U.S. patent application number 13/352962 was filed with the patent office on 2012-05-10 for overmolded fenestration building product and method of manufacture.
This patent application is currently assigned to VTECH PATENTS LLC. Invention is credited to John E. Nemazi, G. Daniel Templeton.
Application Number | 20120112383 13/352962 |
Document ID | / |
Family ID | 39674964 |
Filed Date | 2012-05-10 |
United States Patent
Application |
20120112383 |
Kind Code |
A1 |
Nemazi; John E. ; et
al. |
May 10, 2012 |
OVERMOLDED FENESTRATION BUILDING PRODUCT AND METHOD OF
MANUFACTURE
Abstract
A method for manufacturing a fenestration article includes
placing a light transmitting pane on a first conformable seal in a
first mold portion. The pane has an overmold flange. The method
also includes placing a second conformable seal is situated opposed
to and positioned on the second side of the pane, the second seal
positioned in cooperation with the first conformable seal and a
second mold portion to form a center opening in the pane. The first
and second portions of the mold are closed, defining a mold cavity
therebetween, into which a plastic material is introduced
encapsulating the overmold flange and forming in the mold cavity a
frame about the light transmitting pane with the center opening
situated further away from the wall than the frame, when the
fenestration article is installed in the wall.
Inventors: |
Nemazi; John E.; (Bloomfield
Hills, MI) ; Templeton; G. Daniel; (Ft. Wayne,
IN) |
Assignee: |
VTECH PATENTS LLC
Houston
TX
|
Family ID: |
39674964 |
Appl. No.: |
13/352962 |
Filed: |
January 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11671726 |
Feb 6, 2007 |
8117790 |
|
|
13352962 |
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Current U.S.
Class: |
264/263 |
Current CPC
Class: |
E04D 2013/0345 20130101;
E04D 13/0315 20130101; B29C 70/76 20130101 |
Class at
Publication: |
264/263 |
International
Class: |
B29C 45/14 20060101
B29C045/14 |
Claims
1-49. (canceled)
50. A method for manufacturing a fenestration article enclosing an
opening in a wall, the method comprising the steps of: placing a
light transmitting pane on a first conformable seal in a first mold
portion, the pane further having a width and a length, positioning
the first side of the pane on the first conformable seal having an
interior width that measures less than the width of the pane, a
difference defining a width of an overmold flange and an interior
length that measures less than the length of the pane, a difference
defining a length of the overmold flange; placing a second
conformable seal such that the second seal is situated opposed to
and positioned on the second side of the pane, the second seal
positioned in cooperation with the first conformable seal and a
second mold portion to form a center opening in the pane; closing
the first and second portions of the mold, defining a mold cavity
therebetween, into which a plastic material is introduced
encapsulating the overmold flange and forming in the mold cavity a
frame about the light transmitting pane with the center opening
situated further away from the wall than the frame, when the
fenestration article is installed in the wall; solidifying the
plastic material; and opening the second portion of the mold to
remove the fenestration article.
51. The method of claim 50, wherein the plastic material has a
thermoset composition.
52. The method of claim 50, wherein introducing the plastic
material includes injecting in a reaction injection molding (RIM)
plastic.
53. The method of claim 50, wherein introducing the plastic
material into the mold cavity to form the frame includes forming a
flashing capable of being capable of being attached to the
wall.
54. The method of claim 53, wherein introducing the plastic
material into the mold cavity simultaneously forms a curb
integrally bonded with the flashing and the frame forming a
unitized article.
55. The method of claim 53, wherein the frame forms a unitary
annular ring.
56. The method of claim 50, wherein introducing the plastic to the
mold cavity simultaneously forms a curb connected to the frame.
57. The method of claim 50, wherein the pane is glass or
plastic.
58. The method of claim 50, wherein the fenestration article is
selected from the group consisting of a unitized skylight, a
unitized tubular skylight, a unitized window, a unitized doorlite,
and a unitized sidelight.
59. The method of claim 50, wherein the light transmitting pane
comprises an insulated glass unit.
60. A method for manufacturing a fenestration article enclosing an
opening in a wall of a building, the method comprising the steps
of: placing a first side of a light transmitting panel having an
insulated unit and a overmold flange at the periphery of the panel
on a first conformable seal in a first mold portion, the seal
suitable for defining a central opening in the panel; placing a
second conformable seal opposite the first conformable seal and on
a second side of the light transmitting panel, the second seal
cooperating with a second mold portion to form the center opening
in the panel; closing the first and section portions of the mold,
defining a mold cavity therebetween capable of forming a frame and
a flashing, into which plastic material is introduced encapsulating
the overmold flange of the light transmitting panel with the
plastic material forming the frame configured as an unjointed,
unitary annular frame situated immediately adjacent to the panel
periphery and fixing the panel to the frame, the annular frame
including the flashing being disposed all the way around the window
and being capable of sealing with the wall, the wall flashing being
situated closer to the wall than the insulated unit; solidifying
the plastic material; and opening the second mold portion to remove
the fenestration article.
61. The method of claim 60, wherein the fenestration article is
selected from the group consisting of a window, a door, a doorlite,
a sidelight, a skylight, and a tubular skylight.
62. The method of claim 60, wherein the plastic material has a
composition including a thermoplastic composition or a thermoset
composition.
63. The method of claim 60, wherein the frame forms a thin shell
frame.
64. The method of claim 63, wherein the thin shell frame includes
an exterior-facing surface skin having a thermoset composition, the
surface skin defining an interior shell cavity including a foamed
thermoset composition material.
65. The method claim 60, wherein introducing the plastic includes a
process selected from the group consisting of a closed mold
process, a reaction injection molding (RIM) process, an injection
molding process, a low-pressure injection molding process, a
casting process, and a rotomolding process.
66. A method for manufacturing a fenestration article enclosing an
opening in a wall of a building, the method comprising the steps
of: placing a first side of a light transmitting panel having an
insulated unit and a overmold flange at the periphery of the panel
on a first conformable seal in a first mold portion, the seal
suitable for defining a central opening in the panel; placing a
second conformable seal opposite the first conformable seal and on
a second side of the light transmitting panel, the second seal
cooperating with a second mold portion to form the center opening
in the panel; closing the first and section portions of the mold,
defining a mold cavity therebetween capable of forming a thin shell
frame and a flashing, into which plastic material is introduced
encapsulating the overmold flange of the light transmitting panel
with the plastic material forming the thin shell frame configured
as an unjointed, unitary annular thin shell frame situated
immediately adjacent to the panel periphery and having an
exterior-facing surface skin defining an interior shell cavity
filled with a foamed composition material, the annular thin shell
frame including the flashing being capable of sealing with the
wall, the wall flashing being situated closer to the wall than the
insulated unit; solidifying the plastic material; and opening the
second mold portion to remove the fenestration article.
67. The method of claim 66, wherein introducing the plastic
includes an open mold process capable of having the plastic
material encapsulate the periphery of the first insulated unit
without damaging or distorting the panel.
68. The method of claim 66, wherein introducing the plastic to the
mold cavity simultaneously forms a curb connected to the annular
thin-shell frame.
69. The method of claim 66, further comprising forming the panel as
a domed panel.
70. The method of claim 66, further comprising the step of
connecting the fenestration article to a light pipe.
71. The method of claim 66, wherein introducing the plastic
material includes introducing a reinforced plastic material.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an overmolded fenestration
building product and its method of manufacture.
[0003] 2. Background Art
[0004] Fenestration building products have been used to allow light
into residential, commercial and industrial buildings. The
fenestration buildings products typically fit in an opening in the
building. Non-limiting examples include windows, doors, doorlites,
sidelights, skylights and tubular skylights. The fenestration
products will ideally allow light into the building while keeping
other environmental elements out. However since the installation of
the fenestration building products involves providing an opening in
the building, sealing such units has presented a number of
challenges.
[0005] In a typical fenestration building product installation, the
opening is flashed with a sheet or part of a sheet to provide a
leaktight seal between the fenestration products frame and the wall
section or door to which it is attached. Many of these fenestration
products are fabricated during the installation of the fenestration
product. Leaktight seals applied during field installation, which
may have initially been effective, often degrade over time and
begin to allow leaks of air and water. Minimizing the degradation
of the seals or eliminating the sealing points all together, may
improve the reliability of fenestration building products in terms
of preventing air and moisture leakage.
[0006] The use of plastics to consolidate parts in an assembly is
well known. Many of the joints which comprise a significant number
of sealing points in certain fenestration building products can be
eliminated by use of single-piece molded plastics. In general many
objects can be overmolded by injecting plastic on to at least part
of the edge of the object when it has been pressed between two
platens of a mold. Experience has shown though that the use of this
technique although satisfactory for many products, such as
electrical equipment, poses a number of problems when applied to
fragile materials, such as glass and thin sheets of relatively
brittle plastic.
[0007] Overmolding of glass for a skylight has been disclosed in
U.S. Patent Application 2005/0055901 filed by certain inventors of
this application. The '901 application discloses a skylight frame
molded about an insulated glass unit. The skylight frame assembly
includes a frame section which has U-shaped channel molded by
reaction injection molding (RIM). The U-shaped channel is adapted
to hold one or more panels of glass. The skylight frame is then
attached to a curb made by the (RIM) process using very expensive
thermoset polyurethane material. The connection of the frame
assembly and the curb provides a pathway for wind and water
penetration if the seal is not effective.
[0008] The skylight of the '901 application does not fully transmit
the light because the RIM material absorbs a significant amount of
the light due to its relatively low surface reflectivity. This is
particularly a problem when dealing with a tubular skylight where
the light must travel at least one or more floors to reach the
intended room.
[0009] What is needed is a building fenestration product that is
suitable for all residential, commercial, and industrial uses and
which minimizes the pathways that water can enter the building
through the openings and which is economical to manufacture. It
must also assist in transferring the light efficiently to the
interior rooms and in particular in the rooms that are not adjacent
to exterior walls or roofs.
SUMMARY OF THE INVENTION
[0010] The thin shell base has an exterior side opposed to a
portion of an interior side forming a first cavity. The first
cavity selectably receiving a filler. The thin shell has a first
distal end of the exterior side which may be selectably
positionable adjacent to and securable to a roof member. The roof
member defines a second aperture leading to a room in a
building.
[0011] The interior side of the thin shell defines a second cavity
adjacent to the pane. The frame is securable to the thin shell
base. The frame and thin shell base are molded using a process
selected from thermoforming, rotomolding, compression molding, or
injection molding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a house having fenestration
building products according to embodiments of the present
invention;
[0013] FIGS. 2a-e are fragmentary cross-sectional views of
non-limiting examples of overmolded fenestration units according to
certain embodiments of the present invention;
[0014] FIG. 3 is a fragmentary cross-sectional view of a window
according to an embodiment of the present invention;
[0015] FIG. 4a is a fragmentary cross-sectional view of skylight
according to an embodiment of the present invention;
[0016] FIGS. 4b and 4c are fragmentary cross-sectional detail views
of overmoldings according to certain embodiments of the present
invention;
[0017] FIGS. 5a-b are fragmentary cross-sectional views of tubular
skylights according to certain embodiments of the present invention
illustrating a light pipe sealing flange cooperating with a light
pipe;
[0018] FIGS. 6a-b are fragmentary cross-sectional views of a
unitized tubular skylight according to embodiments of the present
invention illustrating overmolded light-transmitting units and
non-limiting examples of cooperation with a light pipe;
[0019] FIG. 7 is a fragmentary cross-sectional view of a
non-limiting example of an open mold for thermoforming an
overmolded fenestration building unit according to certain
embodiments of the present invention.
[0020] FIG. 8 is a fragmentary cross sectional view of a
non-limiting example of a closed mold for shaping molten plastic
into an overmolded fenestration building unit according to certain
embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0021] Reference will now be made in detail to embodiments of the
present invention according compositions and methods which
constitute the best modes of practicing the invention presently
known to the inventors. With reference to FIG. 1, a perspective
view of a house 1 is illustrated. The house 1 includes a vertical
wall 3 and a non-vertical wall 5. Non-limiting examples of
fenestration building products on the house 1 typically on the
vertical wall 3 may include a window 7, a door 9, a doorlite 11,
and a sidelight 13. On the non-vertical wall 5, non-limiting
examples of fenestration building products may include a skylight
15 and a tubular skylight 17. The phantom lines indicate a light
pipe 19 extending from the roof 21 to an interior room not
immediately adjacent to the roof 21. The flashing for the
fenestration building products is covered over by shingles 23, a
siding 25, and/or a housewrap 27. The sash 29 of the window 7 may
be all that is visible on the exterior of the building adjacent to
the siding 25.
[0022] FIGS. 2a-e are fragmentary cross-sectional views of certain
overmolded fenestration unit embodiments of the present invention.
FIG. 2a illustrates a non-limiting example of an overmolded
insulated unit 31 having opposed panes 33 separated by a spacer 35.
The panes 33 and spacer 35 are overmolded by an overmolding 37. A
pane-overmolding interface 39 has the pane 33 immediately adjacent
to the overmolding 37. The pane-overmolding interface 39 may be
understood to have the pane 33 activated by a chemical or a
physical means to improve adhesion of the overmolding 37 to the
pane 33. While the overmolding 37 may function as a sealant
preventing moisture vapor achieving access to the interior of the
insulated unit 31, it should be understood that the insulated unit
31 may additionally have an insulated unit seal 41 non-limiting
examples of which may include butyl rubber, silicone, polyurethane,
or polysulfide materials, typically found in the insulated unit
industry. The pane 33 may be made of a light-transmitting material.
Non-limiting examples of the light-transmitting material include
acrylic family plastics, glass, polycarbonate family plastics, and
combinations thereof. FIG. 2b illustrates another embodiment of the
present invention where gasket 43 protects the edges of the
insulated unit 31 from thermal and mechanical stresses accompanying
the overmolding process. The gasket 43 may also provide additional
sealing capabilities for the fenestration building product. The
gasket 43 is adjacent to an interior side 45 of the insulated unit
31, the insulated unit seal 41, and an exterior side 47 of the
insulated unit 31. The gasket 43 may be formed of many materials
known in the art. Non-limiting examples of the materials include
relatively high melt temperature thermoplastics; thermoset polymers
such as epoxy, nitrile rubber or EPDM; metal foil such as aluminum;
or combinations of the above. In the embodiment illustrated in FIG.
2b, the overmolding 37 entirely encapsulates the gasket 43.
[0023] FIG. 2c illustrates an embodiment of an overmolded single
pane unit 49 having a plastic pane 51. It should be understood that
a single pane unit may also be employ the gasket. The overmolding
37 is connected to the plastic pane 51 to form a watertight seal.
It should be understood that at an interface 53 primers and other
adjuvants or mechanical, plasma, flame, and electrical surface
treatments may be used to improve the adhesion of the overmolding
37 to the plastic pane 51 without violating the intent of this
embodiment.
[0024] The plastic pane 51 may be formed by methods known in the
art. The plastic pane 51 may include additional coextruded layers
or applied coatings to augment features and enhance benefits
without violating the intent of certain embodiments. Non-limiting
examples may include an ultraviolet light resistant layer, a
decorative film, an absorptive layer, light wavelength bandpass
filter, or a tint.
[0025] Referring to FIG. 2d, the plastic pane 55 is a single-paned
skylight plastic dome according to an embodiment of this invention.
The single-paned skylight dome has a top side 57, a bottom side 59,
and is shaped so as to have a land 61 in an encapsulation zone
63.
[0026] An overmolding 67 adapted to receive the plastic pane 55 and
two-sided tape 65 contacts the pane 55 in the encapsulation zone 63
and encapsulates a portion of the encapsulation zone 63 including
all of the two-sided tape 65 positioned on the top side 57 of the
pane 55.
[0027] Referring to FIG. 2e, the insulated unit 69 is an insulated
skylight plastic dome according to an embodiment of this invention.
The insulated skylight plastic dome has two plastic panes 71 and 73
each having peripheral edges 75 and 77. The peripheral edges are
bonded together by an elongated two-sided plastic taped seal 79,
which is interposed between the peripheral edges 75 and 77 to form
a seal enclosing a central region 81. A non-limiting example of
two-sided tape 79 is described in co-pending U.S. patent
application Ser. No. 11/671,657 filed on Feb. 6, 2007 which is
commonly owned and, which is incorporated in its entirety by
reference. It should be understood that other two-sided adhesive
products may be used and not depart from the spirit of this
embodiment of the invention. The central region is provided with
air or another suitable gas 83 to provide a relatively increased
thermal barrier when the skylight is installed on the roof of the
building. Non-limiting examples of the gas may include group eight
gases such as argon, krypton, and xenon, or glass with a molecular
weight in excess of 27 or having a molecular cross-sectional area
greater than carbon dioxide.
[0028] FIG. 3 is a fragmentary cross-sectional view of a window 85
according to an embodiment of the present invention. The window 85
has an exterior 87 and an interior 89. The window 85 is fitted on
to a vertical wall 91. The wall 91 includes a framing header 93 and
a base buck 95. Adjacent to the exterior wall 97 is a flashing 99
for the window 85. The flashing 99 is secured to the exterior wall
97 by means known in the art such as nails, staples, screws, or
construction adhesive. A house wrap (not shown) and/or a flashing
tape 101 are applied over the flashing 99 at a sill 103, which sits
adjacent to the buck 95, opposed sides 105 and 107 of the window
85, and the header 93. A siding 109 is placed adjacent to a frame
111 of the window. The frame 111 includes the overmolding 113 and
encapsulates the insulated unit 115. The frame 111, as illustrated
in the non-limiting example of the FIG. 3 embodiment, includes two
sets of opposed sides 117 and 119 of a rectangle forming an
aperture. It should be understood that any geometric shape may be
used and not depart from the spirt of this embodiment of the
invention. The opposed sides 117 and 119 include a channel 121
approximately parallel to the wall 94, and suitable for supporting
one or more window panes 123. The channel is formed during
overmolding of the window panes 123. The channel 121 is adjacent to
an overmolded land area 125. It should be understood that the land
area 125 may also include a gasket and other sealants. The frame
111 further includes a sill flashing 127 extending from the
interior side of the window pane 123 toward an interior wall 129.
The sill flashing 127 may be secured to the buck 95, the sides 105
and 107, and the header 93 of the wall 94 using methods known in
the art such as nails, staples, screws or construction adhesive. An
interior trim piece 131 may be an L-shaped component that may be
attached to the interior wall 129 and cover a portion of the sill
flashing 127.
[0029] FIGS. 4a-c are fragmentary cross-sectional views of a
skylight 133 according to certain embodiments of this invention.
The skylight 133 includes a thin shell frame 135. The thin shell
frame includes an exterior side 137 and an interior side 139, a
light-transmitting pane 141, and a filled cavity 143. The interior
side 139 may include an inside wall 145 which defines a light
cavity 147. The light cavity 147 may have an optional reflective
surface 149 in order to improve the transmission of sunlight to the
interior room 151 below. The exterior side 137 has a skylight
flashing 153 located at the distal end of the thin shell frame 135
and adjacent to a roof member 155 in a non-vertical orientation.
The skylight flashing 153 may be secured to the roof member 155 by
conventional means, such as nails, staples, screws, or construction
adhesive. The light-transmitting pane 141 may include a domed pane
157. It should be understood that a planar pane or a pane having
other non-planar configurations would not depart from the spirit of
this embodiment of the invention. The pane 157 may comprise an
upper end of the light cavity 147. A lower end of the light cavity
147 may be defined by a telescoping L-shaped trim section 159. The
telescoping trim section 159 may extend from a room ceiling 161 of
the room 151 below the skylight 133 and cover the interior side 139
of the thin shell frame 135. The telescoping trim section 159 and
an interior flashing 163 which is an integral part of the thin
shell frame 135 located at the proximal end of the thin shell frame
135, may be trimmed with interior molding or may reduce
construction costs by integrating the trimming function into the
skylight 133 design.
[0030] FIG. 4b is an illustration of another embodiment of the
skylight 133 in which a non-limiting example of a skylight
insulating unit having a skylight sealing gasket 165 is
illustrated. The sealing gasket 165 covers the vulnerable edge of
an insulated light-transmitting pane 167. The sealing gasket 165
also provides weathertightness for the skylight 133. A skylight
insulated unit overmolding 169 entirely encapsulates the sealing
gasket 165 and is adjacent to the light-transmitting pane 167 at a
portion of an encapsulation zone 171. It should be understood that
the overmolding 169 may incorporate a portion of the sealing gasket
165 or the insulating unit 163. It is not a requirement that the
overmolding 169 be a continuous layer of plastic. It should be
understood that the overmolding 169 may be discontinuous.
Non-limiting examples of structures that may make the overmolding
169 discontinuous include a portion of the gasket, an insert, a
tail of a polyvinylbutylene layer when a laminated glass is used in
the pane 167, or an incomplete molding.
[0031] FIG. 4c is a fragmentary cross-sectional view of the
skylight 133 having a single acrylic pane 171 in a skylight
light-transmitting pane. In this non-limiting embodiment, the
overmolding 173 is adjacent to the acrylic pane 171 in an
encapsulation zone 175. It should be understood that the acrylic
pane 171 may also include adhesion promoting means to improve the
adhesion of the overmolding 169 in the encapsulation zone 175. It
should be understood that the overmolding 169 may be discontinuous
particularly when surrounding the periphery of the pane 173. It
should be further understood that the pane may include optional
coatings and/or surface treatments. A non-limiting example may be a
ceramic frit for aesthetic purposes.
[0032] FIGS. 5a-b illustrate embodiments of a tubular skylight 177.
Referring to FIG. 5a, the tubular skylight 177 includes three
components: a cap assembly 179, a thin shell base 181 and a light
pipe 183, which extends through an aperture 185 in a roof member
187 and leads to an interior room 189, which the ceiling of which
is located a relatively long distance from the roof member 187. The
cap assembly 179 includes a frame 191 housing the
light-transmitting pane 193. The light-transmitting pane 193 is
secured to the frame 191 by a tubular skylight overmolding 195
which forms a channel 197 that entirely encapsulates a top side 199
of the light-transmitting pane 193, as well as a bottom side 201 of
the light-transmitting pane 193. The cap assembly 179 further
includes a downstanding flange 203 that provides extra coverage and
weatherproofing for the protection of an interface when the cap
assembly 179 is connected to a thin shell base 205. The
weathertight seal between the cap assembly 179 and the thin shell
base 205 is enhanced with an optional sealing notch 207 in the cap
assembly 179. The sealing notch 207 is positioned to cooperate with
an upstanding rib 209 located on the thin shell base 205. The joint
between the cap assembly 179 and the thin shell base 205 may
optionally be sealed, in addition, with conventional material such
as fasteners, caulking, foam tape, or construction adhesives. It
should be understood that other cooperating features would not
depart from the spirit of this embodiment of the invention.
Non-limiting examples of cooperating features besides the notch 207
and the upstanding rib 209 include a tongue-and-groove
configuration, an inclined plane, embedded magnets, or a weep
channel. It should be understood that the thin shell base 205 may
include bases comprised of a skin layer and a bulk layer without
departing from the spirit of the embodiment. The bulk layer may, as
non-limiting example, comprise a reduced density layer. A
non-limiting example of the reduced density layer may be foamed
thermoplastic. The bulk layer may also, as a non-limiting example,
comprise a filled thermoplastic, an example of which is calcium
carbonate filled polystrene.
[0033] The thin shell base 205 includes an exterior side 211 and an
interior side 213. A distal end 215 of the exterior side 211 forms
a securing flange 217 which may be secured to the roof member 187
by means well known in the art. The exterior side 211 has an inside
face 221. An inside face 223 of the interior wall of the thin shell
213 is positioned approximately opposite the inside face 221 of the
exterior thin shell wall. Together they form a cavity 225. The
cavity 225 has an upper end at least partially formed by the inside
face 221 at a proximal end 229 of the thin shell exterior wall 211.
The cavity 225 may optionally be filled with a material 231 to
provide insulation, structural strength, or a combination thereof.
Non-limiting examples of the material 231 include inexpensive
fillers, especially inexpensive fillers that reduce relative
thermal conductivity, such as packaging foam, adhered reflective
glass spheres, and/or relatively low density polyurethane foam. It
is advantageous if the material 231 additionally increases
structural strength.
[0034] The interior wall 213 of the thin shell base 181 includes a
sealing flange 233 at a distal end 235 which optionally may
cooperate with an upper end 237 of the light pipe 183. The light
pipe 183 may extend to the interior room 189 located a relatively
long distance from the roof member 187. The light pipe 183 allows
some light to be directed to the interior room 189 which would
otherwise not have exposure to sunlight. The light pipe 183 may be
trimmed out with an L-shaped trim section 243, which has a flange
245 that may be secured to a ceiling 247 of the interior room 189.
An optional diffuser 249 may be applied to the light pipe 183 to
enhance the dispersion of the sunlight.
[0035] The thin shell base 215 is relatively easily shaped in a
relatively few number of processing steps. Non-limiting examples of
materials for the thin shell base may include polyolefins,
polyvinyl chloride, polyalkyl terephthalates, liquid silicone
rubber, bulk molding compound, polystyrene, and reinforced
plastics. These materials may be shaped by open and close mold
methods. Non-limiting examples of methods may include
thermoforming, injection molding, rotomolding, and compression
molding.
[0036] FIG. 5b illustrates a fragmentary cross-sectional view of a
tubular skylight 251 having an insulated unit 253. In this
non-limiting example, the diameter of a light pipe 255 exceeds the
diameter of a light cavity 257 defined by an interior wall 259 of a
thin shell base 261. A distal end 263 of the interior wall 259
includes a light pipe sealing flange 265. The light pipe sealing
flange 265 cooperates with the light pipe 255 and lies adjacent to
a roof member 267. The thin shell base 261 includes the interior
wall 259 and an exterior wall 269. The exterior wall 269 is opposed
to the interior wall 259 and defines a filler cavity 271. The
filler cavity 271 is filled with a compliant filler 273 such as a
polyurethane foam. The compliant filler 273 allows the light pipe
sealing flange 265 to embed itself into the filler 273 allowing the
tubular skylight 251 to remain approximately flush with the roof
member 267. This may assist in assuring weathertightness. It should
be understood that the filler 273 may comprise more than one layer.
A non-limiting example may include a polyrethane foam layer capped
by a putty layer which is covered by a peel-off layer to protect
the compliant putty layer from dirt and debris during
installation.
[0037] The interior wall 259 of the thin shell base 261 defines the
light cavity 257. In certain embodiments, to enhance the ability of
the light cavity 257 to transmit sunlight to the room below, the
light cavity 257 includes a reflective coating 275. It should be
understood that the reflective coating 275 may also be optionally
applied to the light pipe sealing flange 265 and the light pipe
235.
[0038] FIGS. 6a-b illustrate fragmentary cross-sectional views of
the tubular skylight 277 according to embodiments of this
invention. FIG. 6a illustrates a single-paned unitized tubular
skylight top 279. The top 279 may be positioned on a roof member
281 having an aperture 283. The unitized tubular skylight top 279
includes an encapsulated light-transmitting pane 285 which is
encapsulated in a channel 287 formed during the molding process of
the unitized top 279. The unitized top 279 has an exterior side 291
and an interior side 293, where the exterior side is approximately
opposed to the interior side 291 and forms a filler cavity 295. The
inside face 297 of the exterior side and the interior face 299 of
the interior side may be coated with a thermally reflective coating
301, of which aluminum paint is a non-limiting example. The filler
cavity 295 may then be filled with a filler 303 that reduces the
thermal conductivity and/or increases the structural rigidity of
the unitized tubular skylight top 279, of which expanded
polystyrene foam is a non-limiting example.
[0039] Referring to FIG. 6a, the distal end 305 of the single-paned
unitized tubular skylight top 277 may be secured to a top side 307
of the roof member 281, while the distal end 311 of the interior
side 293 may cooperate with a light pipe 313. The light pipe 313
may be below, even with, or extend above (as shown) the top side
307.
[0040] FIG. 6b illustrates an insulated pane unitized tubular
skylight top 315 having an insulated unit 317. The unitized tubular
skylight top 315 has an exterior side 319 and an interior side 321.
The exterior side 319 may further have a capstock 323 which may
optionally be continued to the interior side 321. The capstock 323
may provide protection from ultraviolet degradation as well as
provide a relatively reflective surface for both the exterior and a
light cavity 325 defined by the interior side walls 321. A
non-limiting example of the capstock 323 material may include
vapor-deposited metal film. A distal end 327 of the interior side
321 may include a light pipe seal flange 329. The light pipe seal
flange 329 assists to seal a light pipe 331 to the light cavity 325
to avoid loss of light being reflected from the light cavity 325,
as well as prevent debris from entering the light pipe 331.
[0041] FIG. 7 illustrates one embodiment of a method for making the
fenestration building product such as the window 3, the skylight 5
and the tubular skylight 7 according to certain embodiments of this
invention. The method involves providing a light-transmitting pane
333 such as the pane 33 (FIG. 2a), the insulated unit 115 (FIG. 3),
and the insulated unit 253 (FIG. 5b). The light-transmitting pane
333 has a interior side 335 and an exterior side 337. The
light-transmitting pane 333 has a length and a width according to
the design of the fenestration building product.
[0042] An open mold 339 has a cavity side 341 and a core side 343.
The cavity side has a conformable seal 345. The conformable seal
345 contacts the exterior side 337 of the light-transmitting pane
333. This conformable seal 345 provides a barrier to a dispersion
of a molten plastic from an encapsulation land 347 such as
illustrated in the encapsulation zone 171 (FIG. 4b). This provides
an aesthetically pleasing finish to the plastic making it appear
like a snapped-on bezel. The core side has another conformable seal
349 contacting the interior side 335 of the light-transmitting pane
333. These conformable seals 345 and 349 may be selectively
positioned and generally are approximately opposed on the interior
side 335 and the exterior side 337 of the light-transmitting pane
333. An inside dimension of the seals relative to a length and
width of the light-transmitting pane 333 is less than the
respective length and width of the light-transmitting panel 333.
The encapsulation land 347 may include the annulus resulting from
overlaying the conformable seals 345 and 349 on the
light-transmitting panel 333.
[0043] Referring to FIG. 7, a shaping method for forming the
fenestration building product may also use a sheet of plastic 351
and the open mold 339. The sheet of plastic 351 may be the single
thermoplastic or a composite material including the thermoplastic.
A non-limiting example of such a composite thermoplastic includes a
plastic with a capstock that is resistant to ultraviolet light. A
non-limiting example of such a capstock is an
acrylate-styrene-acrylonitrile (ASA) layer which is co-extruded on
the thermoplastic, a non-limiting example being polyvinyl chloride
(PVC). Additional layers may be co-extruded or applied to a sheet
such as a physical vapor deposited metal film or a spray paint. It
may be advantageous to have a metal film on the exterior side of
the products because the metal could assist in forming the
reflective cavity such as reflective cavity 149 (FIG. 4a). The
metal film would also provide good ultraviolet light protection to
the exterior side 137 (FIG. 4a).
[0044] In forming an overmolded window for a fenestration building
product as illustrated in FIG. 3 using an open mold method,
non-limiting examples of typical methods would include various
thermoforming methods. Non-limiting examples of thermoforming
methods include free forming, plug-assist forming, drape forming,
match mold forming, slip forming, snap-back forming, simultaneous
twin sheet pressure forming, encapsulation thermoforming, and
combinations thereof.
[0045] Of particular concern in the open mold process is developing
sufficient pressure differential to get the molded plastic to go
around the edge of the light-transmitting layer to form an
overmolded edge. Further, the overmolded edge must adhere to the
light-transmitting layer without causing distortion or breakage of
the light-transmitting layer. Non-limiting examples of such
techniques are known in the art and may include practical placement
of a vent opening 353 to draw the plastic 351 into the
encapsulation area, the use of surge tanks to provide extra
pressure differential relative to that which can be developed
simply by a vacuum pump, the use of differential cooling to cause
the plastic to snap back into overmolded areas, and/or combinations
thereof.
[0046] Referring to FIG. 8, if closed mold methods are used,
non-limiting examples of which are reaction injection molding
(RIM), injection molding, low pressure injection molding, casting
or rotomolding, the mold closes to form a mold cavity 355 into
which materials are provided. The formable material may include
thermoplastics, thermosets, or combinations thereof classified by
grades appropriate to each shaping method. Sufficient pressure is
applied to the formable material to form the material over the
encapsulation zone 345 and bond the material to the encapsulation
land 343 of the light-transmitting pane 333. The mold is then
cooled to a temperature allowing the formable material to solidify.
The mold is opened and the fenestration building product is removed
from the mold.
[0047] 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.
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