U.S. patent application number 11/758926 was filed with the patent office on 2008-12-11 for fenestration product such as a skylight having a laminated glazing unit.
Invention is credited to John E. Nemazi, G. Daniel Templeton, Arthur J. Valentz.
Application Number | 20080302032 11/758926 |
Document ID | / |
Family ID | 40094567 |
Filed Date | 2008-12-11 |
United States Patent
Application |
20080302032 |
Kind Code |
A1 |
Valentz; Arthur J. ; et
al. |
December 11, 2008 |
Fenestration Product Such as a Skylight Having a Laminated Glazing
Unit
Abstract
A fenestration is provided having a peripheral frame defining a
frame opening, the frame being adapted to being installed upon an
opening in a building panel. Cooperating with the peripheral frame
is a laminated panel which is structurally mounted to and sealingly
spans the peripheral frame opening to form a structural and leak
proof interconnection. The laminated panel is formed of three
structural layers; an outer and inner plastic sheet and a resin
layer interposed therebetween which are collectively bonded
together to form a structural laminate, the laminated panel being
capable of transmitting visible light therethrough.
Inventors: |
Valentz; Arthur J.; (Sugar
Land, TX) ; Nemazi; John E.; (Bloomfield Hills,
MI) ; Templeton; G. Daniel; (Ft. Wayne, IN) |
Correspondence
Address: |
BROOKS KUSHMAN P.C.
1000 TOWN CENTER, TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075
US
|
Family ID: |
40094567 |
Appl. No.: |
11/758926 |
Filed: |
June 6, 2007 |
Current U.S.
Class: |
52/200 |
Current CPC
Class: |
E04D 13/03 20130101;
E04D 2013/0345 20130101 |
Class at
Publication: |
52/200 |
International
Class: |
E04D 13/03 20060101
E04D013/03 |
Claims
1. A skylight assembly, the assembly comprising: a peripheral frame
defining an opening; and a laminated panel having a periphery, the
panel cooperating with the peripheral frame and spanning the
opening, the laminated panel having a first sheet of plastic, a
second sheet of plastic, and an interposed layer of resin between
the first and second sheets of plastic, the first sheet being
bonded to the resin layer, the resin layer being bonded to the
second sheet, the laminated panel being selectably formable into a
three-dimensional shape.
2. The skylight assembly of claim 1, wherein the frame is a single
piece frame.
3. The skylight assembly of claim 2, wherein a portion of the
laminated panel is overmolded by the frame forming a watertight
seal when measured by ASTM E547-00 and ASTM E331-00.
4. The skylight assembly of claim 2, wherein the single piece frame
includes a curb.
5. The skylight assembly of claim 1, wherein the laminated panel is
formed in the shape of an outwardly convex dome.
6. The skylight assembly of claim 1 wherein the dome comprises a
thermoformed laminated panel.
7. The skylight assembly of claim 1, wherein the layer of resin
includes polyvinyl butyral, ethylene vinyl acetate or
polyurethane.
8. The skylight assembly of claim 1, wherein at least one sheet of
plastic includes an acrylic, a polycarbonate, a terephthalate, a
vinyl, or a polyolefin sheet.
9. The skylight assembly of claim 8, further including a
mar-resistant layer adjacent to the plastic sheet.
10. The skylight assembly of claim 1, further comprising: a third
sheet of plastic, wherein the third sheet of plastic and the second
sheet of plastic define a cavity spanning a portion of the
opening.
11. The skylight assembly of claim 1, further having a reflective
interior surface positioned below the opening.
12. The skylight assembly of claim 11, wherein the reflective
interior surface has an end adjacent to a roof member.
13. The skylight assembly of claim 1, further including a light
pipe cooperating with the laminated panel, the light pipe extending
to an interior room below the roof.
14. A skylight assembly comprising: a laminated panel having a
periphery, the laminated panel including a first sheet of plastic,
a second sheet of plastic, and a layer interposed between the first
sheet and the second sheet, the laminated panel being shaped into a
convex configuration; and a peripheral frame defining an opening,
the frame being configured to connect to a roof and defining an
opening, wherein the laminated panel spans the opening.
15. The skylight assembly of claim 14, wherein the peripheral frame
is formed of a moldable polymeric material entrapping the periphery
of the laminated panel and forming a leak-tight structural joint
therewith, where the structural aspect of the joint is measured
according to ASTM E330-02 at a positive/negative load exceeding 250
pounds per square foot, the leak-tightness aspect of the joint
being measured according to ASTM E547-00 and ASTM E331-00, allowing
no leakage.
16. The skylight assembly of claim 14, the laminated panel passing
tests TAS201 and TAS203, wherein no cracks or tears occur at less
than 90 pounds per square foot when measured according to
TAS203.
17. The skylight assembly of claim 14, wherein at least one sheet
of plastic is comprised of an acrylic, a polycarbonate, a
terephthlate, a vinyl, or a polyolefin plastic.
18. The skylight assembly of claim 14, wherein the first sheet and
the second sheet are comprised of different plastics.
19. The skylight assembly of claim 14, wherein the peripheral frame
is formed of a material including at least one of a reaction
injection molding material, a thermoplastic material, or a material
filled with reinforcing fibers.
20. A method for making a skylight assembly, comprising: forming a
laminated panel having a periphery by providing a first sheet of
plastic, providing a second sheet of plastic, bonding the first and
second sheets together by interposing a resin layer therebetween;
attaching a frame to the periphery of the laminated panel, the
frame adapted to receive the periphery of the laminated panel and
configured to be connected to a roof.
21. The method of claim 20, wherein at least one sheet comprises an
acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin
material.
22. The method of claim 20, wherein the resin layer includes
polyvinyl butyral, ethylene vinyl acetate, or polyurethane.
23. The method of claim 20, wherein the frame is a single piece
frame.
24. The method of claim 23, wherein attaching the single piece
frame includes applying a plastic adjacent to the periphery of the
laminated panel.
25. The method of claim 24, wherein the plastic includes a
thermoset material, a thermoplastic material, or a fiber reinforced
plastic.
26. A method for making a skylight assembly, comprising: providing
a first sheet of plastic having a first melting point; providing a
second sheet of plastic having a second melting point; providing a
layer of resin interposed between the first sheet of plastic and
the second sheet of plastic; forming a laminated panel including
the first sheet of plastic, the second sheet of plastic, and the
interposed layer of resin; degassing the laminated panel to remove
a gas from between the first sheet of plastic, the second sheet of
plastic, and the interposed resin layer; positioning the laminated
panel within a first mold half; warming the laminated panel to a
temperature less than the lesser of the first or the second melting
points; conforming the laminated panel to the first mold half;
removing the formed laminated panel from the first mold half;
positioning the formed laminated panel in a closed mold; closing
the closed mold; injecting a plastic adjacent to the periphery of
the formed laminated panel, to form a continuous frame between the
frame and the laminated panel; opening the mold; and removing the
skylight assembly.
27. The method of claim 26, wherein at least one sheet of plastic
includes an acrylic, a polycarbonate, a terephthalate, a vinyl, or
a polyolefin sheet.
28. The method of claim 26, wherein the resin includes polyvinyl
butyral, ethylene vinyl acetate copolymer, or polyurethane.
29. The method of claim 26, wherein the plastic injected adjacent
to the periphery of the laminated panel includes a reaction
injection molded plastic, a thermoset, a thermoplastic, or a fiber
reinforced plastic.
30. A fenestration product for installation within a building
opening, the fenestration product comprising: a peripheral frame
defining a frame opening and the laminated panel cooperating with
the peripheral frame and spanning the opening to provide a
structural water-tight connection, a panel formed of three
structural layers; a first outer plastic layer, a second inner
plastic layer and an intermediate resin layer interposed
therebetween, laminated together to form a structural member;
wherein the peripheral frame is formed of a single piece of
polymeric material which is molded in situ about the outer
periphery of the laminated panel.
31. The fenestration product of claim 30, wherein the fenestration
product passing tests TAS 201 and TAS 203, wherein no cracks or
tears occur at less than 90 lbs. per square when measured according
to TAS 203.
32. The fenestration product of claim 30, wherein the laminated
panel includes a three-dimensional shape.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fenestration products,
particularly, a skylight having a laminated glazing unit.
[0003] 2. Background Art
[0004] Fenestration building products have been used to allow light
into residential, commercial, and industrial buildings and
typically fit in an opening in the building. Examples of
fenestration products include skylights and tubular skylights.
Skylights typically do not require the same degree of optical
quality of windows. Therefore, low cost and lightweight plastic
panels can be used in place of glass. Skylights are typically
formed of a light transparent panel of glass or plastic mounted in
a peripheral frame formed of wood, metal or extruded plastic. In
order to achieve structural rigidity the plastic panels are
frequently outwardly domed in a convex manner, the peripheral edges
of the plastic panels being mounted in a rectangular or circular
mounted frame.
[0005] Skylights are typically mounted on non-vertical surfaces of
the building, particularly a roof. As a consequence, they are
subjected to damage when items fall on them. Examples of these
items may include hail, swaying tree limbs, or wind driven missiles
such as during a hurricane. Sudden breaching of the skylight window
subjects the underlying room to potentially substantial water
damage and possibly could pressurize or depressurize the building
causing the failure of other windows or doors. In extreme
situations, breaching a skylight can allow strong winds to
pressurize a building leading to the loss of a roof or other major
structural failures.
[0006] In order to address missile impact failures, skylights in
hurricane regions frequently use laminated tempered glass panels or
very thick wall domed acrylic panels. However, laminated glass
canopies are relatively heavy and relatively expensive. Their
weight often demands stronger, more expensive support structures,
like the door, larger roof joists, and larger size equipment for
installation. Both of these increase the overall cost of the
skylights.
[0007] What is needed is an inexpensive fenestration product which
is inexpensive and lighter in weight that prevents catastrophic
breaching such as with skylights by falling or windblown
debris.
SUMMARY OF THE INVENTION
[0008] In its simplest form, the present invention comprises a
fenestration product, such as a window or a skylight, to be mounted
in a building opening. The fenestration product is provided with a
peripheral frame to be mounted on the building defining a frame
opening. Within the frame opening is a laminated panel capable of
transmitting visible light into the building. The laminated panel
is an outer periphery which is held by the peripheral frame
spanning the panel opening. The laminated panel is made up of a
first sheet of plastic, a second sheet of plastic and an interposed
layer of resin which bonds the first and second sheets of plastic
internal resin layer into a structural member. The laminated panel
is selectively formable into a three-dimensional shape.
[0009] A preferred embodiment of the invention is a skylight
assembly having a peripheral frame defining a frame opening. Within
the frame opening is a laminated panel which sealingly cooperates
with the peripheral frame to close the peripheral frame opening.
The laminated panel is transparent to visible light and is made up
of three layers, a first sheet of plastic, an intermediate sheet of
resin and a second sheet of plastic which are collectively bonded
together to form a laminate. Preferably, the laminate is
selectively thermal formed so that the central region of the
laminate forms a dome.
[0010] Another preferred embodiment of the invention, the dome
laminated panel has a the peripheral frame molded in situ about to
form a leak resistant bond between the single piece molded frame
and the laminated panel.
[0011] In yet another embodiment of the invention, the skylight
assembly described above having a peripheral frame and a laminated
panel is further provided with the secondary transparent panel
located in spaced relation to the laminated panel and cooperating
with the frame to define an enclosed space which is filled with gas
to improve the insulating qualities of the skylight assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a side elevational view of a skylight
used as part of a tubular skylight assembly installed in a building
on a roof;
[0013] FIG. 2 illustrates a perspective view of a skylight
according to an embodiment of the present invention;
[0014] FIG. 3 illustrates a fragmentary cross-sectional view taken
along line 3-3 of FIG. 2 according to an embodiment of the present
invention;
[0015] FIG. 4 illustrates a perspective view of an alternative
rectangular skylight embodiment of the present invention; and
[0016] FIG. 5 illustrates a fragmentary cross-sectional view taken
along line 5-5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0017] Reference will now be made in detail to compositions,
embodiments, and methods of the present invention known to the
inventors, however it should be understood that the disclosed
embodiments are merely exemplary of the present invention which may
be embodied in various alternative forms. Therefore, specific
details disclosed herein are not to be interpreted as limiting
rather merely as a representative basis for teaching one skilled in
the are to variously employ the present invention. Except where
expressly indicated all numerical quantities in this description
indicating the amounts of material or conditions it is understood
as modified by the word "about" in describing the broadest scope of
the present invention. Practice within the numerical limits is
generally preferred.
[0018] In referring to FIG. 1, a building 2 is illustrated with a
non-vertical surface, namely a roof 4. The roof 4 has an opening 6
into which a skylight assembly 8 is fitted. The skylight assembly 8
includes a skylight canopy 10 connected to a frame 12. The frame 12
is optionally provided with a curb 14 and a flashing 15. The
skylight assembly 8 has a collector 16 reflective interior surface
which is adjacent to a joist 18 of the roof 4. The reflective
interior surface of collector 16 is connected to a light pipe 20
which will conduct light to an interior room below defined by the
ceiling of the room 22. The ceiling of the room 22 has an opening
24 through which the light pipe 20 passes and is connected to an
interior flange 26 that is adjacent to the interior room side of
the ceiling 22. Attached to the interior flange 26 is a diffuser 28
that permits light from the skylight to be spread more broadly
about the room below.
[0019] It should be understood that the reflective interior surface
of collector 16, the light pipe 20, the interior flange 26, and the
diffuser 28 are optional items in the skylight assembly 8.
[0020] The optional curb 14 and flashing 15 may be secured to the
roof by methods known in the art. It should be understood that the
frame 12 may include other securing elements without exceeding the
spirit of the invention.
[0021] It should be further understood that while illustrations of
certain embodiments are directed to skylight assemblies, other
fenestration products may not exceed the spirit of the invention.
Non-limiting examples of other fenestration products may include
windows, patio doors, sidelights, doorlites, and transoms.
[0022] Referring now to FIG. 2, a circular skylight embodiment 8 is
illustrated showing an example of the current invention. It should
be understood that the shape of the skylight may be an
architectually suitable shape providing sufficient structural and
sealing integrity, such as round, oval, square, or rectangular
shapes. In this example, the skylight directly opens into the
building interior space without using a light pipe 20.
[0023] Referring to FIG. 3 which is an embodiment of the
cross-section 3-3 shown in FIG. 2, the canopy 10 is illustrated as
having a first sheet of plastic 40 having a periphery 42, a second
sheet of plastic 44 having a periphery 46, and a resin layer 48
with a periphery 50.
[0024] The sheets of plastic 40 and 44 may be formable when
laminated with the resin layer 48 in certain embodiments. These
sheets range in thickness from 0.75 mm to 100 mm, with typical
thicknesses independently selected from 2 mm, 3 mm, 4 mm, 5 mm, 10
mm or 20 mm. Non-limiting examples of forming processes for these
sheets may include thermoforming, vacuum forming or pressure
forming. The forming process in certain processes may occur at a
temperature below a melting point of the selected plastics used in
sheets 40 and 44. The processing temperature for forming should
exceed a service temperature for the skylight, which in certain
embodiments may range from 60-95.degree. C. Examples of formable
materials include acrylic and polycarbonate.
[0025] The sheets of plastic 40 and 44 are adjacent to the resin
layer 48. It should be understood that the plastic 40 and 44 may be
bonded, adhered or otherwise secured to the resin layer to form a
multi-layer structural laminate. The fitness-for-use requirements
of the inner plastic sheet 44 may be less stringent than the outer
plastic sheet 40. The sheet 40 being on the outer layer may be
exposed to a harsher environment than the sheet 44 on the inner
layer in regards to temperature extremes, ultraviolet radiation,
physical abrasion, and other conditions. It should be understood
that the outer and inner sheets may be different or identical
materials without violating the intent of the invention. Examples
inner plastic sheets 44 may further include polyolefin, vinyl, and
terephthalate. Since the inner plastic sheets 44 may not provide as
much structural strength as the outer plastic sheets 40 the
thickness of the inner sheet 44 may also be relatively thinner than
the outer plastic sheet 40.
[0026] The resin layer 48 may be comprised of a resin. Non-limiting
examples of the resin include polyvinyl butyral, ethylene vinyl
acetate polymer or copolymer, or polyethylene. The resin layer may
be applied as a liquid, a film or a sheet according to certain
embodiments of this invention. Other physical forms of the resins
may be used in this invention without violating the intent of the
invention.
[0027] The periphery 51 of the canopy 10 which includes the
periphery 42 of the first sheet 40, the second sheet 44 and the
resin layer 48 is overmolded into the peripheral frame 12. It
should be understood that other means of securing the canopy 10 to
the frame 12 may be used without violating the spirit of this
invention. Examples of securing means may include a gasket or a
sealer. In certain embodiments, an optional spaced apart inner
layer of plastic 52 may be included in the skylight assembly 8 in
order to improve the thermal transmission resistance of the
assembly 8. The multi-layer canopy 10 and the inner plastic layer
52 are preferably bonded together about their peripheral edges by a
two-sided tape seal 53 to form an insulated unit. The two-sided
tape seal 53 is described in detail in co-pending commonly owned
U.S. patent application Ser. No. 11/671,657, entitled "Polymeric
Insulated Glazing Unit with Molded Frame", which is incorporated
herein in its entirety.
[0028] The frame 12 may be formed of multiple pieces in a
conventional manner. The multiple pieces may be fitted around the
periphery of the canopy 10 to form the skylight assembly 8. An
example is a rectangular frame having four individual frame
sections that may corner-keyed and sealed. The frame is then sealed
to the laminated panel using methods and materials known in the
art.
[0029] Preferably the frame 12 is formed as a single piece. The
single piece may be made as a separate molded part having no
joints. The separate molded part then being sealed to the laminated
panel. As an alternative, the frame 12 may be the single piece
molded in-situ encapsulating the periphery of the laminated panel
and simultaneously forming a watertight seal.
[0030] Materials that may be suitable for forming a single piece
frame may include polymers, such as thermoset plastics like
reaction injection molded plastics, thermoplastics, and fiber
reinforced plastics. These materials may be shaped by processes
known in the art, such as reaction injection molding, high pressure
injection molding, extrusion, thermoforming, or compression
molding.
[0031] Further, the skylight assembly 8 either alone or as part of
a tubular skylight may have a reflective interior surface 54. This
provides a good seal against dust and other small debris dropping
from the inside of the roof, as well as allowing the skylight to be
trim finished from an interior perspective. The reflective interior
surface 54 aids in transmitting light to the room below. In
addition, the reflective interior surface 54 may also connect with
the light pipe 20 to further enhance the amount of light going to
the room.
[0032] An example of the skylight assembly having the light pipe is
disclosed in detail in co-pending, commonly owned U.S. patent
application Ser. No. 11/671,726, entitled "Overmolded Fenestration
Building Product and Method of Manufacture", which is incorporated
herein in its entirety.
[0033] As an option, a mar-resistant coating 56 may be applied to
an exterior exposed surface of the plastic sheet 40 of the canopy
10. Siloxane or polymethyl methacrylate coatings or the like can be
used to provide a hard, mar resistant exterior surface to the
canopy 10.
[0034] To make the skylight assembly 8, take two sheets of plastic
40 and 44 which will be large enough to span the opening 6. In
certain embodiments, the first 40 and second 44 sheets are bonded
together by interposing the resin layer 48 between them. The sheets
are laminated using methods known in the art. Non-limiting examples
of methods may include pressure and/or heat, or heat under vacuum.
Such a step removes any gas that may be trapped between the layers,
as well as provides any curing or bonding necessary for the resin
layer 48.
[0035] The laminated panel formed above optionally may be formed
into a three-dimensional shape, such as a pyramid, a dome or
similar convex configuration. The three-dimensional shape may
provide additional structural strength relative to a flat sheet.
Further, the three-dimensional configuration may less the impact
force by deflecting the impact of some of the energy of relatively
concentrated short-term loads such as 2''.times.4'' lumber missiles
driven by a hurricane-force wind. These concentrated short-term
loads are simulated by a missile impact test like TAS 201 used by
the Miami-Date County Building Department. As described above, the
laminated sheet may be formed using processes known for shaping. In
an example of an embodiment of the method, a laminated panel may be
positioned in a first mold half which is warmed sufficiently to
soften the laminated panel. By applying a relatively mild pressure,
the laminated panel, when softened, may then be shaped to conform
to the first mold half. The laminated panel, once shaped, can be
removed from the first mold half and positioned in a second mold
that is a closed mold. The closed mold then is injected with a
plastic in an area adjacent to the periphery of the laminated
panel.
[0036] In this embodiment of the method of making the skylight
assembly 8, a continuous frame 12 of plastic is molded in situ and
the plastic forms a seal between the frame and the laminated panel.
Once the frame 12 is cured, a substantially complete skylight
assembly 8 can then be removed from the open mold. Forming the
single piece frame encapsulating the laminated panel eliminates
extra seals and joints, and is an example of the method to limit
the opportunities for water to leak into a residence or commercial
building. Seals and joints of other designs may deteriorate with
environmental exposure, as well as fail due to fatigue originating
with cyclic wind pressures and thermal expansions. The formation of
a molded polymer frame is disclosed in published U.S. patent
applications US2005/0178078A1 dated Aug. 18, 2005 and
US2005/0055901A1 dated Mar. 17, 2005, both of which are co-pending,
commonly owned, and incorporated by reference herein in their
entirety.
[0037] The leak-tightness of the skylight assembly 8 may be tested
according to ASTM E547-00 and ASTM E331-00. For areas of the United
States that often suffer hurricane force winds and driven rain, an
acceptance criterion for these standards is allowing no leakage
during the period of the test. Structurally, the skylight assembly
8 may be tested according to ASTM E330-02 where there is a positive
and negative wind load placed on the skylight assembly 8. The
acceptance standard for a hurricane velocity wind zone is where the
skylight assembly 8 exceeds the load of 250 pounds per square
foot.
[0038] Even more significant performance criteria for the skylight
assembly 8 are the missile impact test and a cycling test of TAS201
and TAS203 used by the Miami-Dade County Building Department. When
measured using these two methods, an acceptance criterion is that
no cracks or tears occur in the skylight assembly 8 at less than 90
pounds per square foot of force when measured using TAS203.
[0039] FIG. 4 illustrates an alternative embodiment of the
invention; a rectangular skylight 60. The rectangular skylight 60
includes a peripheral frame 62 which is generally rectangular in
shape defining a rectangular frame opening 64. Oriented within
frame opening 64 is a laminate panel 66 which has a rectangular
outer peripheral edge which cooperates with frame 62 in a secure
and water-tight manner. Preferably, laminated panel 66 is convexly
domed as shown. Laminated panel 66 is transparent to visible light,
and it can either be transparent or translucent. Frame 62, as
illustrated, is of a simple cap construction adapted to fit upon a
raised curb mounted on the building roof opening. Alternatively,
frame 62 can have an integrally formed curb and a flashing as
illustrated in the FIG. 3 embodiment.
[0040] The skylight 60 of FIG. 4 is shown in cross-sectional side
elevation in FIG. 5. In this embodiment, a single laminated panel
66 is provided, however, a spaced apart second panel similar to
plastic sheet 52 shown in FIG. 3, can be provided if an insulated
skylight is desired. Frame 62 is designed to fit over a curb 68
shown in phantom outline in FIG. 5. A sealant is preferably
installed between the top surface of the curb and corresponding
cooperating surface of peripheral frame 62. Once installed in
place, the screws 70 would be driven through a skirt portion 72 of
frame 62 to securely attach the skylight assembly 60 to the curb
68. Preferably, the roofing member 74 will extend between flange 72
and the curb to provide a water-tight roof system.
EXAMPLE 1
[0041] Commercial buildings are using large skylights to allow
natural light into the building and reduce their reliance on
florescent overhead lighting. Such a commercial skylight is a
curb-mounted cap. In this example, a curb with the outside maximum
diameter of 46''.times.94'' can be prepared in the commercial roof
to receive the nominal 4'.times.8' curb-mounted cap having a
laminated panel. The laminated panel is comprised of two 3 mm thick
sheets of polymethyl methacrylate with 1.5 mm thick layer of
polyvinyl butyral resin between the two sheets of acrylic. The
laminated panel then is thermoformed into the shape of a dome. The
domed laminated panel is then encapsulated with a frame of
aliphatic polyurethane material which is colored bronze for
aesthetic purposes. This curb-mounted cap then is mounted on the
roof on the prefabricated curb.
EXAMPLE 2
[0042] In this example, the skylight for a residence is mounted on
the roof having less than a 20.degree. slope. A 3'.times.3'
residential skylight assembly is fitted into a 30.5''.times.30.5''
rough opening with a self-flashing curb attached to the roof. A
curb-mounted cap having maximum outside dimensions of
34.5''.times.24.5'' is attached to the seamless self-flashing curb.
The curb is trimmed out on the interior using approximately 1/4''
thick sheets of trim stock wood. Trim stock is attached to the roof
joists and finished to meet with the interior ceiling.
[0043] The curb-mounted cap includes a laminated panel having a 3
mm acrylic sheet on the exterior layer and a 2.5 mm polyethylene
terephthalate interior layer. Between the layers a sheet of 0.5 mm
ethylene vinyl acetate copolymer is bonded. The laminated panel is
shaped to a dome configuration using vacuum-assisted thermoforming
at a temperature of approximately 120.degree. C. to 150.degree.
C.
EXAMPLE 3
[0044] For a residence in a high velocity wind zone such as within
one mile of the Florida coast, a higher impact material may be
necessary for the canopy 10. A skylight having this higher impact
resistance is formed with a laminated panel having 4 mm
polycarbonate on the outer layer and 2 mm polycarbonate sheet on
the interior layer. The polyvinyl butyral layer in between the two
sheets of polycarbonate is 2.5 mm. The outer layer of polycarbonate
is protected with a coating of polymethyl methacrylate for
increased resistance to degradation by ultraviolet light. On top of
the polymethyl methacrylate layer, a layer of tetraorgano
polysiloxane is applied as a scratch resistant coating. The
laminate is encapsulated in a frame of aliphatic polyurethane
material. This forms the curb-mounted cap which is then applied to
the residential seamless self-flashing curb as in Example 2. The
cap is secured to the curb with deck screws or the like.
[0045] It should be appreciated that various fenestration products
may be manufactured utilizing the novel laminated panel and frame
assembly and the invention is not limited to skylights per se.
While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *