U.S. patent application number 10/944714 was filed with the patent office on 2006-04-06 for knock-down roof curb.
Invention is credited to Richard R. McClure.
Application Number | 20060070315 10/944714 |
Document ID | / |
Family ID | 36119203 |
Filed Date | 2006-04-06 |
United States Patent
Application |
20060070315 |
Kind Code |
A1 |
McClure; Richard R. |
April 6, 2006 |
Knock-down roof curb
Abstract
A standardized, corrosion-resistant roof curb that can be
shipped in a disassembled state, which an installer may assemble,
size, locate and configure to provide an appropriate roof slope on
any roof without welding, includes a panel and an extrusion
configured to receive the panel, wherein the panel is trimmed
according to the pitch of the roof. Methods of making and
installing the roof curb also are disclosed.
Inventors: |
McClure; Richard R.;
(Basehor, KS) |
Correspondence
Address: |
SHOEMAKER AND MATTARE, LTD
10 POST OFFICE ROAD - SUITE 110
SILVER SPRING
MD
20910
US
|
Family ID: |
36119203 |
Appl. No.: |
10/944714 |
Filed: |
September 21, 2004 |
Current U.S.
Class: |
52/200 |
Current CPC
Class: |
E04D 13/0315
20130101 |
Class at
Publication: |
052/200 |
International
Class: |
E04B 7/18 20060101
E04B007/18 |
Claims
1. Roof curb comprising: a panel; and an extrusion configured to
receive said panel; wherein said panel is trimmable according to a
roof pitch.
2. Roof curb of claim 1, wherein said extrusion is constructed of
aluminum.
3. Roof curb of claim 1, wherein said extrusion is configured to
provide continuous contact along the roof.
4. Roof curb of claim 3, wherein said extrusion is configured to
provide continuous contact along a rib in the roof.
5. Roof curb of claim 1, further comprising: a second extrusion;
and a connection block for interconnecting said extrusion and said
second extrusion.
6. Roof curb of claim 1, further comprising a channel configured to
mount on a building to support said extrusion.
7. Roof curb of claim 6, further comprising: a second extrusion
that is connectable with said extrusion; and a second channel
configured to mount on said channel to support said second
extrusion.
8. Roof curb of claim 1, further comprising a diverter angle
configured to mount on said extrusion.
9. Roof curb of claim 8, further comprising: a channel configured
to mount on a building to support said extrusion; and a diverter
plate configured to mount on said channel for supporting said
diverter angle.
10. Method of making a roof curb comprising: providing a roof curb
kit including an extrusion; determining a curb size; and cutting
the extrusion according to said determining.
11. Method of claim 10, wherein the extrusion is configured to
accommodate a roof rib; said method further comprising ascertaining
an orientation of the extrusion relative to a roof rib to provide
continuous contact along the roof and rib; wherein said cutting
corresponds to said ascertaining.
12. Method of claim 10, wherein: said cutting produces a sized
extrusion; and the roof curb kit includes a connection block; said
method further comprising: cutting a second extrusion according to
said determining, defining a second sized extrusion; and
interconnecting the sized extrusion and the second sized extrusion
with the connection block.
13. Method of claim 12, further comprising, prior to said
interconnecting, drilling holes in at least one of the sized
extrusion and the second sized extrusion corresponding to passages
in the connection block.
14. Method of claim 12, further comprising, prior to said
interconnecting, applying sealant to one or both of the connection
block and the sized extrusion or second sized extrusion.
15. Method of claim 10, wherein the kit includes a panel, further
comprising mounting the panel on the extrusion.
16. Method of claim 15, further comprising trimming the panel
according to a roof pitch.
17. Method of installing a roof curb comprising: attaching a roof
curb base to a roof; trimming a panel according to a roof pitch;
and mounting the panel on the roof curb.
18. Method of claim 17, further comprising, prior to said
attaching, cutting the roof according to the roof curb base and a
diverter plate.
19. Method of claim 18, further comprising, between said cutting
and said attaching, installing the diverter plate.
20. Method of claim 19, further comprising mounting a diverter
angle on the roof curb base and the diverter plate.
Description
BACKGROUND OF THE INVENTION
[0001] Metal buildings having metal roofing have become popular for
commercial, industrial and warehousing uses. These buildings often
require roof openings for skylights, fans, air conditioning units
and the like. The installation of such equipment requires a roof
curb for support.
[0002] Traditionally, roof curbs have been designed specifically
and custom made to provide a relatively horizontal mounting
structure for a particular rooftop appliance given the shape and
pitch of a particular roof. Designing and building these
traditional roof curbs, often formed from a singular piece of metal
to uniquely accommodate a particular roof pitch, has been a
laborious and time consuming task for roof curb manufacturers and
rooftop appliance installers. Further, because these roof curbs are
installed in a metal roof system, the actual opening may vary with
respect to the roof panel corrugations, seams or ribs, which may be
ascertainable only shortly before installation. This untimely
design-and-build practice delays appliance installation.
[0003] Manufacturers developed standardized roof curbs to help
limit installation delays. See, for example, U.S. Pat. No.
4,559,753, issued Dec. 24, 1985, to Ralph H. Brueske, for Method of
Installing a Prefabricated Curb Unit to a Standing Seam Roof, which
describes a method of installing a metal roof curb in which the
rims of the curbs are pre-welded to a roof panel, and the curb
containing-panel is attached to a large opening cut into the roof.
However, this method requires cutting a hole in the roof that is
larger than the opening for the equipment that may be susceptible
to leakage.
[0004] Prefabricated roof curbs tend to be quite large, thus have
been difficult to ship in a cost effective and timely fashion, let
alone by traditional rapid delivery methods. Consequently, roof
curb manufacturers have had to ship their products by truck, which
is slower and more expensive.
[0005] Traditional roof curbs include four coated steel curb walls
positioned to define an open rectangular frame joined by factory
welding at the corners. Because welding burns off the corrosion
resistant coating of the steel, the manufacturer or installer must
provide an additional coating of rust inhibitor paint to keep the
roof curb from rusting when installed on the roof. Routine rust
inhibitor paint coatings are required to protect the roof curb
throughout the life of the product. Mechanical attachment, such as
with threaded fasteners, may secure the corners without welding.
However, on-site sizing and drilling of traditional roof curb
panels creates exposure to corrosive weathering.
[0006] What is needed is a standardized, corrosion-resistant roof
curb that can be shipped in a disassembled state, which an
installer may assemble, size, locate and configure to provide an
appropriate roof slope on any roof without welding.
SUMMARY OF THE INVENTION
[0007] The invention is a standardized, corrosion-resistant roof
curb that can be shipped in a disassembled state, which an
installer may assemble, size, locate and configure to provide an
appropriate roof slope on any roof without welding.
[0008] The invention provides improved elements and arrangements
thereof, for the purposes described, which are inexpensive,
dependable and effective in accomplishing intended purposes of the
invention.
[0009] An embodiment configured according to principles of the
invention includes an aluminum panel and an extrusion configured to
receive the panel, wherein said panel is trimmed according to the
pitch of the roof.
[0010] Other features and advantages of the invention will become
apparent from the following description of the preferred
embodiments which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention is described in detail below with reference to
the following figures, throughout which similar reference
characters denote corresponding features consistently, wherein:
[0012] FIG. 1 is an environmental perspective view of an embodiment
constructed according to principles of the invention;
[0013] FIG. 2 is an exploded environmental perspective view of the
embodiment of FIG. 1;
[0014] FIG. 3 is an environmental perspective view of a portion of
the embodiment of FIG. 1;
[0015] FIG. 4 is a cross-sectional detail view drawn along line
IV-IV in FIG. 2;
[0016] FIG. 5 is an environmental perspective view of another
embodiment constructed according to principles of the
invention;
[0017] FIG. 6 is an exploded environmental perspective view of the
embodiment of FIG. 5;
[0018] FIG. 7 is a flow chart of a method of making the embodiment
of FIG. 1;
[0019] FIG. 8 is a schematic representation of the embodiment of
FIG. 7;
[0020] FIG. 9 is a flow chart of a method of making the embodiment
of FIG. 5;
[0021] FIG. 10 is a schematic representation of the embodiment of
FIG. 9;
[0022] FIG. 11 is a flow chart of a method of installing the
embodiment of FIG. 1;
[0023] FIG. 12 is a schematic representation of the embodiment of
FIG. 11;
[0024] FIG. 13 is a flow chart of a method of installing the
embodiment of FIG. 5; and
[0025] FIGS. 14a and 14b are a schematic representation of the
embodiment of FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring to FIGS. 1-3, an embodiment of a roof curb 100
configured according to the invention includes four walls 105
interconnected with four connection blocks 110, defining a roof
curb base 112, for mounting on a roof R. Four composite boards 115
mount on walls 105 and support an appliance (not shown).
[0027] In practice, walls 105 are cut into standardized lengths
that foster ready packaging in standard shipping containers along
with other components described herein for conventional or
overnight courier delivery. Aluminum extrusion stock permits
on-site sizing of the standard pieces without local burning off of
corrosion resistant coatings ordinarily required for steel stock.
Using aluminum stock also eliminates routine rust inhibitor paint
coatings that would be required to protect steel stock.
[0028] Referring also to FIG. 4, each wall 105 is constructed of
extruded aluminum having a lower flange 120 and an upper channel
125. Each flange 120 is inwardly-disposed to limit exposure of
fasteners and other mounting mechanisms and sealing to the
elements. Each flange 120 has chamfered ends 130 that promote
flushness along the entire contacting surface of flange 120 with
roof R.
[0029] Each channel 125 is configured to receive and retain a
composite board 115. Channels 125 are inwardly disposed so as to
define, in conjunction with wall 105, a generally uniform vertical
wall 127 without ledges or partial enclosures that might find favor
with unwanted insects and vermin.
[0030] Flange 120, vertical wall 127 and channel 125 define a
pocket 128 for receiving insulation, as described below.
[0031] Side walls 105a have an edge 107a that provides a
continuous, water-tight seal with roof R. Top and bottom walls 105b
have notches 109 for alignment with and accommodation of seams or
ribs F extending from roof R, thus defining an edge 107b that also
provides a continuous, water-tight seal with roof R.
[0032] Referring to FIG. 3, each connection block 110 is
constructed from aluminum and has pre-drilled throughbores 114 at
predetermined locations. In practice, a roof curb installer
introduces holes at the ends of walls 105 according to a template,
as shown in FIG. 8, that register with throughbores 114.
[0033] Preferably, composite boards 115 are Trex.RTM. boards, which
are constructed from a combination of reclaimed wood and plastic.
The plastic component shields the wood component from moisture and
insect damage, reducing or eliminating rotting or splintering. The
wood component protects the plastic component from ultraviolet
radiation damage from ordinary sunlight, ensuring integrity longer
than would be expected from products constructed from purely
plastic or purely wood.
[0034] As shown in FIG. 2, unique to roof curb 100 is a top support
channel 135. Top support channel 135 is similar to bottom support
channel 140, which is common to roof curb 100 and roof curb 200, as
shown in FIG. 6. Top support channel 135 and bottom support channel
140 each have generally perpendicular ribs 136 and 141,
respectively. Ribs 136, 141 strengthen and enhance top support
channel 135 and bottom support channel 140 load bearing
capabilities.
[0035] Top support channel 135 has flanges 137 and bottom support
channel 140 has flanges 143 that mount onto structural members S
supporting roof R. When installed, top support channel 135 and
bottom support channel 140 each support a wall 105b, and support
members S support the remaining walls 105a.
[0036] Referring to FIGS. 5 and 6, another embodiment of a roof
curb 200 configured according to the invention provides for
diverting water that otherwise might accumulate along the upper,
laterally-extending intersection of roof R and roof curb 200. The
water diverting feature of roof curb 200 is intended for larger
installationsthat would be susceptible to collecting large amounts
of water. Roof curb 200 includes four walls 205 interconnected with
four connection blocks 210, defining a roof curb base 212, that
mounts on roof R. Four composite boards 215 mount on walls 205 and
support an appliance (not shown). Roof curb 200 is similar to roof
curb 100, except as described below.
[0037] As shown in FIGS. 5 and 6, unique to roof curb 200 are a
diverter plate 235 and a diverter angle 245. Diverter plate 235
covers a portion of roof R removed so that ribs F in roof R do not
prevent flush mounting of diverter angle 245 on roof R against roof
curb 200. Like top support channel 135, diverter plate 235 has
strengthening ribs 236 for supporting wall 205 and diverter angle
245.
[0038] Diverter angle 245 has upstanding flanges 247 that define an
impervious dihedral angle 249. Angle 249 is such that flanges 247
provide a flow path for water to pass around roof curb 200, rather
than collect against the upwardly disposed wall 205, which, over
time, might cause local corrosion or sealant failures. Diverter
angle 245 is sealingly connected to diverter plate 235. In
operation, water flowing down roof R toward roof curb 200 would
encounter then flow along flanges 247, then onto the portion of
roof R lateral to roof curb 200, thereby bypassing roof curb 200
and continuing to flow down roof R.
[0039] Referring to FIG. 7, an embodiment of a method of making 300
roof curb 100 configured according to the invention includes: a
step 305 of determining curb size; a step 310 of cutting
extrusions; a step 315 of cutting bottom extrusion; a step 320 of
cutting steel channels; a step 325 of drilling corner connections;
a step 330 of applying corner block mastic; a step 335 of
assembling extrusion corners; a step 340 of determining composite
board dimensions; and a step 345 of cutting composite boards.
[0040] Referring also to FIG. 8, step 305 involves determining a
curb size to ascertain a curb length for walls 105a, as shown in
FIG. 1, and a curb width for walls 105b, top support channel 135
and bottom support channel 140, as shown in FIG. 2.
[0041] Step 310 involves cutting the side extrusions or walls 105a
according to the curb length of step 305. Preferably, a roof curb
assembler uses a 12-inch compound-sliding miter-saw with a carbide
tooth blade for cutting aluminum. Mitering the interfaces among
walls 105 promotes relative flushness as well as flushness with
respect to roof R.
[0042] Step 315 involves cutting the top and bottom extrusions or
walls 105b according to the curb width of step 305. Step 315
differs from step 310 in that a roof curb assembler must cut walls
105b so as to accommodate seams or corrugations in roof R.
[0043] Step 320 involves cutting top support channel 135 and bottom
support channel 140 according to the curb width of step 305.
Preferably, a roof curb assembler uses an angle grinder with cutoff
blade. Top support channel 135 and bottom support channel 140 also
may require notching to accommodate roof support structures.
[0044] Step 325 involves aligning a template relative to and
drilling pilot holes through walls 105 so as to register with
throughbores 112 in connection blocks 110. A roof curb assembler
temporarily maintains relative positioning of the template and
walls 105 with a locking C-clamp. The roof curb assembler drills
two 5/16-inch diameter holes at each end of each of walls 105.
[0045] Step 330 involves applying a 5/16-inch diameter bead of gun
grade sealant, preferably Panlastic, to the top, bottom and corner
of each of corner blocks 110 with a caulking gun. This provides
roof curbs 100 and 200 with an integral water-tight seal that is
superior to post-installation sealant treatments common to other
roof curbs.
[0046] Step 335 involves driving 1/4-inch.times.1/2-inch phillips
head bolts through the holes in walls 105 and corner connection
blocks 110. Tightening the bolts urges walls 105 and corner
connection blocks 110 to come together, and urges the mastic
applied to corner connection blocks 110 at step 330 to flow into
any gaps, thereby sealing the joint.
[0047] Step 340 involves determining the slope or pitch of roof R,
and an appropriate measurement for the "X" dimension shown in FIG.
8, corresponding to the pitch so that composite boards 115 provide
a generally level mounting area for an appliance (not shown). The
"Y" dimension is fixed, preferably at 5-1/2 inches. Preferably,
stock Trex.RTM. boards 115 for cutting are
5/4-inch.times.6-inches.
[0048] Step 345 involves using a circular, table or radial-arm saw
equipped with a wood-cutting carbide blade to cut stock Trex.RTM.
boards 115 as required to fit tightly in channels 125.
[0049] Referring to FIG. 9, an embodiment of a method of making 500
roof curb 200 configured according to the invention includes: a
step 505 of determining curb size; a step 510 of cutting
extrusions; a step 515 of cutting bottom extrusion; a step 520 of
cutting steel channels; a step 523 of cutting diverter plate; a
step 525 of drilling corner connections; a step 530 of applying
corner block mastic; a step 535 of assembling extrusion corners; a
step 540 of determining composite board dimensions; and a step 545
of cutting composite boards.
[0050] Referring also to FIG. 10, method of making 500 is
substantially identical to method of making 300 except for an
additional step 523. Step 523 involves cutting diverter plate 235
according to the curb width determined at step 505, which is
similar to step 305. A roof curb assembler must cut diverter plate
235 so as to accommodate seams, corrugations or ribs F in roof R.
Specifically, holes in diverter plate 235 must align with ribs
F.
[0051] Referring to FIG. 11, an embodiment of a method of
installing 400 roof curb 100 configured according to the invention
includes: a step 405 of marking roof for cutout; a step 410 of
placing walkboards for support; a step 415 of cutting panel; a step
420 of installing side support channels; a step 425 of installing
rear support channel; a step 430 of applying mastic for curb; a
step 435 of installing curb base; a step 440 of cleaning area; a
step 445 of applying sealant; a step 450 of applying mastic; a step
455 of installing composite boards; a step 460 of applying foam
tape and sealant at board joints; a step 465 of cutting out
insulation; and a step 470 of installing retainers.
[0052] Referring also to FIG. 12, step 405 involves placing roof
curb 100, as assembled above, onto the portion of roof R where an
appliance is desired. Bottom wall 105b should vertically register
with supporting structural purlin. A minimum 6-inch distance should
exist between top wall 105b and the upper supporting structural
purlin. A roof curb installer then traces along the interior of
flanges 120 of roof curb 100 with a standard lead or grease
pencil.
[0053] Step 410 involves disposing boards or paneling, having
sufficient strength to maintain a roof curb installer's weight on
roof R, just outside of the tracing generated in step 405,
proximate to where the roof curb installer will cut roof R.
[0054] Step 415 involves drilling 1/2-inch starter holes in roof R
at each corner of the tracing of step 405, then using a double-cut
shear, which minimizes shavings and chips, to cut roof R along the
tracing. A roof curb installer will need a reciprocating saw to cut
through corrugations in roof R.
[0055] Step 420 involves sizing and temporarily clamping in place
side support channels on top of any insulation and between the
upper supporting structural purlin and lower supporting structural
purlin, just outside of the lateral edges of the hole in roof R
generated at step 415.
[0056] Step 425 involves sizing and temporarily clamping in place a
bottom support channel between the side support channels installed
in step 420, just outside of the bottom edge of the hole in roof R
generated at step 415.
[0057] Step 430 involves inserting lockseam plugs on the bottom
corrugations occurring along the bottom edge of the hole in roof R
generated at step 415. Once installed, the lockseam plugs may be
filled with mastic. A roof curb installer applies
1/8-inch.times.1/2-inch Panlastic tape over the lockseam plugs
around and aligned with the edges defining the hole in roof R. The
tape should be butted, not lapped, at corners. Finally, the roof
curb installer applies a continuous bead of sealant on top of the
tape.
[0058] Step 435 involves positioning roof curb 100 over the
prepared hole in roof R and securing flanges 120 of roof curb 100
to the support channels with self-drilling 1/4-inch.times.7/8-inch
metal screws at six-inch intervals.
[0059] Step 440 involves sweeping or vacuuming away all metal chips
and shavings.
[0060] Step 445 involves applying a continuous bead of sealant
around the intersection of roof R and roof curb 100.
[0061] Step 450 involves applying gun grade mastic in the outer
corner of channels 125 of walls 105 and to the butt ends of
composite boards 115.
[0062] Step 455 involves attaching composite boards 115 to walls
105 with self-drilling 1/4-inch.times.7/8-inch metal screws, and to
adjoining composite boards 115 with self-drilling #6.times.2-inch
screws.
[0063] Step 460 involves applying sealant along the joint between
walls 105 and composite boards 115. The roof curb installer then
applies foam tape on the top surfaces of the composite boards
115.
[0064] Step 465 involves trimming a four-inch wide roll of
insulation from building scrap. The roof curb installer places the
insulation in pocket 128 in walls 105 defined by channel 125,
vertical wall 127 and flange 120, as shown in FIG. 4. Temporary
adhesive may aid in retaining the insulation in pocket 128. The
roof curb installer then slits the building insulation from each
roof curb corner inwardly, then removes the insulation from the
facing. The roof curb installer folds the facing up each inner side
of roof curb 100 and secures the folds thereto with retainers and
self-drilling screws. The roof curb installer then tapes each
corner to seal vapor retarder completely.
[0065] Referring to FIG. 13, an embodiment of a method of
installing 600 roof curb 200 configured according to the invention
includes: a step 605 of marking roof for cutout; a step 607 of
marking roof for diverter plate; a step 615 of cutting panel; a
step 620 of installing side support channels; a step 625 of
installing rear support channel; a step 627 of preparing diverter
plate; a step 628 of installing diverter plate; a step 630 of
applying mastic for curb; a step 635 of installing curb base; a
step 637 of preparing diverter angle; a step 638 of installing
diverter angle; a step 640 of cleaning area; a step 645 of applying
sealant; a step 650 of applying mastic; a step 655 of installing
composite boards; a step 660 of applying foam tape and sealant at
composite board joints; a step 665 of cutting out insulation; and a
step 670 of installing retainers.
[0066] Referring also to FIGS. 14A and 14B, method of installing
600 is substantially identical to method of installing 400 except
for steps 607, 627, 628, 637 and 638. Step 607 involves placing
diverter plate 235 adjacent to the top edge of the tracing
generated in step 605, which is similar to step 405, and tracing
around diverter plate 235.
[0067] Step 627 involves attaching corrugation plugs to diverter
plate 235 over the holes aligned with ribs F in roof R. The roof
curb installer applies tape Panlastic over the side and outer edges
of diverter plate 235, being careful to butt and not lap the ends,
so that a minimum of 1/4 inch is exposed around the panel cut out.
The roof curb installer applies gun grade mastic over the tape
Panlastic.
[0068] Step 628 involves placing diverter plate 235 in the cutout
in roof R so that corrugation plugs snugly fit in the corrugations
in roof R. Self-drilling threaded fasteners secure diverter plate
to roof R. Mastic must be applied around holes on the bottom side
of the panel strips.
[0069] Step 637 involves applying a 5/16-inch bead of mastic to the
back and 1/8-inch.times.11/2-inch tape Panlastic to bottom of
diverter angle 245, then positioning diverter angle 245 against
roof curb 200 on roof R.
[0070] Step 638 involves securing diverter angle 245 to roof curb
200 and roof R with self-drilling threaded fasteners.
[0071] The invention is not limited to the particular embodiments
described herein, rather only to the following claims.
* * * * *