U.S. patent application number 10/860742 was filed with the patent office on 2006-01-05 for modular skylight frame and system.
This patent application is currently assigned to VKR HOLDING A/S. Invention is credited to Eric Brinton, Samuel H. Darmer, Leonard Kenneth Moody.
Application Number | 20060000161 10/860742 |
Document ID | / |
Family ID | 34970235 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060000161 |
Kind Code |
A1 |
Darmer; Samuel H. ; et
al. |
January 5, 2006 |
Modular skylight frame and system
Abstract
A pre-assembled skylight frame module and system is provided. A
module includes opposed first and second skylight mounts, each
including opposed rafters and opposed purlins to define a
rectangular aperture between them. The skylight frame module
includes an obtuse angle between the two attached first and second
skylight mounts. The skylight mounts are adapted for receipt of
pre-assembled skylight assemblies. The skylight frame module is
configured for side-by-side attachment to adjacent such skylight
frame modules, to provide a skylight frame assembly. The skylight
system may be adapted to a variety of skylight openings by varying
the rafter and purlin lengths and the angle between the connected
skylight mounts.
Inventors: |
Darmer; Samuel H.;
(Greenwood, SC) ; Moody; Leonard Kenneth;
(Greenwood, SC) ; Brinton; Eric; (Greenwood,
SC) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Assignee: |
VKR HOLDING A/S
|
Family ID: |
34970235 |
Appl. No.: |
10/860742 |
Filed: |
June 3, 2004 |
Current U.S.
Class: |
52/200 |
Current CPC
Class: |
E04D 13/032 20130101;
E04D 3/06 20130101 |
Class at
Publication: |
052/200 |
International
Class: |
E04B 7/18 20060101
E04B007/18 |
Claims
1. A pre-assembled skylight frame module, comprising: a first
skylight mount, said first skylight mount including a first rafter
and an opposed second rafter, an upper purlin defining a purlin
length and an opposed lower purlin, said first and second rafters
and upper and lower purlins of said first skylight mount
interconnected to define a first rectangular aperture therebetween,
a second skylight mount, said second skylight mount including a
first rafter and an opposed second rafter, an upper purlin defining
a purlin length and an opposed lower purlin, said first and second
rafters and upper and lower purlins of said second skylight mount
interconnected to define a second rectangular aperture
therebetween, said first skylight mount attached to said second
skylight mount along said purlin lengths of respective said upper
purlins.
2. The pre-assembled skylight frame module of claim 1, wherein said
attachment of said first skylight mount and said second skylight
mount defines an obtuse angle between said first and second
skylight mounts.
3. The pre-assembled skylight frame module of claim 1, wherein said
attachment of said first skylight mount and said second skylight
mount is substantially rigid.
4. The pre-assembled skylight frame module of claim 1, wherein each
of said first and second skylight mounts is configured for
engagement with a pre-assembled skylight lens assembly of
predetermined size over said rectangular aperture.
5. The pre-assembled skylight frame module of claim 1, wherein each
said upper purlin defines a cross-sectional configuration and said
lower purlin defines substantially the same cross-sectional
configuration.
6. The pre-assembled skylight frame module of claim 1, wherein each
said first rafter defines a cross-sectional configuration and said
second rafter defines substantially the same cross-sectional
configuration.
7. The pre-assembled skylight frame module of claim 1, wherein at
least one of said lower purlins includes a hinge member adapted for
attachment to a roof curb hinge.
8. The pre-assembled skylight frame module of claim 1, further
including at least one hinge connected with at least one of said
lower purlin for hingeable attachment to a roof curb.
9. The pre-assembled skylight frame module of claim 1, wherein said
rafters and purlins include a top wall configured for abutment with
a skylight lens assembly gasket.
10. The pre-assembled skylight frame module of claim 1, wherein
said rafters and purlins include a screw receiver for receipt of
screw attachments from a skylight system.
11. The pre-assembled skylight frame module of claim 1, wherein at
least one of said rafters defines a channel therein.
12. The pre-assembled skylight frame module of claim 1, wherein at
least one of said purlins defines a channel therein.
13. The pre-assembled skylight frame module of claim 1, wherein at
least one of said pre-assembled skylight frame modules is adapted
for attachment of skylight accessories.
14. A skylight frame system, comprising: at least two pre-assembled
skylight frame modules for side-by-side installation, each said
module including: a first skylight mount, said first skylight mount
including opposed rafters, an upper purlin and an opposed lower
purlin, said rafters and purlins interconnected to define a
rectangular aperture therebetween, a second skylight mount, said
second skylight mount including opposed rafters, an upper purlin
and an opposed lower purlin, said rafters and purlins
interconnected to define a rectangular aperture therebetween, said
first skylight mount attached to said second skylight mount at
respective said upper purlins, wherein adjacent said rafters
between said modules are configured for attachment one to the
other.
15. The skylight frame system of claim 14, wherein said attachment
of said first skylight mount and said second skylight mount defines
an obtuse angle between said first and second skylight mounts.
16. The skylight frame system of claim 14, wherein said attachment
of said first skylight mount and said second skylight mount is
substantially rigid.
17. The skylight frame system of claim 14, wherein each of said
first and second skylight mounts are each adapted for engagement
with a pre-assembled skylight lens assembly of predetermined size
over said rectangular aperture.
18. The skylight frame system of claim 14, wherein at least one of
said rafters defines therein a secondary gutter.
19. The skylight frame system of claim 14, wherein at least one of
said lower purlins includes a hinge member adapted for attachment
to a roof curb hinge.
20. The skylight frame system of claim 14, further including a
hinge connected with at least one said lower purlin for hingeable
attachment to a roof curb.
21. The skylight frame system of claim 14, wherein each said first
rafter of a said skylight mount defines a cross-sectional
configuration and each said second rafter defines substantially the
same cross-sectional configuration.
22. The skylight frame system of claim 14, wherein each said upper
purlin of a said skylight mount defines a cross-sectional
configuration and each said lower purlin defines substantially the
same cross-sectional configuration.
23. The skylight frame system of claim 14, wherein each said module
includes at least one said rafter disposed for engagement with at
least one rafter of an adjacent said module upon said side-by-side
installation, one of said rafters of one of said modules including
a male member and the adjacent said rafter of the adjacent said
module including a female member configured for engagement with
said male member.
24. The skylight frame system of claim 14, wherein at least one of
said rafters defines a channel therein.
25. The skylight frame system of claim 14, wherein at least one of
said purlins defines a channel therein.
26. The skylight frame system of claim 14, wherein said at least
one of said pre-assembled skylight frame modules is adapted for
attachment of skylight accessories.
27. The skylight frame system of claim 14, wherein said rafters and
purlins include a top wall configured for abutment with a gasket
carried by a skylight lens assembly.
28. The skylight frame system of claim 14, wherein said rafters and
purlins include a screw receiver for receipt of screw attachments
from a skylight system.
29. A skylight frame system, comprising: at least two pre-assembled
skylight frame modules for side-by-side installation, each said
module including: a first skylight mount, said first skylight mount
including a first rafter and a second rafter parallel to said first
rafter, said first skylight mount further including an upper purlin
and a lower purlin parallel therebetween and perpendicular to said
first and second rafters, said rafters and purlins defining an
opening therein of predetermined dimensions, a second skylight
mount, said second skylight mount including a first rafter and a
second rafter parallel to said first rafter, said second skylight
mount further including an upper purlin and a lower purlin parallel
therebetween and perpendicular to said first and second rafters,
said rafters and purlins defining an opening therein of
predetermined dimensions and an outside perimeter therearound,
respective said upper purlins of said first and second skylight
mounts substantially rigidly attached to define a predetermined
angle between said first and second skylight mounts, said first and
second skylight mounts each adapted for receipt of a pre-assembled
skylight lens assembly of predetermined size over said opening,
said at least two pre-assembled skylight frame modules configured
for attachment one to the other.
30. The skylight frame system of claim 29, further including a male
hinge member upon at least one of said lower purlins of said
skylight mounts adapted for attachment to a receiving hinge member
upon a roof curb.
31. The skylight frame system of claim 29, wherein at least one of
said lower purlins is attached to a hinge for connection to a roof
curb.
32. The skylight frame system of claim 29, wherein said rafters and
purlins include a top wall configured for abutment with a gasket
carried by a skylight lens assembly.
33. The skylight frame system of claim 29, wherein at least one of
said rafters defines a secondary gutter therein.
34. The skylight frame system of claim 29, wherein said rafters and
purlins include a screw receiver for receipt of screw attachments
from a skylight system.
35. The skylight frame system of claim 29, wherein said rafters and
purlins are configured for mechanical engagement with a skylight
lens assembly.
36. The skylight frame system of claim 29, wherein each said module
includes at least one said rafter disposed for engagement with at
least one rafter of an adjacent said module upon said side-by-side
installation, one of said rafters of one of said modules including
a male member and the adjacent said rafter of the adjacent said
module including a female member configured for engagement with
said male member.
37. The skylight frame system of claim 29, wherein at least one of
said rafters defines a channel therein.
38. The skylight frame system of claim 29, wherein at least one of
said purlins defines a channel therein.
39. The skylight frame system of claim 29, wherein said at least
one of said pre-assembled skylight frame modules is adapted for
attachment of skylight accessories.
40. The skylight frame system of claim 29, further including a top
ridge cap over said attachment of said purlins.
41. The skylight frame system of claim 29, wherein each said upper
purlin of a said skylight frame mount defines a cross-sectional
configuration and each said lower purlin defines substantially the
same cross-sectional configuration.
42. The skylight frame system of claim 29, wherein each said first
rafter of a said skylight frame mount defines a cross-sectional
configuration and each said second rafter defines substantially the
same cross-sectional configuration.
Description
BACKGROUND
[0001] Skylights are useful and popular features in buildings.
Allowing natural lighting to the interior of buildings, skylights
are used with residences, schools, shopping malls, office
buildings, and the like.
[0002] A skylight involves an opening through the roof of a
building, above which is constructed a perimeter curb for support
of the skylight about the opening upon the roof. Construction of
the skylight itself, under existing systems, may involve erection
and interconnection of various struts, standards, beams, channels,
gutters, and the like above the curb. Thereafter, glazing units may
be installed and weatherproofed to the constructed frame assembly.
Such weatherproofing might involve wet glazing, often undertaken on
the job site by professional glaziers. Alternatively, dry glazing
may be used, in which a complicated series of gaskets and seals are
installed. Dry glazing is considered inferior by some in the
market, in that it requires numerous parts that must be fitted
together exactly, it is aesthetically complicated, and it requires
increased maintenance. On the other hand, wet glazing on the job
site may be problematic, in that professionally-trained glaziers
must be located and retained, job quality may be irregular, and
later responsibility for leaks or failure may be disputed between
various tradesmen or material suppliers.
[0003] Assembly of existing skylight systems is primarily completed
on the job site itself. Lacking standardization, various pieces and
parts are brought to the site, along with the requisite relatively
large number of tools for the assembly. So located, the skylight
system is then constructed, piece by piece, over the sometimes
large and always dangerous opening in the roof. Moreover, existing
gabled skylight systems often produce lateral loading upon the
mounting structure, such as the roof curb, which requires more than
minimal professional design and engineering considerations. Of
course, the tooling costs necessary to produce the various pieces
and parts of existing skylight systems is not insignificant, as
numerous parts, often of varying configurations, must be
manufactured.
[0004] Once assembled, existing skylight systems often suffer from
inferior drainage features. As an outside structure, skylight
systems are exposed to rain and must shed that rain in an efficient
and effective manner, yet existing systems often provide for
inefficient or inelegant, and unattractive, drainage systems.
[0005] Transportation of the skylight system to the job site is
required. Accordingly, the transportability of the various
components comprised by the skylight system is an issue to be
considered in design. Furthermore, the skylight system must be
moved to the roof of the building for installation, which presents
another transportability issue. For example, a system so bulky and
cumbersome that a crane is required for lifting the system from a
truck to a rooftop is less desirable than a system in which
components may be handled manually by workers on site.
[0006] It is also recognized that pre-assembled individual single
unit skylight lens assemblies involving a single light aperture,
have reached a high level of sophistication, engineering, and
reliability. Such units are delivered complete from the factory.
Glazing of the light panels has already been completed, under
controlled, standardized conditions in a factory by workers with
specialized expertise. Installation has been simplified, and
performance of these units installed in the field has been
superior. Such skylight lens assemblies are available pre-assembled
in several standard sizes, such as 2.times.2 feet, 2.times.4 feet,
3.times.3 feet, 4.times.4 feet, and 4.times.6 feet. Several models
of such skylights include an integrated flashing system,
weatherproofing the entire assembly. An example of such a skylight
lens assembly is disclosed in application Ser. No. 10/612,386,
entitled "Skylight With Sealing Gasket," owned by the same Assignee
as the present invention and incorporated herein by reference.
[0007] Accessories, such as awnings, shades, blinds, electrochromic
mechanisms, and photovoltaic systems, are available for some single
unit skylights. Existing skylight systems may not provide for the
inclusion of such accessories, either in allowing for attachment of
such systems or providing for structural support of the added
weight of such systems, or providing for efficient or aesthetic
wiring of electrically powered accessories.
[0008] The present invention relates to improvements upon the known
skylight frame systems and provides distinct advantages over the
conventional systems and methods.
SUMMARY OF THE INVENTION
[0009] In response to the discussed difficulties and problems, a
new skylight frame and system has been discovered.
[0010] Certain aspects of the present invention provide for a
pre-assembled skylight frame module, to be installed upon new
construction or in retrofitting a newer skylight to an existing
structure.
[0011] As used herein, "pre-assembled" is understood to mean a
construction that is fabricated and assembled distant from the
installation site at which the skylight system is to be
mounted.
[0012] According to certain aspects of the present invention, a
first skylight mount is provided. The first skylight mount includes
opposed first and second rafters and opposed upper and lower
purlins, the rafters and purlins interconnected to define a
rectangular aperture between them. Likewise, a second skylight
mount is provided, it, too, including first and second opposed
rafters, and upper and lower opposed purlins, the rafters and
purlins interconnected to define a rectangular aperture between
them. The first skylight mount is attached to the second skylight
mount along the respective upper purlins. Attachment of the first
skylight mount to the second skylight mount at the respective upper
purlins may define an angle between the first and second skylight
mounts ranging from 90 degrees to 180 degrees. Such attachment may
be substantially rigid.
[0013] Each of the two skylight mounts of the pre-assembled
skylight frame module may be configured for engagement with a
pre-assembled skylight lens assembly, of predetermined size, over
each of the rectangular apertures of the skylight mounts.
[0014] Other aspects of the present invention also provide that the
cross-sectional configuration of the upper and lower purlins may be
substantially the same. Likewise, the cross-sectional
configurations of the first and second rafters may be substantially
the same.
[0015] The lower purlins may include a hinge member adapted for
attachment to a roof curb hinge. The roof curb hinge, so used, may
attach the pre-assembled skylight frame module to the roof curb or
other mounting structure upon the building roof. In one embodiment,
the lower purlins of the skylight mounts may include within their
structure a hinge member adapted for attachment to a roof curb
hinge.
[0016] The skylight mounts, constructed of the rafters and purlins,
may include a top wall configured for abutment with a skylight lens
assembly gasket of a pre-assembled skylight lens assembly.
[0017] Adapted for receipt of a pre-assembled skylight lens
assembly, the pre-assembled skylight frame modules of the present
invention may include a screw receiver for receipt of screw
attachment of the pre-assembled skylight assemblies to the skylight
mounts.
[0018] Channels within the rafters of the skylight mounts may also
be provided. Similarly, the purlins of the skylight mounts may
include channels.
[0019] Further, at least one of the skylight frame modules of the
present invention may be adapted for attachment of skylight
accessories, such as awnings, shades, blinds, electrochromic
mechanisms and photovoltaic systems.
[0020] According to certain other aspects of the present invention,
a skylight frame system is provided, comprising at least two
pre-assembled skylight frame modules. Such pre-assembled skylight
frame modules are configured for side-by-side installation, each
such module including a first and second skylight mount. Each of
the first and second skylight mounts include opposed rafters, an
upper purlin and an opposed lower purlins, the rafters and purlins
interconnected to define a rectangular aperture between them.
Within such skylight frame system, each first and second skylight
mounts are attached together at their respective upper purlins.
Such attachment may be at an obtuse angle, thereby forming a gable,
or may be at 180 degrees. Further, the rafters between the modules
are configured for attachment one to the other, for instance at the
job site. The attachment of the first skylight mount and the second
skylight mount may be substantially rigid, for instance by
welding.
[0021] Each of the first and second skylight mounts are adapted for
engagement with a pre-assembled skylight lens assembly, of
predetermined size, over the rectangular apertures.
[0022] Some of the rafters of the skylight mounts may include
within them a secondary gutter, for drainage of water.
[0023] At least one of the lower purlins of one of the skylight
mounts of the skylight frame system herein may include a hinge
member adapted for attachment to a roof curb hinge. Alternatively,
a hinge may be connected with at least one of the lower purlins for
hingeable attachment to a roof curb.
[0024] The rafters of the skylight mounts of the within skylight
frame system may have substantially the same cross-sectional
configuration. Likewise, the purlins may have substantially the
same cross-sectional configuration.
[0025] The skylight frame system disclosed herein may include
skylight frame modules in which at least one of the rafters is
configured to engage with another rafter of an adjacent module upon
installation of the module side-by-side, one of the rafters having
a male member and the adjacent rafter having a complementary female
member configured to engage with the male member.
[0026] The skylight frame system may also include channels within
the rafters, or within the purlins, or within both.
[0027] The skylight frame system disclosed herein also may include,
with at least one of the skylight frame modules, configuration for
attachment of skylight accessories.
[0028] The rafters and purlins of the skylight mounts of the
skylight frame modules of the within skylight frame system may
include a top wall configured for abutment with a gasket carried by
a pre-assembled skylight lens assembly. Similarly, the rafters and
purlins may also include a screw receiver for receipt of screw
attachment of a pre-assembled skylight system.
[0029] Structural and operational details of preferred designs of
the modular skylight frame and system and components embodying the
invention and advantages obtained thereby will become apparent from
the appended drawings and the detailed description to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The aspects described above, as well as other apparent
aspects, advantages, and objectives of the present invention are
apparent from the detailed description below in combination with
the drawings. It should be noted that the appended drawings are not
necessarily to scale in all instances, but may have exaggerated
dimensions in some respect to illustrate the principles of the
invention.
[0031] FIG. 1 is a perspective, partially disassembled view of a
modular skylight system in accordance with certain aspects of the
present invention, with two pre-assembled skylight systems
installed thereupon along with two accessories;
[0032] FIG. 2 is a perspective view of a modular skylight frame
suitable for use in the system of FIG. 1, or alone;
[0033] FIG. 3A is a cross-sectional perspective view taken along
line B-B in FIG. 1;
[0034] FIG. 3B is a cross-sectional view of one exemplary
embodiment of one aspect of the present invention, taken along line
B-B in FIG. 1;
[0035] FIG. 3C is a cross-sectional view of an alternative
exemplary embodiment, taken along line B-B in FIG. 1;
[0036] FIG. 4A is a cross-sectional view of one embodiment, taken
along line C-C in FIG. 1;
[0037] FIG. 4B is a cross-sectional view of an alternative
exemplary embodiment, taken along line C-C in FIG. 1;
[0038] FIG. 5 is a cross-sectional perspective view of an exemplary
embodiment, taken along line D-D in FIG. 1;
[0039] FIG. 6 is a cross-sectional perspective view, taken along
line E-E in FIG. 1.
DETAILED DESCRIPTION
[0040] Reference will now be made in detail to the presently
preferred embodiments of the invention, one or more examples of
which are illustrated in the drawings. Each example is provided by
way of explanation of the invention, and is not meant as a
limitation of the invention. For example, features illustrated or
described as part of one embodiment may be used on another
embodiment to yield a still further embodiment. It is intended that
this application includes such modifications and variations as come
within the scope and spirit of the invention. Repeat use of
reference characters throughout the present specification and
appended drawings is intended to represent the same or analogous
features or elements of the invention.
[0041] FIG. 1 shows an exemplary embodiment of a modular skylight
frame system in accordance with certain aspects of the present
invention. The frame system, generally 10, is adapted for
installation about an opening through a building roof. The frame
system 10 may be used with new construction or may be used to
retrofit a newer skylight system to an existing building structure.
The system depicted in FIG. 1 illustrates six skylight apertures
and, as will be appreciated from the description below, is
constructed of three skylight frame modules. For illustration
purposes, two lens assemblies 20 are depicted on FIG. 1. Likewise,
each of the skylight lens assemblies 20 upon system 10 may include
an accessory 84.
[0042] FIG. 2 illustrates a modular skylight frame 15. Modular
skylight frame 15 includes first skylight mount 18 and second
skylight mount 19. Each of the skylight mounts includes an upper
purlin 30 and a lower purlin 40. Likewise, each of the two skylight
mounts includes a left rafter 50 and a right rafter 60. The rafters
and purlins of each skylight mount are interconnected to define
rectangular apertures therebetween; aperture 23 is defined within
first skylight mount 18 and aperture 24 is defined within second
skylight mount 19.
[0043] As illustrated in FIG. 2, upper purlins 30 of the respective
skylight mounts 18 and 19 are attached at purlin juncture 17. Such
attachment may be by weldment or by mechanical connection. In the
illustrated embodiment, purlin juncture 17 is configured to define
angle A between first skylight mount 18 and second skylight mount
19, thereby forming a gable.
[0044] It will be appreciated that system 10 depicted in FIG. 1
comprises three skylight frame modules 15, interconnected
side-by-side. Within the scope of this invention, combinations of
skylight frame modules 15, of matching rafter lengths and of either
equal or varying purlin lengths, may be used to constitute system
10. FIG. 3A, taken at line B-B in FIG. 1, illustrates the
attachment of a left rafter 50 of one such skylight module with a
right rafter 60 of an adjacent skylight module. As depicted in FIG.
3A, left rafter 50 is abutted against right rafter 60. Left rafter
50 may be attached to right rafter 60 by a variety of means,
including bolting, or by male-female interfitting configurations as
will be described below with reference to FIG. 3C. Still with
reference to FIG. 3A, rafters 50, 60 are understood to include
rafter grooves 51. Rafter grooves 51 are adapted for receipt of
screw attachment of pre-assembled skylight lens assemblies 20 upon
the skylight mounts. Such screws may be passed through the flashing
or other mounting structures of the pre-assembled skylight
assemblies, and received within rafter grooves 51 for secure
attachment of such pre-assembled skylight assemblies to the modular
skylight frame system 10.
[0045] Rafters 50, 60 may also be understood to include secondary
gutters 52. Secondary gutters 52, disposed lower than skylights
mounted upon rafters 50, 60, are configured for receipt of water
from above and shedding of such water out of the skylight system
10. Such water is prevented from entering beneath the skylight
assembly 10 by gutter cap 53, which bridges between the two
secondary gutters 52 of rafters 50, 60.
[0046] Also depicted in FIG. 3A is rafter cap 56. Rafter cap 56, in
cooperation with rafters 50, 60, forms channel 57. Rafter cap 56
may be installed after wiring, insulation, or the like is passed
through channel 57, thereby concealing such material from view and
presenting an aesthetically appealing outer surface, and may be
removable for later access to channel 57. Such wiring may be
utilized for accessories 84, such as awnings, shades, blinds,
electrochromic mechanisms, and photovoltaic systems.
[0047] With reference now to FIG. 3B, greater detail may be
understood as to one embodiment of rafters 50, 60. As depicted
therein, for example, rafter 50 may include a top wall 581. Top
wall 581 may include a gasket registration notch 32, adapted for
receipt of a skylight gasket 21 of a pre-assembled skylight lens
assembly 20. First wall 581, in cooperation with such a gasket 21,
allows for a weatherproof seal between rafter 50 and a skylight
lens assembly 20.
[0048] Rafter 50 may also include interior wall 582. Interior wall
582 is interior to system 10 and lies within the interior space of
building upon which system 10 is installed.
[0049] Rafter 50 may also include a third wall 583, in a preferred
embodiment generally perpendicular to first wall 581, and presented
for attachment to a skylight lens assembly 20 mounted thereon.
Third wall 583 may include rafter groove 51, for receipt of screw
attachment of skylight lens assembly 20 to rafter 50.
[0050] Rafter 50 may also include a fourth wall 584, in a preferred
embodiment generally perpendicular to third wall 583. Fifth wall
585 is connected with fourth wall 584, in a preferred embodiment
generally perpendicularly, and sixth wall 586 is connected to fifth
wall 585 generally perpendicularly in a preferred embodiment. Fifth
wall 585 and sixth wall 586 form two of the three sides of
secondary gutter 52. Secondary gutter 52 is completed by the upper
extension of seventh wall 587. Eighth wall 588, in a preferred
embodiment, is oriented generally perpendicularly and inwardly from
seventh wall 587. Finally, ninth wall 589 extends from eighth wall
588 to complete the cross-sectional configuration of one embodiment
of rafter 50.
[0051] As illustrated for example in FIG. 3B, a rafter cap 56 is
depicted attached to rafter 50. Rafter cap 56 may be configured for
snap-fit engagement with rafter cap cleats 590 on interior wall 582
and ninth wall 589.
[0052] In one embodiment, rafter 50 is attached to rafter 60 with
rafter bolt 54. Rafters 50, 60 may also include screw bosses 55,
for receipt of the head of rafter bolt 54. So configured, and with
the use of washer 58, rafter 50 may be attached to rafter 60 with
use of only a single wrench, as the head of rafter bolt 54 is kept
by a screw boss 55.
[0053] As illustrated in FIG. 3B, attachment together of rafters
50, 60 define between them a primary gutter 599. Primary gutter 599
is defined by respective opposing walls 583, respective fourth
walls 584, and gutter cap 53.
[0054] With reference to FIG. 3B, it will be understood that
rainwater falling upon a skylight lens assembly 20 may be shed off
of skylight lens frame 22 toward fourth wall 584, and shed from
system 10 by primary gutter 599. From there, water is prevented
from entering between rafters 50, 60 by gutter cap 53. Instead,
such water may be allowed to enter secondary gutter 52, and thereby
be shed from the system 10.
[0055] FIG. 3C illustrates an alternative embodiment for attachment
of adjacent rafters of modules 15. As depicted therein, left rafter
50' is attached to right rafter 60'. Such attachment is provided by
receipt of flange 93 within the gutter defined by alternative fifth
wall 585', alternative sixth wall 586', and wall 594. Alternative
seventh wall 587' is configured to attach directly to alternative
fourth wall 584, eliminating walls 585 and 586 from the alternative
embodiment depicted in FIG. 3B, to create a hidden standing seam
between rafters 50', 60'. Such configuration allows for attachment
of left rafter 50' to right rafter 60' without use of nuts or other
mechanical fasteners. Rainwater falling upon a skylight lens
assembly 20 may be shed from skylight lens frame 22 to fourth wall
584'. Such rainwater would either be shed from the system by fourth
wall 584', or may enter between walls 585' and 594, to be shed from
the system.
[0056] Comparison of FIGS. 3B and 3C illustrate that, in one
embodiment of the present invention depicted in FIG. 3B, left
rafter 50 and right rafter 60 may have cross-sections that are
substantially identical. As such, a beam extruded or otherwise
fabricated to form a left rafter 50 may be oriented reversely and
thus form a right rafter 60, with the two rafters 50, 60 thereby
attachable one to the other. Alternatively, in the embodiment
depicted in FIG. 3C, left rafter 50' differs from right rafter 60',
requiring a different extrusion or other formative process.
[0057] FIG. 4A illustrates a cross-sectional view of a purlin 40
attached to a curb 70. Purlin 40 may include a top wall 481,
including a gasket registration notch 32 for receipt of a skylight
lens assembly gasket 21. Purlin 40 may also include an interior
wall 482, oriented for presentment to the interior of the skylight
system 10 upon completion of installation. Lower purlin 40 may also
include third wall 483, disposed from the opposed end of top wall
481. Third wall 483 may include purlin groove 31, for receipt of
screw attachment of a skylight lens assembly 20. Oriented away from
third wall 483 is fourth wall 484, in a preferred embodiment at a
right outward angle from third wall 483. Fifth wall 487 is attached
to the end of fourth wall 484, in a preferred embodiment at
approximately right angle. Along the length of fifth wall 487 may
be included counterflashing flange 496, for receipt of and
attachment to counterflashing 75. Attached to fifth wall 487 is a
bottom wall 488, and extending from bottom wall 488 is lower wall
489. Interior wall 482 and bottom wall 489 may include cleats 490,
for snap-fit engagement with purlin cap 46. As will be observed,
lower purlin 40 and purlin cap 46 cooperate to form channel 491,
adapted for receipt and concealment of electrical wiring,
insulation, and the like.
[0058] Attached to bottom wall 488 may be male hinge piece 42,
which may be attached with hinge bolt 45. It is to be understood
that male hinge-piece 42 may be an elongated member, extending all
or part of the length of lower purlin 40. At installation, male
hinge piece 42 is slidably installed within female hinge piece 43,
and female hinge piece 43 may then be bolted or screwed to curb 70,
for example with curb bolt 44. Disposed between curb 70 and female
hinge piece 43 is curb flashing 71. Curb flashing 71 includes
inboard lip 72, configured to prevent drainage of condensation or
water to the interior of a building and instead to prompt drainage
of such water outboard of system 10. Curb flashing 71 may also
include outboard flange 73, for further protection of curb 70 from
water draining from curb flashing 71.
[0059] Lower purlin 40 may include a plurality of holes 499, for
drainage of condensation from within system 10.
[0060] FIG. 4B illustrates an alternative embodiment of lower
purlin 40, in which male hinge piece 42 is not a separate component
to be bolted to lower purlin 40, but instead male hinge piece 498
is a part of and extends outwardly from alternative bottom wall
488'.
[0061] FIG. 5 is a cross-sectional view taken at line D-D of FIG.
1, showing the attachment of upper purlins 30 of two skylight
mounts 18, 19 in a skylight frame module 15. As shown therein, two
upper purlins 30 are attached at purlin juncture 17. Purlin
juncture 17 is understood to the point of proximity of the
respective intersections 390 of walls 387 and bottoms 488 of the
upper purlins 30 of skylight mounts 18, 19. Such attachment may be
by way of mechanical attachment (not shown) or by weldment. In the
case of weldment, such weldment may be along the entirety of the
lengths of upper purlins 30, or only a portion or portions of such
length.
[0062] Also as shown in FIG. 5, an alternative purlin cap 46' is
depicted, for comparison with purlin cap 46 depicted in FIG. 4A.
Between upper purlin 30 and purlin cap 46' is defined channel
491.
[0063] Purlin juncture 17 is provided to attach upper purlins 30 at
angle A.
[0064] Also as depicted in FIG. 5, top cap 16 is disposed at top
walls 484 of the respective upper purlins 30 to prevent intrusion
of water to purlin juncture 17, and may be weatherproofed thereto
with caulking, gasketing, or the like. Top cap 16 may be attached
by conventional methods.
[0065] Comparison of lower purlin 40 in FIG. 4A to upper purlins 30
in FIG. 5 reveals that the same cross-sectional configuration may
be used for lower purlins 40 and upper purlins 30. Alternatively,
different cross-sectional configurations may be used, as revealed
by comparison of the alternative lower purlin 40' in FIG. 4B to the
upper purlins 30 in FIG. 5.
[0066] FIG. 6 illustrates the cross-sectional view of an exemplary
end glazing panel, to close the ends of the skylight system 10. As
depicted therein, glazing rails 83 may carry glazing panels 85, and
are configured for attachment to right rafter 60 and curb 70. An
alternative end cap seal 81 may be provided for attachment to right
rafter 60, in snap-fit engagement to cleat 591 and glazing rail 83.
Alternatively, solid panels (not shown) may be used to clear the
ends of system 10. Ridge joint end cap 86 may be used in
cooperation with top cap 16 to close the end of system 10.
[0067] Consideration of the foregoing description illustrates that
system 10 may be adapted for a wide variety of skylight
applications. For a skylight opening of a given length and width,
only three variables need be considered. First, from the available,
standardized pre-assembled skylight systems commercially available,
which length and width may be chosen for the intended length and
width of skylight opening. Once such selection is made, angle A may
be calculated. For example, an opening six and a half feet wide and
twenty feet long might result in the selection of standardized,
pre-assembled 4.times.4 foot skylight assemblies. Angle A may then
be calculated to be approximately 93 degrees, and five
pre-assembled skylight frame modules could be constructed
accordingly. Thereafter, each such module approximately
4.times.61/2 feet in footprint, could be stacked one atop the
other, shipped to the site, carried by hand to the skylight
opening, and assembled thereon with simple and few tools.
Thereafter, ten such 4.times.4 foot standardized pre-assembled
skylight assemblies could be installed upon the constructed
skylight frame system. Male hinge piece 42 (FIG. 4A) and female
hinge piece 43 allow for a broad range of such gable angles A, such
as 90.degree. to 180.degree., and attachment of upper purlins 30
together result in a rigid frame producing minimal lateral stress
upon curb 70.
[0068] System 10 provides for superior drainage of rainwater from
system 10. For example, rainwater falling upon top cap 16 would be
shed to fourth wall 484 (FIG. 3B). Such rainwater may flow from
fourth wall 484, or may flow into secondary gutters 52. In either
event, such rainwater would flow from the rafters 50, 60 and be
disposed outboard of system 10 upon counter flashing lip 76 (FIG.
4A) to the roof.
[0069] It will also be observed that the skylight mounts 18, 19
(FIG. 2, for example) also are adapted for receipt of accessories.
For example, rafters 50, 60 are structurally rigid to support such
systems and are capable of accepting interior shade accessories.
The pre-assembled skylight frame modules 15 are also capable of
accepting exterior awning accessories and the like. Furthermore,
upper purlins 30 and lower purlins 40 are structurally rigid to
support hinges and electrical ventilation operators, for opening
the skylight lens assemblies 20 for example.
[0070] While the invention shown herein is capable of attaining the
objects of the invention, it is to be understood that it is the
presently preferred embodiments of the present invention and is
thus representative of the subject matter that is broadly
contemplated. It is to be further understood that the scope of the
present invention fully encompasses other embodiments that may
become obvious to those skilled in the art. It is intended that the
present invention include such modifications and variations as come
within the scope of the appended claims and their equivalents, in
which reference to an element in the singular is not intended to
mean "one and only one" unless explicitly so stated, but rather
"one or more."
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