Patent Grant
9534390
Various systems are known for supporting loads on roofs, and for installing skylights and/or smoke vents 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 aperture in the roof and is mounted to building support members inside the building. Ambient daylight passes through the lens and thence through the roof aperture 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 aperture 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 aperture in the roof, similar in size to the aperture which extends through the box structure while accounting for the thickness of the elements of the box structure. The skylight assembly thus mounts inside the building enclosure, and extends through an aperture in a separately mounted roof structure. Fitting skylight assemblies into such roof aperture, in a separately-mounted roof structure, presents problems in that 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.
To achieve desired levels of daylighting, conventional skylight installations use multiple roof apertures 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 aperture; and the aperture 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 elevated above elongate centralized panel flats which extend the lengths of the panels, whereby the sides of adjacent such roof panels are joined to each other to form elongate elevated joints, referred to herein as elevated ribs. The aperture for a conventional skylight cuts across multiple such elevated ribs in order to provide a large enough aperture 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 aperture and about the perimeter of the aperture, thus to support the skylight lens above the flats of the roof panels, as well as above the elevated ribs. Conventional pliable tube construction sealants are applied about the perimeter of the roof aperture, 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 are 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 mastic 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, thus developing the above-mentioned leaks.
Such multiple curbs, each extending through a separate roof aperture, 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 are influenced by, 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, and supported by the building structural support system 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 and the building structural support system 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 or other roof penetration while substantially reducing the incidence/frequency of leaks occurring about such smoke vents or other roof penetrations, as well as reducing the incidence/frequency of condensate accumulation in the areas of such roof penetrations.
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 roof load supports such as roof closure structures, optionally skylights and/or smoke vents, optionally including two or more such cover structures in end-to-end relationship, onto the major rib elevations of a building's metal roof panel system, thereby utilizing the beam strength of the roof rib elevations on the surface of the roof, as the support for such loads. Where skylight assemblies are placed in end-to-end relationship over a common roof aperture, the upper diverter and lower closure at the facing ends of such skylight assemblies are optionally replaced with male and female mating strips. Numerous roof structures include such ribs and rib elevations, sometimes deemed “ribs” or “corrugations”, including the standing seam and exposed fastener roof types. The roof support and/or closure structures of the invention are fastened to the rib structures of the metal roof panels above the water line. By mounting the loads above the water line, the number of incidents of water leaks, especially leaks about the mounting structure, is greatly reduced. By mounting the loads on the roof panels, themselves, the supported loads, such as skylights or vents, can move with the respective roof panels as the roof panels expand and contract in accordance with temperature changes in the ambient environment outside the building.
The invention thus utilizes the beam strength of the rib elements of the roof panels as an integral part of the closure support structure.
In addition, the invention further improves control of water leakage and condensation formation inside the climate-controlled building envelope. Water leakage is reduced by suitably designing the upper diverter and the lower closure, and by providing a male/female intermediate joint where skylight assemblies meet end to end intermediate the length of the roof aperture. Condensation is reduced by providing insulation about the inner side of the support structure, thus to cover the sides of the load support structure which face the space surrounded by the load support structure above the aperture, optionally providing a no-fastener securement of the insulation at an upper location in the closure support structure, and providing thermally insulating materials as barriers to penetrating portions of fasteners, penetrating from outside the climate controlled building envelope, preventing such fasteners from entering the climate-controlled building envelope.
In a first family of embodiments, the invention comprehends a side rail for supporting one of opposing sides of a skylight or other cover over a roof penetration, the side rail having first and second opposing sides, and a length, and comprising an upstanding elongate web having a top and a bottom; and an upstanding elongate cavity wall laterally displaced from, and extending alongside, said upstanding web. A relatively upper portion of the cavity wall is connected to an intermediate portion of the upstanding web between the top and the bottom of the upstanding web. The combination of the upstanding cavity wall and the upstanding web defines a cavity between the upstanding web and the upstanding cavity wall, the cavity having a top and a bottom, and an elongate opening along the bottom of the cavity and proximate the bottom of the upstanding web.
In some embodiments, the side rail further comprises a lower shoulder extending laterally away from one of the upstanding elongate web and the upstanding elongate cavity wall proximate the bottom of the cavity.
In some embodiments, the lower shoulder comprises a first shoulder panel extending at an angle generally perpendicular to one of the upstanding web and the upstanding cavity wall.
In some embodiments, the side rail further comprises a second shoulder panel extending down from the first shoulder panel.
In some embodiments, the side rail further comprises a first lower shoulder extending laterally away from the upstanding web proximate the bottom of the cavity and away from the cavity, and a second lower shoulder extending laterally away from the upstanding wall proximate the bottom of the cavity, and away from the cavity, and away from the first lower shoulder.
In some embodiments, one of the first and second lower shoulders comprises a first shoulder panel extending laterally away from the cavity and a second shoulder panel extending down from the first shoulder panel.
In some embodiments, the other of the first and second lower shoulders comprises a third shoulder panel extending laterally away from the cavity and away from the first one of the first and second lower shoulders, and a fourth shoulder panel extending down from the third shoulder panel.
In some embodiments, the side rail further comprises a thickness reinforcement at a joinder of the upstanding web and the upstanding cavity wall.
In some embodiments, the side rail is an extruded metal side rail.
In some embodiments, the upstanding web and the first lower shoulder are defined in a first piece part and the upstanding wall and the second shoulder are defined in a second different piece part, and the first and second piece parts are joined to each other at an elevation at or above the top of the cavity.
In some embodiments, the side rail further comprises an upper flange extending laterally away from the upstanding web.
In some embodiments, the invention comprehends a load support structure on a sloping metal roof of a building, such roof of such building comprising a plurality of elongate metal roof panels which collectively define a plurality of elongate upstanding ribs extending between a ridge and an eave of the building, the ribs defining upstanding seams which have folded over terminal edges of the respective adjacent roof panels, the load support structure comprising first and second side rail structures comprising at least first and second ones of the side rails mounted on first and second ones of the upstanding ribs, the first and second side rail structures each having an up-slope end and a down-slope end, an upper diverter extending between the up-slope ends of the first and second side rail structures, and a lower closure extending between the down-slope ends of the first and second side rail structures.
In some embodiments, the invention comprehends a sloping metal roof of a building, the roof comprising a plurality of elongate metal roof panels which collectively define a plurality of elongate upstanding ribs extending between a ridge and an eave of the building, the ribs defining upstanding seams which have folded over terminal edges of the respective adjacent roof panels, a load support structure being mounted on the roof, the load support structure comprising first and second side rail structures comprising at least first and second ones of the side rails mounted on first and second ones of the upstanding ribs, the first and second side rail structures each having an up-slope end and a down-slope end, an upper diverter extending between the up-slope ends of the first and second side rail structures, and a lower closure extending between the down-slope ends of the first and second side rail structures.
In some embodiments, each of the first and second side rails further comprise an upper flange extending laterally away from the respective upstanding web and toward the other of the first and second side rails, and an inside web extending down from the respective upper flange, thereby defining a second cavity between the upstanding web and the inside web, an elongate block of thermal insulation being disposed in the second cavity and extending from the upper flange to the respective lower shoulder.
In some embodiments, the load support structure extends about an aperture in the roof, a layer of thermally-insulating material underlying the sloping metal roof about the aperture, the layer of thermally-insulating material extending up through the aperture and alongside the second cavity and between the block of thermal insulation material and a space surrounded by the load support structure over such aperture.
In some embodiments, the thermally insulating material underlying the roof comprises roof insulation, edges of the roof insulation being held against an upper portion of the side rail.
In some embodiments, the upstanding roof seam is disposed in the first cavity.
In some embodiments, a fastener extends through one of the upstanding web and the upstanding wall and into the upstanding seam in the first cavity.
In a second family of embodiments, the invention comprehends a side rail for supporting one of opposing sides of a skylight or other cover over a roof penetration, the side rail having first and second opposing sides, and a length, and comprising as a first piece part, an upstanding elongate web having a top and a bottom; as a second piece part, a cavity ridge comprising a first upstanding cavity wall, having a top and a bottom, and a second upstanding cavity wall having a top and a bottom, and being displaced from, and extending alongside, the first cavity wall, the first and second cavity walls being connected to each other at respective tops thereof thereby to define a cavity therebetween having a top and a bottom, and an elongate opening along the bottom of the cavity, the upstanding elongate web being joined to the cavity ridge along the second cavity wall, further comprising a lower shoulder connected to, and extending laterally away from, one of the upstanding web and the first cavity wall, and away from the cavity.
The present invention will be further appreciated and understood when considered in combination with the following description and accompanying drawings. It will be understood, however, that the following description is by way of illustration and not of limitation. Certain changes and modifications can be made within the scope of the invention without departing from the spirit of the invention, and the invention includes all such changes and modifications.
FIG. 8A1 is an enlarged end/profile view of a side rail of the invention mounted at a standing seam, and illustrating a gap plug in the space between the outer panel of the rail and the metal roof seam, under the turned-over edges of the 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 which close off apertures in metal roofs. For purposes of simplicity, “load support structure” will be used interchangeably to mean various forms of closed-perimeter structures which are mounted on ribs of raised elevation metal roof structures, which surround an aperture in a roof, including across the flat of a roof panel, and which support either a cover over the aperture, or a vent or other conduit which extends through the roof aperture. Skylight assemblies and smoke vents are non-limiting examples of covers over such roof apertures. Air handling operations such as vents, air intakes, 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 aperture. 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 aperture is necessarily involved there can be mentioned, without limitation, such loads as 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, including the strengths of the standing seams, 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 support system which utilizes the beam strength of the major rib structures, in the roof panels, as the primary support structure for mounting and fastening the e.g. skylight assembly to the roof.
One family of support structures of the invention comprehends a skylight system where a load support structure which supports such skylights is overlaid onto, and mounted to, the roof panels, and exposes the load support structure to the same ambient weather conditions which are experienced by the surrounding roof panels. Thus, the load support structure experiences approximately the same thermal expansions and contractions as are experienced by the respective roof panel or panels to which the load support structure is mounted. This is accomplished through direct attachment of the load support structure to the underlying metal roofing panels. According to such roof mounting, and such ambient weather exposure, expansion and contraction of the load support structure 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 cave. 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 aperture in the metal roof, the aperture 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 load support structure is illustrative of support structures of the invention which extend about the perimeter of roof-penetrating apertures, thus closing off lateral approach to such apertures from the sides and ends. Such load support structure surrounds the aperture in the roof, and 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 such load support structures. A such support structure is secured to the conventional metal roofing panels, and surrounds a roof aperture formed largely in the intervening flat region of a single metal roof panel.
Skylight assembly 130, which is part of the aperture closure system, 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 skylight lens 134 mounted to, and overlying, 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.
Referring to
Lower closure 150 closes off the roof aperture from the outside elements at the down-slope end of the e.g. skylight or strip of skylights, thus to serve as a barrier to water leakage at the down-slope end of the aperture in the roof.
Referring now to
The profile of rail shoulder 242 is shaped to fit closely over the outside profile of the roof rib 32, and is secured to roof rib 32 by a plurality of fasteners 310 such as rivets or screws spaced along the length of the rib.
In each rib joint, the edges of the two roof panels are folded together, one over the other, as illustrated in e.g.
Where space 239 faces away from outer 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 outer web 238, and between plug 243 and the standing seam, is filled with e.g. a pliable construction sealant 245. Plug 243 thus provides a solid fill piece at spaces 239 where there is some risk of water entry into the aperture, 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 outer 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
Rails 142, 144 fit closely along the contours of ribs 32 whereby cross-section profiles of the rails closely follow the cross-section profiles of the ribs such that the ribs and rails are in face-to-face contact with each other over extended lengths of the respective rails and ribs, optionally along the top to bottom heights of areas of the rails which face the ribs. Upper diverter 146 and lower closure 150 have similar end contours which match the cross-panel contours of the respective ribs 32 as well as flats 114. The various mating surfaces of structure 100 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 (
The uncompressed, rest cross-section of rod 260 in cavity 264 is somewhat greater than the slot-shaped opening/access path 268 between inside panel 244 and the top of standing seam 18. 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 web 238 and panels 240 and 244 of the cavity while remaining sufficiently compressed to urge facing sheet 250 against web 238 and panels 240, 244, and 246 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.
In other embodiments of the side rails, inside panel 244 is resiliently deflectable outwardly and away from web 238, whereby panel 244 can deflect to admit a generally non-deformable, e.g. generally non-compressible rod 260. While all materials exhibit some degree of deformability and compressibility, even if miniscule, the rods considered non-deformable and non-compressible are generally considered rigid and/or hard, thus not soft foams or rubbers.
Upper diverter 146 and lower closure 150, discussed in more detail hereinafter, extend across the flat of the metal roof panel between the upper and lower ends of roof aperture 249 to complete the closure of load support structure 100 about the perimeter of the skylight aperture. The upper diverter and the lower closure have upper support structures 237 having cross-sections corresponding to the cross-sections of upper support structures of rails 142, 144. Those upper support structures thus have corresponding flange cavities which are used, with rods 260, to capture and hold 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 load support structure about the entire perimeter of the load support structure. Bridging tape or the like can be used to bridge between the side portions and end portions of insulation facing sheet 250, such that the facing sheet completely separates the interior of the surrounded space inside skylight cavity 274 from the respective elements of load support structure 100.
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 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.
In the process of installing a skylight system of the invention, a short length of one of the ribs 32, to which the load support structure is to be mounted, is cutaway, forming diversion gap 122 in the respective rib, to accommodate drainage at the upper end of the load support structure (toward ridge cap 120). Such diversion gap 122 is typically used with standing seam, architectural standing seam, and snap seam roofs, and can be used with any other roof system, such as an exposed fastener system, which has elevated elongate joints and/or ribs. In some instances, especially where the roof has no standing seams, the ribs on both sides of the skylight may be cut.
The retained portions of rib 32, namely along the full length of the skylight as disposed along the length of the respective roof panel, and especially the standing seams, 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/aperture.
As part of the installation of upper diverter 146, a stiffening plate structure 148, illustrated in
Stiffening plate 148 also provides lateral support, connecting adjacent ribs 32 to each other. Stiffening plate 148 is typically steel or other material of sufficient substance, rigidity as to provide a rigid support to the upper diverter, as part of the load support structure at diverter 146.
Load support structure 100 is configured such that the skylight subassembly can be easily fastened directly to the side 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, and parallel to, panel flat 14 of the respective roof panel. Diverter 146 also has a diversion surface 420, and fastener holes 430 along lower flange 410. Diversion surface 420 is, without limitation, typically a flat surface defining first and second obtuse angles with lower flange 410 and intermediate end panel 415. As indicated in
At the end of lower flange 410, which is closer to the closed rib, is rib mating surface 440. At the end of lower flange 410 which is closer to the cut rib is rib sealing portion 450 of the end panel 415, which functions as an end closure of the rib 32 on the down-slope side of diversion 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 diversion 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 up-slope side and the down-slope side of the rib at diversion gap 122. The up-slope side plug, plus tube sealants, serve as the primary barrier to water entry on the up-slope side of diversion gap 122. Sealing panel portion 450 serves as the primary barrier to water entry on the down-slope side of diversion 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 ribs 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 flange 415, toward sealing portion 450, thence through diversion gap 122 in the rib, away from the up-slope end of load support structure 100 and onto the flat portion of the next laterally adjacent roof panel. Accordingly, so long as the flow channel through diversion 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, and 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 and holding the 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 of the side rails. 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 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 an alternative, panel 537 can be resiliently deflectable whereupon rod 260 need not be compressible.
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 aperture 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 of closure web 520 at a common height 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 common 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 and stiffness/rigidity between the adjoining along ribs 32.
A salient feature of load support structures 100, relative to conventional curb-mounted skylights, is the reduction in the number of roof penetrations, namely roof apertures, 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 aperture in the roof, whereby fewer, though longer, apertures 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 aperture can provide for an equal or greater quantity of ambient light being admitted into the building through a smaller number of roof apertures.
Another salient feature of load 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 water lines of the respective metal roof panels.
Yet another salient feature of load 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/load support structure.
Load 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 aperture 249 at the relatively up-slope ends of a second pair of abutting rails 142B and a corresponding opposing rail 144, on the other side of the aperture as part of the up-slope end of the down-slope skylight assembly illustrated in
Female mating strip 622 has a generally vertically oriented elongate receptacle/slot. Male mating strip 630 has a generally vertically oriented elongate protuberance. Male mating strip 630 is received in female mating strip 622 whereby the male and female mating strips define the joint across aperture 249, thus joining the up-slope and down-slope skylight assemblies to each other. A bead of tube sealant is laid in female receptacle 632 before the male protuberance is mated with receptacle 632. Additional tube sealant is applied along the joint as appropriate.
In the process of installing the closure support structure, the upper diverter is installed first, after cutting a small portion of the aperture 249 near where upper diverter 146 is to be installed. Then the remainder of aperture 249 is cut in the respective roof panel and the rails are installed. The lower closure is then installed, which defines the perimeter of the surrounded space, and the bearing surfaces of the load support structure. The skylight assemblies are then mounted on the perimeter bearing surfaces and secured to the rails. Tube sealant and tape mastic are applied, as necessary, at the respective stages of the process to achieve leak-free joints between the respective elements of the skylight system.
Skylight assemblies of the invention can be connected end to end for as long a distance as necessary to cover a roof aperture, as each skylight assembly unit is supported by the ribs 32 of the respective roof panel through respective rails 142, 144. The standing rib elevations extend longitudinally along the full collective lengths of the respective rails, regardless of the number of skylight assemblies which are used to close off a given aperture in the roof. Water cannot enter over the tops of the rails because of the sealant at 330. Water cannot enter at the upper diverter at the most up-slope 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 diversion gap 122. 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 female receptacle 622 in combination with the sealants applied at the end-to-end joint.
The side rail profiles described so far can all illustrate securing the side rail to the underlying roof rib at a sloping side wall of the rib. Each of such elongate side rails can be fabricated by cutting and bending a single piece of sheet metal stock to form such side rails. Such side rail may be e.g. ten (10) feet long. An elongate upstanding web 238 has a top and a bottom. A lower shoulder 242 extends, as a first shoulder element, perpendicular to the bottom of the upstanding web as an extension of the web material. A second shoulder element may extend down and laterally away from a distal edge of the first shoulder element. Fasteners, such as rivets 310, may be spaced along the length of the side rail and secure the side rail to the underlying roof rib. A bearing panel 240 extends laterally from the top of upstanding web 238. An inside panel 244 extends downwardly from the distal edge of bearing panel 240. Web 238, in combination with panels 240 and 244 define rail cavity 264.
Certain ones of the side rails can be fabricated by extruding the respective profiles, typically using aluminum or aluminum alloy as the material of choice.
All of the side rails illustrated in
Rail lower shoulder 242a extends from the bottom of web 238. Lower rail shoulder 242a extends as a first shoulder panel 242a1 perpendicular to web 238. A second shoulder panel 242a2 extends laterally and downwardly from the distal end of first shoulder panel 242a1.
An elongate upstanding cavity wall 312 is displaced from, and extends parallel to, upstanding web 238. Cavity wall 312 has a bottom 312b located at the top of shoulder flat 16b, thus at an elevation equal to the elevation of the bottom of web 238, and on an opposing side of standing seam 18 from rail shoulder 242a. Cavity wall 312 further has a top 312t remote from bottom 312b. Wall 312 has an upstanding element between bottom 312b and top 312t; and the top of the cavity wall defines a horizontal element 312h of the cavity wall which extends from the upstanding element laterally toward, and makes a unitary connection with, upstanding web 238 at the intermediate portion of the upstanding web. Thus an upper portion of the cavity wall is connected to the intermediate portion of upstanding web 238. The locus of joinder 318 between the cavity wall and web 238 is reinforced by providing a radius at the joinder between web 238 and wall 312 which provides an enhanced thickness compared to the overall average thickness of web 238 and wall 312. Thus, for example, the thicknesses, of web 238 and wall 312 may be e.g. 006 inch, while the maximum thickness dimension taken at the 45 degree location of the radius between the joined elements, can be e.g. and without limitation, 0.09 inch, or greater. The purpose of the enhanced thickness is to reinforce a potentially weak spot in the side rail profile. Those skilled in the art will be able to identify appropriate reinforcement designs for their specific side rail profiles.
The collective cross-section profiles of upstanding web 238 and cavity wall 312 thus define an elongate standing seam cavity 314 which extends substantially the full length of the respective side rail. The left side of cavity 314 is defined by web 238. The right and top sides of cavity 314 are defined by cavity wall 312. The bottom of cavity 314 is open and thus provides an entrance/access path into the cavity.
Side rail 144 is mounted to rib 32 by positioning side rail 144, in an upright orientation as oriented in
The side rail shown in
The side rail shown in
The side rail shown in
The side rail shown in
The side rail shown in
The side rail shown in
The side rail shown in
The structure shown in
The primary reason why the disclosed load support structures do not leak is that a great portion of the perimeter of the structure, namely that which is defined by side rails 142, 144, is above the panel flat, namely above the 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 the joint, no substantial quantity of water routinely enters such failed joint because of the heights of those joints above the water line.
As a general statement, load support structures of the invention close off the roof aperture from unplanned leakage of e.g. air or water through the roof aperture. The load support structure 100 extends about the perimeter/sides of the roof aperture and extends from the roofing panel upwardly to the top opening in the load support structure. The lens subassembly overlies the top opening in the load support structure and thus closes off the top opening to complete the closure of the roof aperture.
Load support structure 140 has been illustrated in detail with respect to one or more variations of the standing seam roofs illustrated in
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.
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| Number | Date | Country | |
|---|---|---|---|
| 20140260068 A1 | Sep 2014 | US |
