U.S. patent application number 15/868898 was filed with the patent office on 2018-05-17 for supporting a load on a roof.
This patent application is currently assigned to T&M Inventions, LLC. The applicant listed for this patent is T&M Inventions, LLC. Invention is credited to Michael J. McLain, Timothy Pendley.
Application Number | 20180135305 15/868898 |
Document ID | / |
Family ID | 44787048 |
Filed Date | 2018-05-17 |
United States Patent
Application |
20180135305 |
Kind Code |
A1 |
Pendley; Timothy ; et
al. |
May 17, 2018 |
Supporting A Load On A Roof
Abstract
The invention provides a system for installing a rail and
closure assembly on a metal roof. The rail and closure assembly
includes a supporting rail and closure structure adapted to be
supported by adjacent rib elevations of the roof, and an overlying
load adapted to be supported by the rail and closure structure. The
rail and closure structure diverts water around the rail and
closure assembly. The entire heights of the side rails, including
the rail bottoms, are above the closest portions of the panel
flats. At least one panel of each of the side rails faces the
respective rib along the full length of the respective side rail.
The rail and closure assembly also includes a lower closure.
Opposing ends of the lower closure extend upwardly and interface
with the ribs. The lower closure further comprises a lower flange
which interfaces with a respective panel flat.
Inventors: |
Pendley; Timothy; (Madera,
CA) ; McLain; Michael J.; (McFarland, WI) |
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Applicant: |
Name |
City |
State |
Country |
Type |
T&M Inventions, LLC |
McFarland |
WI |
US |
|
|
Assignee: |
T&M Inventions, LLC
McFarland
WI
|
Family ID: |
44787048 |
Appl. No.: |
15/868898 |
Filed: |
January 11, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14482471 |
Sep 10, 2014 |
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15868898 |
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13771746 |
Feb 20, 2013 |
8833009 |
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14482471 |
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12932892 |
Mar 8, 2011 |
8438798 |
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13771746 |
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12572176 |
Oct 1, 2009 |
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12932892 |
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61102333 |
Oct 2, 2008 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 13/03 20130101;
E04D 3/36 20130101; E04D 3/364 20130101; E04D 3/24 20130101; E04D
3/365 20130101; E04D 13/0305 20130101; E04D 13/031 20130101; E04D
3/30 20130101; E04D 13/0315 20130101 |
International
Class: |
E04D 13/03 20060101
E04D013/03; E04D 3/24 20060101 E04D003/24; E04D 3/367 20060101
E04D003/367; E04D 3/30 20060101 E04D003/30; E04D 3/365 20060101
E04D003/365 |
Claims
1-20. (canceled)
21. A load system for installing a load on a metal panel roof, such
metal panel roof comprising elongate metal roof panels, each having
a length and a width, such roof panels defining elevated roof panel
ribs, panel flats being disposed between such roof panel ribs, said
load system comprising: (a) a rail and closure structure comprising
(i) a first side rail, having first and second ends, a first length
between the first and second ends, a first top, and a first bottom,
a first downwardly-facing surface of said first side rail being
mounted directly to a first upwardly-facing surface of a first such
rib along an entirety of the first length of said first side rail,
and (ii) a second side rail, having third and fourth ends, a second
length between the third and fourth ends, a second top, and a
second bottom, a second downwardly-facing surface of said second
side rail being mounted directly to a second upwardly-facing
surface of a second such rib along an entirety of the second length
of said second side rail, the bottom of at least one of said first
and second side rails, at a given point along the length of the
respective said side rail, being spaced above an elevation of a
portion of the respective panel flat which most closely underlies
the respective said side rail at such point along the length of the
respective said side rail; and (b) a load adapted to be supported
by said rail and closure structure.
22. A load system as in claim 21 wherein a portion of only a single
such roof panel rib is cut away, leaving first and second cut rib
edges, respectively up slope and down slope on such roof, and an
empty space between the up-slope and down-slope cut rib edges, at
least one of the cut rib edges being spaced from the respective
said side rail.
23. A load system as in claim 22 wherein said load comprises first
and second adjacent skylights supported end to end over a single
aperture in the roof.
24. A load system as in claim 22 wherein said cut away portion of
the respective roof panel rib is made at only one of the respective
roof panel ribs to which said side rails are directly mounted.
25. A load system as in claim 21 wherein said system comprises
first and second adjacent skylights supported end to end over a
single aperture in the roof.
26. A load system as in claim 21 wherein said first and second side
rails overlie said ones of such roof panel ribs along full lengths
of said first and second rails.
27. A load system as in claim 21 wherein the downwardly-facing
surfaces of said first and second side rails are fastened directly
to the upwardly-facing surfaces of such first and second ribs by
screws or rivets spaced from each other along the lengths of said
first and second side rails.
28. A load system as in claim 21, installed on a roof and overlying
a roof penetration.
29. A load system as in claim 21 wherein said load extends upwardly
above the tops of said first and second side rails.
30. A load system for installing a load on a metal panel roof, such
metal panel roof comprising elongate metal roof panels, each having
a length and a width, such roof panels defining elevated roof panel
ribs, panel flats being disposed between such roof panel ribs, said
load system comprising: (a) a rail and closure structure suitable
for being supported by ones of the elevated roof panel ribs, said
rail and closure structure comprising a first side rail, for
mounting directly to a first such rib wherein a first bottom panel
of said first side rail faces a panel of such first rib, along a
full length of said first side rail, and a second side rail, for
mounting directly to a second such rib, wherein a second bottom
panel of said second side rail faces a panel of such second rib,
along a full length of said second side rail; and (b) a load
adapted to be supported on said rail and closure structure.
31. A load system as in claim 30 wherein, when said load system is
installed on such roof, a portion of a such rib is cut away,
leaving first and second cut rib edges, and a space between the cut
rib edges, one of the cut rib edges being spaced from a respective
said rail.
32. A load system as in claim 31 wherein only one of the respective
roof panel ribs, to which said rails are mounted, is cut away to
define such space between the cut rib edges.
33. A load system as in claim 30 wherein said load system, when
installed on such roof, comprises first and second adjacent
skylights supported end to end over a single aperture in such
roof.
34. A load system as in claim 30 wherein, when said load system is
installed on such roof, said rail and closure structure overlies
adjacent ones of the roof panel ribs along the full lengths of said
first and second rails.
35. A load system as in claim 30, installed on a roof, said load
overlying a hole in the roof.
36. A load system for installing a load on a metal panel roof, such
metal panel roof comprising elongate metal roof panels, each having
a length and a width, such roof panels having upstanding rib
elevations, defining elevated roof panel ribs, at opposing sides of
the respective roof panels, panel flats being disposed between such
roof panel rib elevations, said load system comprising: (a) a rail
and closure structure comprising (i) a first side rail, having
first and second ends, a first upstanding web, a first mounting
flange at a top of said first upstanding web, and a first lower
shoulder extending from a first bottom of said first upstanding
web, said first lower shoulder being mounted to a first such rib,
and (ii) a second side rail, having third and fourth ends, a second
upstanding web, a second mounting flange at a top of said second
upstanding web, and a second lower shoulder extending from a second
bottom of said second upstanding web, said second lower shoulder
being mounted to a second such rib, roof panel profiles being
defined by cross-sections extending across the widths of such roof
panels, further comprising (c) a lower closure structure having
opposing upwardly-extending ends thereof, configured to interface
with the metal roof panel profiles at the ribs to which said side
rails are mounted, and a lower flange configured to interface with
an intervening panel flat between such ribs, said lower closure
further having an upstanding panel, extending upwardly from said
lower flange and extending between such first and second ribs,
thereby to prevent flow of water from an up-slope side of said
lower closure structure to a down-slope side of said lower closure
structure.
37. A load system for installing a load on a metal panel roof, such
metal panel roof comprising a plurality of elongate metal roof
panels, each having a length and a width, such roof panels defining
elevated roof panel ribs, panel flats being disposed between such
roof panel ribs, said load system comprising: (a) a rail and
closure structure comprising (i) a first side rail having first and
second ends, a first length between the first and second ends, a
first top, and a first bottom, said first side rail being mounted
to a first such rib along an entirety of the first length of said
first side rail, (ii) a second side rail, having third and fourth
ends, a second length between the third and fourth ends, a second
top, and a second bottom, said second side rail being mounted to a
second such rib along an entirety of the second length of said
second side rail, at a given point along the length of each said
side rail, an entirety of a height of the respective said side
rail, from the bottom of said side rail to the top of said side
rail, being spaced above an elevation of a portion of the
respective panel flat which most closely underlies the respective
said side rail at such point along the length of the respective
said side rail; and (b) a load supported by said rail and closure
structure.
38. A load system as in claim 37, further comprising an upper
diverter extending between the first and third ends of said first
and second side rails, and a lower closure extending between the
second and fourth ends of said first and second side rails.
39. A load system as in claim 37 wherein said load extends upwardly
above the first and second tops of said first and second side
rails.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation application, under 35
U.S.C. 120, of Ser. No. 14/482,471, filed Sep. 10, 2014, which is a
Continuation of Ser. No. 13/771,746, filed Feb. 20, 2013, now U.S.
Pat. No. 8,833,009, which is a Continuation of Ser. No. 12/932,892,
filed Mar. 8, 2011, now U.S. Pat. No. 8,438,798, which is a
Continuation-In-Part of Ser. No. 12/572,176, filed Oct. 1, 2009,
now abandoned, which is a Non-Provisional patent application of
U.S. Provisional Patent Application Ser. No. 61/102,333, filed Oct.
2, 2008, the complete disclosure of each of which is incorporated
herein, in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The field of the invention is skylights systems.
Description of Related Art
[0003] Various systems are known for using curb construction for
inserting skylights and smoke vents into roofs.
[0004] The most commonly used skylighting systems are those that
incorporate translucent or transparent layers in a framework that
penetrates the roof structure, so as to allow ambient daylight into
the building.
[0005] In the past, roof penetrating installations have required a
complex structure beneath the roofing panels in order to support a
roof curb to which the skylight was attached. Skylight curbs are
generally in the form of a preassembled box structure, that is
fixed within a roof cutout. The retrofitting of such curb systems
into existing roof structure is problematic.
[0006] U.S. Pat. No. 4,296,581, to Heckelsberg, issued Oct. 27,
1981, provides an example of a roofing structure of the type that
is constructed of a series of metal panels having flanges that
interlock when the panels are laid side by side and which are
subsequently tightly seamed together to convert the individual
panels into an integrated roof forming membrane. This roof
structure is mounted to the purlins with clips that permit the
panels to expand or contract in response to temperature and
pressure changes, thereby minimizing roof stressing.
[0007] U.S. Pat. No. 4,703,596, to Sandow, issued Nov. 3, 1987, and
titled "Grid Skylight System", provides a grid skylight support
apparatus that includes prefabricated grid row frames, each of
which form a number of connected beam supports which define a
number of bays. Each bay has a skylight curb formed by upper
flanges of the beam supports to receive a preassembled skylight
unit. The sides of each grid row frame provide a mating edge that
can register with the mating edge of an adjacent grid row frame
during assembly. The skylights have peripheral support skirts that
register upon each bay and a light-transmitting skylight panel to
cover the peripheral support. Cross gutters on each grid row frame,
which are positioned between adjacent skylights, extend at an angle
toward the mating edge of the grid row frame for carrying rainwater
to a main gutter channel formed by field-assembly of the mating
edges of two adjacent grid row frames. The main gutter channel
includes a pair of longitudinally extending gutter sections, each
of which have a main gutter channel surface with a lower elevation
than the elevation of the cross flow channel. Fasteners assemble
the grid row frame mating edges together and form a continuous seal
to prevent rainwater leakage at the mating edges of adjacent grid
row frames.
[0008] U.S. Pat. No. 4,520,604, to Halsey et al., issued Jun. 4,
1985, entitled "Skylight Structure", teaches a curb structure that
is dimensioned to be passed through an opening in a roof and then
attached in moisture impervious relation to the roof from within a
building interior. A skylight assembly including a frame and light
transmitting member secured to the frame is dimensioned to be
passed through the opening and attached in a sealing engagement to
the curb structure from within the building interior for covering
the opening. The skylight assembly is then secured to the rafters
and headers at an interior location. The frame includes upper and
lower clamping jaws and spaced fulcrum links attached to the jaws
for clamping the light transmitting member thereto. The lower
clamping jaw includes a channel which engages and is interlocked
with the curb structure.
[0009] Other skylight systems, as contemplated in U.S. Pat. No.
4,470,230, by Weisner, provide a prefabricated skylight support
curb that is formed to be a protective packaging for the skylight
during shipment and then used as a curb for mounting the skylight
on a roof. A prefabricated skylight support curb for supporting a
skylight thereover has a bottom flange angled, upright sides, and a
top lip round the top of the sides forming an opening through the
curb. A skylight is adapted to cover the opening through the
skylight support curb when installed, and has a domed portion and
an angled portion extending from the dome portion and a drip edge
on the curb portion.
[0010] In another skylight system, as contemplated in U.S. Pat. No.
3,791,088, by Sandow, et al., a prefabricated multiple dome unit or
skylights and composite is provided, wherein each multiple dome
unit has several domes of transparent or translucent material
mounted together on a common frame, and wherein means are provided
for assembling a plurality of such dome units into a composite
thereof on a building, with the units lapped and interfitted so as
to provide a continuous drainage system discharging to the exterior
of the units in the composite assembly.
[0011] In yet another skylight system, as contemplated in U.S. Pat.
No. 4,621,466, by Sonneborn et al., a flashing frame is described
for roof windows to be installed adjacent to each other with edges
facing each other in the installed position with a connecting
flange of its upper flashing members extending beneath the roofing
and, if need be, with its lower flashing members and required
intermediary flashing members, obliquely outwardly bent connecting
webs and each with a connecting bar with supporting webs which
rearwardly engage the connecting webs.
[0012] In today's world of mandated energy efficiency in all types
of buildings, the metal building industry needs a more economical
and less detrimental way to use skylights and smoke vents to
daylight their buildings. To ensure adequate daylighting, however,
typical skylight and smoke vent installations require multiple roof
penetrations that cut through and remove plural major elevations in
standing seam and other roof panel profiles. These curbs create
multiple opportunities for water to enter the interior of the
building, due to multiple curb locations and the width of the
curbs, as well as the challenge to effectively seal the roof at the
high ends of such curbs.
[0013] The traditional curb constructions and methods of attachment
in most cases require a complicated support structure to be
installed below the roof panel which can restrict movement
associated with the thermal expansion and contraction of the metal
roof due to temperature changes and the like.
SUMMARY OF THE INVENTION
[0014] The invention provides a curbless construction system for
installing two or more adjacent skylights and smoke vents end to
end onto the major rib elevation of a building's metal panel roof
system. Numerous roof structures include such elevations, sometimes
deemed "ribs" or "corrugations", including the standing seam, snap
seam and "R" panel roof types. The rail and closure system is
fastened to the metal roof panels along the rib structures, so that
the system can move with the expansion and contraction of the
roof.
[0015] The invention utilizes elements of the roof surface
structure as an integral part of the skylight support structure. In
the preferred embodiment, the system includes a rail and closure
structure adapted to be supported on a major rib elevation a metal
roof, typically where a rib elevation has been cut to accommodate
drainage. The balance of the rib is to provide structural support
for the rail and closure structures.
[0016] The invention includes a skylight adapted to be supported on
the rail and closure structure, and a bearing plate structure for
supporting and sealing the portion of the metal roof panel where
the rib elevations have been cut away, thus preventing water
accumulation at the upper surfaces of the roof panels, thereby
preventing water ingress into the building.
[0017] In some embodiments, the invention provides a skylight
system (including smoke vents) where the bearing plate structure
cooperates with the rail and closure assembly to close the cut away
portion to water ingress.
[0018] In another embodiment, the invention provides a rail and
closure structure where the rib has been cut in only one
location.
[0019] In a further embodiment, the invention provides a rail and
closure structure where the standing seam roof has trapezoidal rib
elevations.
[0020] In another embodiment, the invention provides a rail and
closure structure where the metal roof is an exposed fastener roof
system.
[0021] In another embodiment, the invention provides a rail and
closure structure where ribs have been cut in two locations.
[0022] In another embodiment, the invention provides a rail and
closure structure having a trapezoidal or rectangular rib elevation
8'' to 12'' on center.
[0023] In another embodiment, the invention provides a rail and
closure structure where the exposed fastener roof is of the type
having roof panels fastened directly to the roof purlins from the
top side of the roof panel.
[0024] In another embodiment, the invention provides a rail and
closure structure where the system comprises two or more skylights
supported end to end.
[0025] In another embodiment, the invention provides a rail and
closure structure where each of the skylights is about 10 feet in
length.
[0026] In another embodiment, the invention provides a rail and
closure structure where the rail and closure assembly moves with
the rib elevations.
[0027] In another embodiment, the invention provides a rail and
closure structure further comprising a ridge cap configured to fit
over the rib elevations at the ridge of the roof.
[0028] In another embodiment, the invention provides a rail and
closure structure where a lower closure of the rail and closure
structure extends across the top of the metal roof panel
profile.
[0029] In another embodiment, the invention provides a rail and
closure structure where the lower closure is configured to match
the roof panel surface adjacent rib elevations for sealing.
[0030] In another embodiment, the invention provides a rail and
closure structure where the lower closure is pre-cut to match the
roof surface and adjacent rib elevations for sealing.
[0031] In another embodiment, the invention provides a rail and
closure structure where the rail and closure structure is fastened
directly to the rib elevations using screws or rivets.
[0032] In another embodiment, the invention provides a rail and
closure structure where the rail and closure structure forms a
water tight seal with a respective rib elevation.
[0033] In a still further embodiment, the invention provides a rail
and closure structure where a portion of only one adjacent rib
elevation is cut away to accommodate drainage along the roof
surface.
[0034] In another embodiment, the invention provides a rail and
closure structure where portions of two or more adjacent rib
elevations are cut away to accommodate drainage along the roof
surface.
[0035] These and other features and advantages of this invention
are described in, or are apparent from, the following detailed
description of various exemplary embodiments of the apparatus and
methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] A more complete understanding of the present invention and
the attendant features and advantages thereof may be had by
reference to the following detailed description when considered in
combination with the accompanying drawings.
[0037] FIG. 1 is a view showing the roof profile of metal roof
panels of the type known as standing seam roof panels.
[0038] FIG. 2 is a view showing the roof profile of metal roof
panels of the type known as architectural standing seam roof
panels.
[0039] FIG. 3 is a view showing the roof profile of metal roof
panels of the type commonly referred to as snap seam roof
panels.
[0040] FIG. 4 is a view showing the roof profile of metal roof
panels of the type commonly referred to as exposed fastener roof
panels.
[0041] FIG. 5 is a view showing the roof profile of metal roof
panels of the type commonly known as foam core panels.
[0042] FIG. 6 is a side view showing the major components of the
system as installed on a metal panel roof.
[0043] FIG. 7 is a top plan view of the installed system, showing
placement of skylights and the direction of water flow over the
roof.
[0044] FIG. 8 is a cross sectional view showing connections of the
skylight frame to the rail and closures structure, and the latter
affixed over the outer surfaces of respective rib elevations of the
metal panel roof.
[0045] FIG. 9 is a perspective view, partially cut away, showing
internal structure of the system as installed on the rib elevations
of a metal panel roof.
[0046] FIG. 10 is a perspective view of the upper diverter of the
rail and closure structure.
[0047] FIG. 11 is a top view of the upper diverter of the rail and
closure structure.
[0048] FIG. 12 is a front elevation view of the upper diverter of
the rail and closure structure.
[0049] FIG. 13 is a perspective view of the lower closure of the
rail and closure structure.
[0050] FIG. 14 is a top view of the lower closure of the rail and
closure structure.
[0051] FIG. 15 is a front elevation view of the lower closure of
the rail and closure structure.
[0052] FIG. 16 is a perspective and partially cut away view showing
a connection of adjacent skylights of the system.
[0053] FIG. 17 shows detail of how the batten connects adjacent
skylights and prevents water ingress between them.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0054] The products and methods of the present invention provide a
rail and closure structure for use in installing various roof
penetrating structures in metal panel roofs. For purposes of
simplicity, "roof penetrating structures" and "skylights" will be
used interchangeably to mean various forms of roof structures
installed for passage of light and/or ventilation to the interior
of the building. In the case of roof ventilation, examples include
simple ventilation openings, such as for roof fans, and smoke
vents, which are used to allow the escape of smoke through the roof
during fires.
[0055] The number of skylights can vary from one to many structures
connecting end to end, limited only by the amount of support
provided by the roof structure, which roof structure is left
largely intact during the skylight installation process.
[0056] The system utilizes the major rib structure in the roof as
the primary structure supporting the skylight assembly. Typical
conventional skylight installations do not allow for continuous
runs, but rather use a curb construction that is typically 2-3
times wider than the present system.
[0057] The present rail and closure structure does not require a
complex structure underneath the roof panels, nor does it require a
separate curb construction to support or attach the skylight. The
rail and closure structure is overlaid onto the roof system and
allows for thermal expansion and contraction of the rail and
closure structure by utilizing the major profiles of the metal
panel roof for support. This is accomplished through direct
attachment of the rail and closure structure to the major roof
panel ribs.
[0058] In reference now to the figures, the system allows the
installation of two or more adjacent skylights in an end to end
fashion along the major rib structure of a building's metal roof
panel profile.
[0059] The rail and closure structure can be applied to various
types of ribbed roof profiles. FIG. 1 shows the roof profile of a
metal panel roof of the type known as the standing seam roof 10.
The "standing seam" roof has trapezoidal major ribs 12 typically
24'' to 30'' on center. Each panel 10 will also include the panel
flat 14, having a shoulder 16 and seamed at adjacent panels forming
a standing seam 18, which is folded over and seamed to prevent
water from penetrating the roof.
[0060] FIG. 2 is a view showing the roof profile of a metal roof of
the type known as an architectural standing seam roof, produced of
a series of overlapping architectural standing seam panels 20. Each
panel 20 comprises a panel flat 24, with an architectural standing
seam 28 formed at the interconnecting panels.
[0061] FIG. 3 is a view showing the roof profile of a metal roof of
the type commonly referred to as an R panel or exposed fastener
panel 30, with each panel having a rib 32, and panel flat 34.
Adjacent R panels are secured to the roof through structural
fasteners 35 in the panel flat, adjacent shoulder 36. The rib is
formed from overlapping regions, or side laps 38, with the adjacent
panels secured to each other by stitch fasteners 39. The
trapezoidal major ribs of the R panel roof are most typically
formed at 8'' to 12'' on center.
[0062] FIG. 4 is a view showing the roof profile of a metal roof of
the type commonly referred to as a snap rib seam panel roof 40. A
snap seam panel roof 40 has panel flats 44 and standing seams or
snap seams 48 at adjacent panels.
[0063] FIG. 5 is a view showing the roof profile of a metal panel
roof of the type commonly known as foam core panel 50, which has a
rib 52, a liner panel 53, a panel flat 54 and a foam core 57. Side
laps 58 are secured by a stitch fastener 59.
[0064] The system of the invention includes a rail and closure
structure adapted to be supported on the major elevations, seams,
rib structures, or other structural elements of such roof profiles,
where the standing structure provides the support, and the skylight
or other load is secured over an opening formed in the intervening,
non-structural roof flat region.
[0065] Turning now to FIG. 6, there is shown an exemplified rail
and closure assembly 100 adapted for attachment to a standing seam
panel roof 110. While the following figures depict such an
assembly, it will be understood that the components could easily be
adapted, by shaping of the elements, for attachments to any roof
system that has a profile with elevations providing a place for
structural support.
[0066] Looking again to the figures, particularly FIGS. 6 and 7,
there is shown such a standing seam panel roof 110 having
structural and other elements including a raised rib 112, a panel
flat 114, shoulder 116 and standing seam 118. Also depicted are the
ridge cap 120 of the roof structure, and cutaway regions, or gaps
122 formed to accommodate the structure, as described more fully as
follows.
[0067] Shown as part of the system, and exemplified in this case,
is a skylight 130, generally comprising a skylight frame 132 and
skylight lens 134. While the figures depict a skylight, it will be
understood that the system could also be adapted for use with any
number of roof penetrating structures, from various types of
skylights to smoke vents or other ventilating structures, which can
all be adapted to be supported on the rail and closure structure
system.
[0068] Again in reference to FIGS. 6 and 7, the system includes
rail and closure structure 140, generally comprised of side rails
142 and 144, an upper diverter 146 disposed at the rib cutaway
section or gap 122, and a lower closure 150. At gap 122, a plate
148 is located under the gap 122 to prevent water leakage into the
underlying building. In assembling the rail and closure structure
to a roof, plate 148 is sealed and fastened securely to the roof
panel supports.
[0069] FIG. 7 shows how the gap 122 in the roof rib 112 allows
water flow 200 along the roof surface, over plate 148, and down and
away from the roof ridge cap 120.
[0070] Lower closure 150 seals the lower end of the system from the
elements.
[0071] In reference now to FIG. 8, there is shown a cross section
through the skylight 130 region of the rail and closure assembly
100, showing the securement of the assembly 100 to the standing
seam panel roof 110. In particular, FIG. 8 depicts the use of the
ribs 112 to support the side rails 142 and 144. Each rail 142 or
144, has a rail upper flange or bearing surface 240 and a rail
shoulder 242. The rail 142 or 144 is secured to the skylight frame
132 by a plurality of fasteners 300.
[0072] The rail shoulder 242 is shaped to fit closely over the
outside of the roof rib 112, and is secured to roof rib 112 by a
plurality of rivets 310. Upper flanges 240 of the rails support the
skylight frame 132. A sealant 330 can be applied to the upper
flange to seal against the passage of water or air.
[0073] It can be seen that the rail and closure structure 140 of
the assembly 100 can be produced to fit closely along the contour
of the roof 110, and can be so configured to have end portions that
match the contour of the ribs 112. The various mating surfaces of
the structure 140 and the roof 110 can be sealed in various ways
known to the roofing art, including caulking or tape mastic, or
various rubber fittings or inserts can be used to seal any open
areas of the roof panels.
[0074] In FIG. 9 a partially cut away perspective view of the rail
and closure assembly 100 is used to show the support of the rail
and closure system by the standing seam panel roof 110,
particularly the elevated rib 112 providing the structural support.
FIG. 9 shows how the rail and closure structure incorporates the
structural profile of the metal roof panels, including the
elevations and ribs used in sealing adjacent panels, to provide the
support of skylights. In this fashion, the system adopts various
advantages of a standing seam roof.
[0075] Most standing seam roofs are seamed using various clip
assemblies that allow the roof to float, along the major elevation.
Typically, the roof is fixed at the cave and allowed to expand and
contract toward and away from the ridge. Very wide roofs can be
fixed at midspan and expand and contract toward and away from both
the cave and the ridge. The design of the rail and closure assembly
100 takes full advantage of the floating features of contemporary
roofing structures, and when a skylight is so secured to the roof
panel elevations, the skylight assemblies themselves are able to
draw strength from the structural load bearing capacity of the
standing seam roof profile.
[0076] Shown in FIG. 9 is the panel flat 114, rib 112 and shoulder
116, as well as the standing seam 118. The ridge cap 120 is also
shown, as well as the gap 122 in a rib at the up-slope end of the
rail and closure assembly.
[0077] The skylight 130 is supported on the rail and closure
structure 140, as previously described.
[0078] The rail and closure structure 140 is secured by its side
rails 142 and 144 by a series of fasteners 300 to the skylight
frame 132 and to the ribs 112 by a series of rivets 310.
[0079] Adjacent the up-slope end of the rail and closure structure
140, a single rib 112 is typically cut away to create gap 122,
thereby to accommodate drainage at the up-slope end of the system
(toward ridge cap 120). This is an important feature for standing
seam, architectural standing seam and snap seam roofs. Two ribs can
be cut for roofs having an "R" panel profile.
[0080] The retained portions of rib 112 function similar to e.g.
flange and web portions of an I-beam, thus to support the side
rails 142 and 144 and maintain a watertight seal along the length
of the assembly. Internal portions of the ribs 112 can be removed
to allow additional light from the skylight 130.
[0081] A single bearing plate structure 148 is used for sealing the
cut away rib. The bearing plate 148 also provides some support to
link adjacent rib elevations 112, and is typically produced of
steel or other material sufficient to provide a rigid substructure
to the skylight rail and closure structure.
[0082] The rail and closure structure 140 is shaped in such a
manner that the skylight can be easily fastened directly to the
rail portion, with rivets or other fasteners such as screws and the
like.
[0083] Looking now to FIGS. 10 through 12, an upper diverter 146
provides closure and diversion of water around the up-slope end of
the assembly to an adjacent panel flat. Diverter 146 also provides
a weather tight seal at the up-slope end of the assembly, with the
plate 148. In reference to the side rails 142 and 144 on a standing
seam panel roof 110, the diverter 146 generally fits the profile of
the rib 112 at the region of the cut away gap 122. The side rails
142 and 144 abut the diverter 146 and the height of the diverter
146 closely matches them in height. The upper flange 400 of the
diverter 146 acts with upper flanges 240 of the side rails 142 and
144 to form the bearing surface of the skylight frame.
[0084] Lower flange 410 of diverter 146 runs along the panel flat
114. The diverter 146 also has a diversion surface 420 and fastener
holes 430 along the lower flange.
[0085] At one end of diverter 146 is a rib mating surface 440 and
at the other end is a rib sealing plate 450.
[0086] FIGS. 13 through 15 show the lower closure 150 that is used
to maintain a weather tight seal at the lower end of the assembly.
Shown in reference to the side rails 142 and 144 in FIG. 13, lower
closure 150 is adapted to fit the profile of the rib 112. The side
rails 142 and 144 abut lower closure 150 and the height of the
lower closure 150 matches the heights of the side rails.
[0087] Lower closure 150 has an upper flange 500 and a lower flange
510, as well as an upstanding closure web 520. The lower flange 510
includes fastener holes 530.
[0088] The lower closure 150 also includes rib mating surfaces 540
and 550 to provide a tight fit along the ribs 112.
[0089] Looking now to FIGS. 16 and 17, the adaptation of the system
for the application of multiple roof penetrating structures is
described. A chief aspect of the assembly 100 is the reduction in
the number of roof penetrations required to provide daylight to the
interior of a structure, as fewer, longer cuts can be made along
the roof elevations. This small number of openings can be
maintained along a single rib, with one continuous opening, rather
than multiple openings, permitting an equal or greater amount of
ambient light into the building.
[0090] In the case of standing seam roofs, the system provides the
ability to remove roof panel material only in the panel flat
portion of the panel. This maintains the structural integrity of
the roof in that multiple sections of major panel elevations are
not removed, as is done to accommodate a "typical" curb assembly.
Thus, the roof's structural integrity is not compromised to that
extent and there are fewer potential areas for water infiltration,
in that the skylight panels can be attached very near the ridge of
the building and run to the eave, requiring water to be diverted
only once near the ridge of the roof plane and only across one
panel flat.
[0091] To the limited extent that cutaways are made to the
elevations, these are made small, on the order of a few inches or
less, solely for the purpose of allowing drainage past the
skylights.
[0092] The rail and closure assembly 100 is particularly useful for
continuous runs of skylights end to end. FIG. 16 shows how two
adjacent skylights of the rail and closure assembly 100 can be
affixed along a standing seam panel roof 110. Instead of producing
the lights with diverters and lower closures, where adjacent lights
abut, the rail and closure structures 140 are provided with upper
and lower standing rib frames 600 and 610 at adjacent ends of the
adjacent structures 140. A batten 620 is provided to secure the
system 100 against the elements.
[0093] FIG. 17 is a side elevation view of the batten 620, showing
how the batten fits over the adjacent upper and lower standing rib
frames 600 and 610.
[0094] As one example, skylights can be produced in units of up to
10 feet long, and connected end to end for as long a distance as
necessary, as each skylight unit is supported by the ribs of the
roof profile. The standing rib elevation (the major corrugation)
runs longitudinally along the length of the assembly and mates with
the respective rails 142, 144 along the entire length of assembly
100, regardless of the number of adjacent structures 140. No water
can enter over the top of the rail and closure assembly.
[0095] Where it is desired that the skylight starts at the ridge of
the roof, a simple flashing can be inserted under the ridge
cap.
[0096] Where the ridge cap has a configuration to fit the rib
elevations (major corrugations) in the roofing panels, a portion of
the one rib may be cut out (approximately 2''), allowing the water
from the roof panel above to be diverted onto the next adjacent
roof panel.
[0097] If desired, a simple rail enclosure extension could be used
to increase the height or distance between the top of the skylight
frame and the roof panel, and can be adapted to simply lay over or
attach to the top of the rail and closure structure. Such an
extension can be produced to extend along the upper flange of the
rail and closure structure, to effectively raise the height of the
skylight or smoke vent to accommodate different skylight depths or
other design features, or to accommodate snow conditions and the
like. In this fashion, the rail and closure structure can be
produced to a standard height, with upward extensions optionally
being used to elevate the overall height of the structure for such
varied purposes. Various forms for such an extension are suitable,
and the skilled artisan will understand various ways and means of
designing and manufacturing such extension to accomplish the goal
of added height to the skylight.
[0098] While this invention has been described in conjunction with
the specific embodiments outlined above, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, the preferred embodiments of
the invention, as set forth above, are intended to be illustrative,
not limiting. Various changes may be made without departing from
the spirit and scope of this invention.
* * * * *