730426 | Weisner et al. | Mar 1988 | A |
| 4776141 | Powell | Oct 1988 | A |
| 4825608 | Makin | May 1989 | A |
| 4848051 | Weisner et al. | Jul 1989 | A |
| 4860511 | Weisner et al. | Aug 1989 | A |
| 4941300 | Lyons, Jr. | Jul 1990 | A |
| 4986039 | Weisner | Jan 1991 | A |
| 5018333 | Bruhm | May 1991 | A |
| 5027576 | Gustavsson | Jul 1991 | A |
| 5323576 | Gumpert et al. | Jun 1994 | A |
| 5511354 | Eidson | Apr 1996 | A |
| 5522189 | Mortensen et al. | Jun 1996 | A |
| 5553425 | Sampson et al. | Sep 1996 | A |
| 5561953 | Rotter | Oct 1996 | A |
| 5896711 | McClure | Apr 1999 | A |
| 5960596 | Lyons, Sr. | Oct 1999 | A |
| 6079167 | Voegele, Jr. | Jun 2000 | A |
| 6151838 | Husein | Nov 2000 | A |
| 6640508 | Lindgren et al. | Nov 2003 | B2 |
| 6966157 | Sandow | Nov 2005 | B1 |
| 7043882 | Gumpert et al. | May 2006 | B2 |
| 7296388 | Valentz et al. | Nov 2007 | B2 |
| 7308777 | Sandow | Dec 2007 | B2 |
| 7395636 | Blomberg | Jul 2008 | B2 |
| 7712279 | McClure | May 2010 | B2 |
| 7721493 | Skov et al. | May 2010 | B2 |
| 7736014 | Blomberg | Jun 2010 | B2 |
| 8438798 | McLain et al. | May 2013 | B2 |
| 8438799 | McLain et al. | May 2013 | B2 |
| 8438800 | McLain et al. | May 2013 | B2 |
| 8438801 | McLain et al. | May 2013 | B2 |
| 20040049996 | Blomberg | Mar 2004 | A1 |
| 20050204674 | Marshall | Sep 2005 | A1 |
| 20060191230 | Gumpert | Aug 2006 | A1 |
| 20070094984 | McClure | May 2007 | A1 |
| 20070101665 | Sandow | May 2007 | A1 |
| 20080040993 | Valentz et al. | Feb 2008 | A1 |
| 20080190050 | McClure | Aug 2008 | A1 |
| 20100162643 | Blomberg et al. | Jul 2010 | A1 |
| 20110252726 | McLain et al. | Oct 2011 | A1 |
| 20110252727 | McLain et al. | Oct 2011 | A1 |
| 20120233941 | McLain et al. | Sep 2012 | A1 |
| 20120233942 | McLain et al. | Sep 2012 | A1 |
| 20130167459 | Pendley et al. | Jul 2013 | A1 |
| 20130239500 | Pendley et al. | Sep 2013 | A1 |
| Number | Date | Country |
|---|---|---|
| 981948 | Feb 1965 | GB |
| 2000336859 | May 2000 | JP |
| 2001214577 | Aug 2001 | JP |
| 2008202372 | Sep 2008 | JP |
| 2010040006 | Apr 2010 | WO |
| Entry |
|---|
| FAA Facility, photos of skylight installation, 3 pages, Sacramento, CA, prior to 2007. |
| Cross-section and pictorial views of SSR-TUF-LITE daylighting panels, 1 sheet. |
| Cross-section of VP TUF-LITE PANEL—attached to the side of SSR rib, 1 sheet. |
| Cross-section of BUTLER LITE PANEL—attached to the side of MR24 rib, 1 sheet. |
| Siemens Building, photos of skylight installation, 6 pages, prior to 2007. |
| R & S Manufacturing and Sales Company, Inc., Standing Seam 24 Light, Quick Installation Instructions, Under/Over Seam Clip, 12 pages, Newbury Park, CA, date unknown. |
| R & S Manufacturing and Sales Company, Inc., SS 24 Light, The First Truely Thermally Broken Metal Building Skylight, informational sheet, 1 page, Newbury Park, CA, date unknown. |
| R & S Manufacturing and Sales Company, Inc., Enlarged sketch of metal roof showing the down slope, 1 page, Newbury Park, CA, date unknown. |
| Daljcon, LLC., Butler Manufacturing, www.daljcon.com, Example of 6 Layer Standing Seam, printed Dec. 11, 2012. |
| Number | Date | Country | |
|---|---|---|---|
| 20130239500 A1 | Sep 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13066487 | Apr 2011 | US |
| Child | 13894158 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13065172 | Mar 2011 | US |
| Child | 13066487 | US |
