U.S. patent application number 10/178287 was filed with the patent office on 2003-12-25 for roof panel for a sun room.
Invention is credited to Mahon, Barry F., Walz, Robert A..
Application Number | 20030233796 10/178287 |
Document ID | / |
Family ID | 29734645 |
Filed Date | 2003-12-25 |
United States Patent
Application |
20030233796 |
Kind Code |
A1 |
Walz, Robert A. ; et
al. |
December 25, 2003 |
Roof panel for a sun room
Abstract
A roof panel (20) for a sun room has a polystyrene foam core
(40) and two aluminum covers (42) and (44) adhered to the top (41)
and bottom (43) of the foam core. At least one groove (46) is cut
into the foam core and a rib (56) is laterally fitted into the
groove. The rib has its minor axis vertically oriented and its
major axis running longitudinally with or parallel to the
longitudinal axis of the panel to provide significant increase in
strength to the panel.
Inventors: |
Walz, Robert A.; (Shelby
Township, MI) ; Mahon, Barry F.; (Eastpointe,
MI) |
Correspondence
Address: |
Steven L. Permut
REISING, ETHINGTON, BARNES,
KISSELLE, LEARMAN & MCCULLOCH, P.C.
P.O. BOX 4390
TROY
MI
48099-4390
US
|
Family ID: |
29734645 |
Appl. No.: |
10/178287 |
Filed: |
June 24, 2002 |
Current U.S.
Class: |
52/200 ;
52/223.7; 52/469 |
Current CPC
Class: |
E04D 3/366 20130101;
E04C 2/292 20130101; E04D 3/352 20130101; E04D 3/355 20130101 |
Class at
Publication: |
52/200 ;
52/223.7; 52/469 |
International
Class: |
E04B 007/18; E04C
002/34 |
Claims
The embodiments in which an exclusive property or privilege is
claimed are defined as follow:
1. A panel for a sun room roof comprising; a structural foam core
member having a thickness with a top and bottom and at least one
groove longitudinally extending therein and intercepts and is open
to one of the top or bottom; a planar structural support member
mounted in a respective one of said at least one groove; a top and
bottom structural cover member adhered onto the respective top and
bottom of the foam core.
2. A roof panel as defined in claim 1 further comprising: said at
least one groove extending from the top of the foam core member and
ending a distance from the bottom of the foam core member such that
said foam core member has at least one bridging span section under
said at least one groove that is thick enough to retain the foam
core member as a single unitary member; and said bottom structural
cover member on the bottom of said foam core member does not touch
any planar structural support member or any groove.
3. A roof panel as defined in claim 2 further comprising: said at
least one respective groove and planar structural support member
both extend substantially the entire length of said panel.
4. A roof panel as defined in claim 3 further comprising: said at
least one respective groove and planar structural support member
each being two in number with each being spaced from a longitudinal
centerline of said panel; a centered sky light hole cut in said
foam core member between said two structural supports; a skylight
mounted in said center hole between said grooves and planar support
members.
5. A roof panel as defined in claim 3 further comprising: said at
least one respective groove and planar structural support member
each being three in number with one of said grooves and one of said
planar structural support members aligned along a longitudinal
centerline and the other two grooves and planar structural support
members being spaced between the longitudinal centerline and a
lateral side of said panel.
6. A roof panel as defined in claim 5 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
7. A roof panel as defined in claim 4 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
8. A roof panel as defined in claim 3 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
9. A roof panel as defined in claim 1 further comprising: said at
least one respective groove and planar structural support member
each being two in number with each being spaced from a longitudinal
centerline of said panel; a centered sky light hole cut in said
foam core member between said two structural supports; a skylight
mounted in said center hole between said grooves and ribs.
10. A roof panel as defined in claim 1 further comprising: said at
least one respective groove and planar structural support member
each being three in number with one of said grooves and one of said
planar structural support members aligned along a longitudinal
centerline and the other two grooves and planar structural support
members being spaced between the longitudinal centerline and a
lateral side of said panel.
11. A sun room having side walls and a roof having a set of
connecting roof panels; said panels have each end supported by a
side wall, said sun room comprising: each roof panel having a
structural first foam core member having a thickness with a top and
bottom at least one groove longitudinally extending therein; at
least one planar structural support member mounted in said at least
one groove; a top and bottom structural cover member adhered onto a
respective top and bottom of the foam core.
12. A sun room as defined in claim 11 further comprising: said
structural first core member being a structural foamed plastic
material.
13. A sun room as defined in claim 12 further comprising: said at
least one groove extending from one of the top or bottom of the
foam core member and ending a distance from the other of the bottom
or top of the foam core member such that said foam core member has
at least one bridging span section that is thick enough to retain
the foam core member as a single unitary member; and one of said
structural cover members of said roof panel does not touch any
planar structural support member or any groove.
14. A sun room as defined in claim 13 further comprising: at least
one respective groove and planar structural support member both
extending substantially the entire length of said panel.
15. A sun room as defined in claim 13 further comprising: said at
least one respective groove and planar structural support member
each being two in number with each being spaced from a longitudinal
centerline of said panel; a centered sky light hole cut in said
foam core member between said two structural supports; a skylight
mounted in said center hole between said grooves and ribs.
16. A sun room as defined in claim 13 further comprising: said at
least one groove and planar structural support member each being
three in number with one of said grooves and one of said planar
structural support member aligned along a longitudinal centerline
and the other two grooves and planar structural support member
being spaced between the longitudinal centerline and a side wall of
said panel.
17. A sun room as defined in claim 16 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
18. A sun room as defined in claim 14 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
19. A sun room as defined in claim 13 further comprising: each
planar structural member being made from aluminum and having a
thickness of approximately 0.065."
20. A sun room as defined in claim 12 further comprising: said at
least one respective groove and planar structural support member
each being two in number with each being spaced from a longitudinal
centerline of said panel; a centered sky light hole cut in said
foam core member between said two structural supports; a skylight
mounted in said center hole between said grooves and ribs.
21. A sun room as defined in claim 12 further comprising: said at
least one respective groove and planar structural support member
each being three in number with one of said grooves and one of said
planar structural support members aligned along a longitudinal
centerline and the other two grooves and planar structural support
members being spaced between the longitudinal centerline and a
lateral side of said panel.
22. A sun room roof assembly comprising: a set of panels sealingly
joined together with one end supported by a panel rail on a wall
and a second end supported by a sun room wall; each of said panels
having a structural foam core member having at least one groove
longitudinally extending therein; at least rib member having its
minor axis vertically oriented and its major axis longitudinally
extending along the length of said panel; said rib being mounted in
said at least one groove; a top and bottom structural cover member
adhered onto a respective top and bottom of the panel foam core
member.
23. A sun room roof assembly as defined in claim 22 wherein at
least one panel has: said at least one respective groove and said
rib each being two in number with each being spaced from a
longitudinal centerline of said panel; a centered sky light hole
cut in said foam core member between said two structural supports;
a skylight mounted in said center hole between said grooves and
ribs.
24. A sun room roof assembly as defined in claim 22 wherein at
least one panel has: said at least one respective groove and said
rib each being three in number with one of said grooves and one of
said ribs aligned along a longitudinal centerline and the other two
grooves and ribs being spaced between the longitudinal centerline
and a lateral side of said panel.
25. A sun room roof assembly as defined in claim 22 wherein at
least one panel has: said at least one groove being formed by a saw
blade or router for cutting into the top or bottom of the foam core
member and said at least one rib laterally positioned into the
respective groove from said top or bottom.
Description
TECHNICAL FIELD
[0001] The field of this invention relates to sun room roofs and
more particularly to a roof panel for a sun room roof.
BACKGROUND OF THE DISCLOSURE
[0002] Sun rooms have long been popular as a common way to extend
the spring and fall seasons for a deck or patio. Sun rooms are also
referred to as patio enclosures, Florida rooms, conservatories, sun
porches, porch enclosures, solariums and sun spaces. The American
Architectural Manufacturers Association (AAMA) sets for the
specific definitions for many of these terms. However, in this
document the term "sun rooms" shall be considered generic and to
incorporate all of the above terms.
[0003] Most building codes take sun rooms into account. Most
building codes relax the energy conservation requirements and also
relax the construction requirements relative to the remainder of a
residential home. For example, the codes often eliminate the
requirement for drywall and stud construction. The relaxation of
the energy requirement makes sun rooms possible because of the
large amount of glass that is used in most sunrooms.
[0004] On the other hand, many codes mandate that sun rooms are not
to be heated or cooled. In addition in many codes, the main
building should maintain or have a closeable exterior door leading
to the sun room. Furthermore, the roof needs to meet certain load
requirements for snow loads and for structural support. A common
load requirement is set at thirty pounds per square foot. In the
past, this load requirement was often met through the use of 3"
thick panels made from a core of polystyrene foam having a density
ranging from 1-2 lbs./cubic foot. The core is adhered to lower and
upper aluminum covers having a thickness of 0.019", 0.024" or
0.032" depending on the strength and specifications. A urethane
adhesive is commonly used to bond the aluminum covers to the
polystyrene core. The individual panels are oriented to have their
longitudinal axis extend substantially transverse from the edge of
a main building. Each panel has a side connected to another using
one of a variety of joining methods to seal against leakage. The
aluminum covers and polystyrene core assembly provides sufficient
strength to meet the thirty pound load test up to lengths of
thirteen feet. The outer end of each panel is supported by an outer
wall of the sun room.
[0005] As such, most sun rooms have been limited to extend from the
main building to a maximum of thirteen feet to the outer wall. If a
person wanted a larger sun room over thirteen feet to sixteen feet,
the required roof strength was accomplished by use of a thicker
polystyrene core having a minimum thickness of 41/4". Six inch
thick polystyrene cores are also used depending on the
specifications and load requirement. In addition, a structural beam
needs to be used for achieving sun room widths being over sixteen
feet
[0006] Besides the added weight and expense of the additional
polystyrene, the thicker panels mandate the use of wider and more
expensive trim pieces for covering the edges of the roofs.
Furthermore, if the roof is lined with a gutter, wider and more
expensive 41/4" and six inch gutters must also be used. The use of
the thicker polystyrene, wider trim pieces, and gutters add
significant costs for only a slightly larger sun room. As a result,
many people settle for a smaller than desireable sun room due to
the great differential in price for the more desirable size.
[0007] In addition, thinner roofs with thinner and narrower trim
pieces and gutters are often cosmetically and aesthetically
desirable over the necessary thicker roof lines for larger sun
rooms.
[0008] However the desire for an increase in size for a sun room
remains for several important reasons. When one takes into account
the furniture in the sun room, the slight increase in the overall
dimensions of the sun room provides for a great increase of the
free aisle and play space in the sun room. This great increase of
free space and play space becomes more apparent when one takes into
account the fixed amount of space used by the furniture such as
tables, sofas and chairs.
[0009] What is needed is an inexpensive sun roof panel that
maintains the standard 3" thickness but can provide for added
strength and achieve lengths of 16 feet and still meet roof load
requirements. The roof loads are set by local governments. The
building codes establish a minimum of 20 pounds per square foot.
Greater loads are set by the local jurisdiction, e.g., thirty
pounds per square foot.
SUMMARY OF THE DISCLOSURE
[0010] In accordance with one aspect of the invention, a panel for
a sun room roof includes a structural foam core member having a
thickness with a top and bottom. At least one groove longitudinally
extends therein and intercepts either the top or bottom of the foam
core member. A planar structural support member is mounted in a
respective groove. A top and bottom structural cover member is
adhered onto the respective top and bottom of the foam core.
[0011] Preferably, each groove extends from the top of the foam
core member and ends a distance from the bottom of the foam core
member such that the foam core member has at least one bridging
span section under each groove that is thick enough to retain the
foam core member as a single unitary member during normal handling
in the manufacturing process. Consequently, the bottom structural
cover member on the bottom of the foam core member does not touch
any planar structural support member or any groove.
[0012] It is also desirable that each groove and planar structural
support member both extend substantially the entire length of the
panel. In one embodiment, there are two grooves and planar
structural support members with each being spaced from a
longitudinal centerline of the panel. A centered sky light hole is
cut in the foam core member between the two planar structural
supports. A skylight is mounted in the centered hole between the
grooves and planar support members.
[0013] In another embodiment, there are three grooves and planar
structural support members with one of the grooves and one of the
planar structural support members aligned along a longitudinal
centerline and the others are spaced between the longitudinal
centerline and a lateral side of the panel.
[0014] It is desirable that each planar structural member is made
from aluminum and having a thickness of approximately 0.065."
[0015] In accordance with another aspect of the invention, a sun
room has side walls and a roof having a set of connecting roof
panels. Each roof panel has each end supported by a wall. Each roof
panel has a structural first foam core member having a thickness
with a top and bottom and at least one groove longitudinally
extending therein. A planar structural support member is mounted in
each groove. A top and bottom structural cover member is adhered
onto a respective top and bottom of the foam core. Preferably, the
structural first core member is made from a structural foamed
plastic material.
[0016] In accordance with a further aspect of the invention, a sun
room roof assembly includes a set of panels sealingly joined
together with one end supported by a panel rail on a wall and a
second end supported by a sun room wall. Each of the panels has a
structural foam core member having at least one groove
longitudinally extending therein. At least one rib has a minor axis
that is vertically oriented and a major axis running along the
length of the panel and is mounted in the at least one groove. A
top and bottom structural cover member is adhered onto a respective
top and bottom of the panel foam core member. Preferably, at least
one panel has two grooves and two ribs with each being spaced from
a longitudinal centerline of the panel. A centered sky light hole
cut in said foam core member between the two ribs and grooves. A
skylight is mounted in the centered hole between the grooves and
ribs.
[0017] In one embodiment the panel has three grooves and ribs. One
of each groove and rib is aligned along a longitudinal centerline
and the other two grooves and ribs are spaced between the
longitudinal centerline and a lateral side of the panel.
[0018] It is preferred that the groove is formed by a saw blade for
cutting into the top or bottom of the foam core member and the rib
is laterally positioned into the respective groove from the top or
bottom. Other manufacturing systems such as the use of a multiple
router head assembly can also form the grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Reference now is made to the accompanying drawings in
which:
[0020] FIG. 1 is a top perspective view of a sun room incorporating
an embodiment of the invention.
[0021] FIG. 2 is a fragmentary lower perpsective view of the sun
roof assembly shown in FIG. 1;
[0022] FIG. 3 is a top perspective and exploded view of the sun
roof assembly;
[0023] FIG. 4 is a front elevational view of an individual roof
panel shown in FIG. 2;
[0024] FIG. 5 is an exploded fragmentary view of the panel shown in
FIG. 4;
[0025] FIG. 6 is a top perspective and partially exploded view
showing a modified embodiment of the invention incorporating a
skylight;
[0026] FIG. 7 is a top perspective view of another embodiment of a
foam core for use in the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to FIG. 1, a sun room 10 extends from a main
building 12 with two opposing side walls 14 and a third outer wall
16. A sun roof 18 extends from the main building to entirely cover
the sun room. As shown in FIGS. 2 and 3, the roof is made from a
series of panels 20 that are joined together via a tongue and
groove joint 22 along the sequential panel edges 24 and 26. Each
panel extends from the roof hanging rail 28 mounted on the main
building 12 to the top of the outer wall 18. The outer side edges
30 and 32 of the roof 18 is finished off with a c-fascia 34 and a
gutter 35 along with two corner trim pieces 36. Top cleat 37 and
bottom cleat 38 both hide the joint 22 and seal the roof panels 20
against leakage.
[0028] The construction of each panel 20 is shown more clearly in
FIGS. 4-5. Panel 20 is approximately 4 feet in width and has a
polystyrene core 40 made from a conventional medium density
polystyrene foam having a density of about 2 lbs./cubic foot. Other
densities as light as 1 lb./cubic foot are also suitable. The foam
panel is approximately 3 inches thick, however, thicker panels up
to 6 inches thickness for more strength are also foreseen.
[0029] The foam core 40 has a top surface 41 covered by a painted
aluminum cover or skin 42 and a bottom surface 43 similarly covered
by a bottom painted aluminum cover or skin 44. Each cover 42 and 44
has a thickness of approximately 0.019". Other thicknesses of
0.024" and 0.032" are also suitable for added strength. Each cover
42 and 44 is bonded to the core with an application of a
commercially available and known urethane adhesive. Each cover 42
and 44 may have a cosmetic dimpled texture embossed therein.
[0030] The foam core has three grooves 46 formed therein at
approximately one foot increments with a center groove extending
along the longitudinal centerline or axis 47 of the panel 20. Each
groove 46 extends fully between the two opposite longitudinal ends
48 of the foam core member 40. The grooves 46 however do not extend
all the way down through the foam core member thickness or height.
Each groove 46 has a bottom 50 that is spaced from the bottom
surface 43 such that a bridging span 54 in the foam core 40 is
formed and has a sufficient thickness of about 1/2" to maintain the
foam core member's structural integrity during normal production
handling while the remainder of the panel is assembled together.
The groove can be formed simply by running a rotary saw blade or
routed longitudinally along the foam along its top surface 41.
[0031] The groove 46 is dimensioned to snugly receive an aluminum
rib 56 therein. The groove 46 is open at the top surface 41 such
that the rib 56 can be fitted laterally into the groove from the
top surface 41 rather than from the ends 48. The aluminum rib 56 is
approximately 0.065" thick and extends the entire length of the
groove 46 as well as substantially the entire height of the groove
46. Other rib thicknesses such as 0.032" are usable and found to
have a benefit for support. Aluminum ribs as thin as 0.019" have
been determined to provide added support to the panel.
[0032] The rib can be a planar support member with its minor axis
vertically oriented and its major axis running longitudinally along
or parallel to the length or axis 47 of panel 20.
[0033] The panel 20 is assembled by first forming the foam core and
then cutting the three grooves 46 therein. The ribs 56 are then
placed in the grooves and then the urethane adhesive is placed on
the top and bottom surfaces of the foam core and the covers are
placed thereon and bonded thereto. The tongue and groove edges 24
and 26 are then properly formed to finish each panel 20.
[0034] It has been found that the addition of the three ribs as
shown in FIG. 3-5 increases a 13 foot long panel's resistance
against structural failure from just above the 30 lbs/sq. ft load
to approximately a 68 lb./sq. ft load. This increase in structural
integrity is achieved without any changes in the overall thickness
of the panel.
[0035] A second embodiment is shown in FIG. 6 which reduces the
number of grooves 46 and ribs 56 to two and repositions them such
that the middle section 58 of the foam core member 40 has an 18"
width and the two existing grooves 46 and ribs 56 are positioned
15" from each side edge 24 and 26. In this fashion, there is enough
width in the middle to cut a hole 58 to accommodate a skylight 60
without the need for cutting into any rib 56. The two ribs having a
thickness of 0.065" produces a significant increase in the
structural integrity of the panel against gravitational loads, even
with the skylight mounted therein.
[0036] A further modified foam core member is shown in FIG. 7 where
the grooves do not extend all the way to each end 48. The ribs 56
are also correspondingly shortened to fit within the grooves 46. In
this embodiment the ribs are concealed from the ends 48 such that
upon full assembly of the panel 20, the panel 20 has the outward
appearance of a conventional panel with no ribs.
[0037] Because of the increased structural strength of the panels
20, they may be lengthened from the present maximum 13 feet up to
16 feet in length or greater. This increase of three feet is
accomplished without increasing the overall thickness of the panel
20. As such, conventional 3" trim facias 34, gutters 35 and corner
trim pieces 36 can still be used with a much larger sun room.
[0038] It should also be noted that the panel 20 is oriented such
that intermediate spanning section 54 is at the bottom surface of
the foam core such that the bottom cover 44 remains free from
contact with the ribs. If there is any interference with the ribs
56 and the cover 44, any undesirable shadowing takes place at the
exterior of the sun room which is less critical than on the
interior ceiling of the sun room.
[0039] It is also foreseen that the ribs can be made from steel,
other structural metal or structural plastic. The thickness of the
ribs is accordingly modified to accommodate the specific strength
characteristics of the steel, metal or structural plastic used in
accordance with standard engineering practices to render the
equivalent strength of the previously described aluminum ribs.
Furthermore, it is foreseen that the cover or skin 42 & 44 can
also be a thin gauged steel or some later developed sheeting from
other material.
[0040] Other variations and modifications are possible without
departing from the scope and spirit of the present invention as
defined by the appended claims.
* * * * *