U.S. patent application number 15/884000 was filed with the patent office on 2018-07-19 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 | 20180202164 15/884000 |
Document ID | / |
Family ID | 44787048 |
Filed Date | 2018-07-19 |
United States Patent
Application |
20180202164 |
Kind Code |
A1 |
Pendley; Timothy ; et
al. |
July 19, 2018 |
Supporting A Load On A Roof
Abstract
The invention provides a system for installing a roof
penetrating structure to a metal roof, the system comprising: a) a
rail and closure structure adapted to be supported by adjacent rib
elevations of said roof; b) a skylight adapted to be supported on
the rail and closure structure; and c) a support member for sealing
a cut away portion of the rib structure to divert water away from
the rail and closure structure.
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.: |
15/884000 |
Filed: |
January 30, 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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15884000 |
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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 13/0315 20130101;
E04D 3/365 20130101; E04D 13/031 20130101; E04D 3/36 20130101; E04D
3/364 20130101; E04D 3/24 20130101; E04D 13/0305 20130101; E04D
3/30 20130101; E04D 13/03 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 sloping metal roof on a building, said sloping metal roof
comprising a plurality of elongate metal roof panels arranged side
by side, such roof panels having lengths and widths, edges of
adjacent such roof panels meeting at elevated rib structure
portions thereof, first and second ones of said rib structure
portions being joined to each other to define elevated roof panel
ribs, having lengths, panel flats being disposed between such
elevated roof panel ribs, said panel flats having widths extending
between respective ones of said elevated roof panel ribs, a load
being mounted on said roof, said load being supported by a load
support structure, said load support structure comprising first and
second rails having lengths extending in same directions as the
lengths of said elevated roof panel ribs, a said rail comprising a
lower shoulder, a generally vertically upstanding web extending
upwardly from the lower shoulder, and a generally horizontal upper
support flange at an upper edge of said generally vertically
upstanding web, first and second ones of said roof panel ribs
underlying, and supporting, said first and second rails, leading,
intermediate, and trailing portions of the length of said first
rail being mounted to a first said rib, said first rail extending
upwardly from and above said first rib to said load, substantially
all of a downwardly-directed force of said load passing downwardly
through said rails at said generally vertically upstanding web, and
from said rails downwardly to underlying ones of said ribs, and
from said ribs downwardly to structural support members of said
building, said load extending between said first and second rails
across an entirety of the width of the respective panel flat.
22. A sloping metal roof as in claim 21, a distance between said
first and second rails spanning an entirety of the width of a given
said panel flat, said panel flat being between said first and
second rails and being sufficiently unobstructed proximate said
load that water can freely flow down said panel flat between said
first and second rails and under said load.
23. A sloping metal roof as in claim 21, a distance between said
first and second rails spanning an entirety of a width of a given
such panel flat, further comprising end closures at up-slope and
down-slope ends of said load support structure, said end closures
extending between said first and second rails and closing off
access to the respective roof panel flat under said load and
between, and alongside said first and second rails.
24. A sloping metal roof as in claim 23, said end closures
comprising an upper diverter at the up-slope end of said load
support structure and a lower closure at the down-slope end of said
load support structure.
25. A sloping metal roof as in claim 24, a lower portion of an end
panel of said upper diverter defining a downwardly-directed slope
extending across the width of the respective metal roof panel
thereby to direct water, flowing by gravity toward said load
support structure, laterally across the respective metal roof panel
at said upper diverter.
26. A sloping metal roof as in claim 21, leading, intermediate, and
trailing portions of the length of said second rail being mounted
to a second such rib, said second rail extending upwardly from and
above such second rib to said load.
27. A sloping metal roof as in claim 21, said load being disposed
above respective elevations of the panel flats which are next
adjacent said load support structure.
28. A sloping metal roof as in claim 21, said load, at a given
location along the length of a given said rail, being disposed
above a top of the given said rail at the given location.
29. A sloping metal roof as in claim 21 wherein said load support
structure spans an entirety of the width of a single panel flat
between said first and second rails.
30. A sloping metal roof as in claim 21, substantially all of the
downwardly-directed force of said load passing downwardly through
respective ones of said roof panels.
31. A sloping metal roof on a building, said sloping metal roof
comprising a plurality of elongate metal roof panels arranged side
by side, such roof panels having lengths and widths, edges of
adjacent such roof panels meeting at elevated rib structure
portions thereof, first and second ones of said rib structure
portions being joined to each other and thereby defining elevated
roof panel ribs, having lengths, panel flats being disposed between
such elevated roof panel ribs, said panel flats having widths
extending between respective ones of said elevated roof panel ribs,
a load being mounted on said roof, said load being supported by a
load support structure, said load support structure comprising
first and second rails having lengths extending in same directions
as the lengths of said elevated roof panel ribs, said load support
structure extending across an entirety of the width of at least one
said panel flat, from a first said elevated roof panel rib to a
second said elevated roof panel rib, said first rail defining a
first side of said load support structure and being mounted to said
first rib at leading, intermediate, and trailing portions of the
length of said first rail, said second rail being mounted to said
second rib at leading, intermediate, and trailing portions of the
length of said second rail at a second opposing side of said load
support structure, said load support structure defining a support
flange at one or more elevations above the panel flat of a
respective next adjacent said first roof panel across an entirety
of the width of said support structure from said first rib to said
second rib, said load being mounted to said load support structure
at said support flange, said load support structure being disposed
between said load and one or more of said roof panels,
substantially all of a downwardly-directed force of said load
passing downwardly through said first and second rails, to
underlying ones of said elevated roof panel ribs, and from said
ribs downwardly to structural support members of said building.
32. A sloping metal roof as in claim 31, said support flange
extending about an entirety of a perimeter of said load support
structure.
33. A sloping metal roof as in claim 31, a distance between said
first and second rails spanning an entirety of a width of a given
said panel flat, said panel flat being between said first and
second rails and being sufficiently unobstructed proximate said
load that water can freely flow down said panel flat under said
load and between and alongside said first and second rails.
34. A sloping metal roof as in claim 31, further comprising end
closures at up-slope and down-slope ends of said load support
structure, said end closures extending between said first and
second rails and closing off access to the respective roof panel
flat under said load and between and alongside said first and
second rails.
35. A sloping metal roof as in claim 34, said end closures
comprising an upper diverter at the up-slope end of said load
support structure and a lower closure at the down-slope end of said
load support structure.
36. A sloping metal roof as in claim 35, a lower portion of an end
panel of said upper diverter defining a downwardly-directed slope
extending across the width of the respective metal roof panel
thereby to direct water, flowing by gravity toward said load
support structure, laterally across the respective metal roof panel
at said upper diverter.
37. A sloping metal roof as in claim 31, substantially all of the
downwardly-directed force of said load passing downwardly through
respective ones of said roof panels.
38. A sloping metal roof as in claim 33, said panel flat being
sufficiently unobstructed proximate said load that water can freely
flow along the respective said panel flat and under said load.
39. A sloping metal roof as in claim 31, said load, at a given
location along the length of a given said rail, being disposed
above a top of the given said rail at the given location.
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 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 Weinser, 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. The skylight curb portion is shaped to fit
over a portion of the prefabricated skylight support curb angled
upright portion and top lip. The skylight support curb is shaped to
nest an accompanying skylight therein having the skylight curb
portion adjacent to the interior of the skylight support curb
angled upright walls to protect the skylight during shipping and
storing.
[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. 4,642,466, by Sanneborn, 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 being adjacent to the width
of the installation distance and are obliquely bent inwardly on
both sides, and at least one inner projection which engages between
the facing corner edges of the connecting webs in the installed
position, thus maintaining these corner edges at the installation
distance.
[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 end 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.
[0014] None of the prior approaches have been able to provide an
installation system for multiple skylights that accomplishes all
the goals of economy and simplicity of installation and will work
equally well for new buildings and as a retrofit in existing
buildings.
SUMMARY OF THE INVENTION
[0015] 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 roof system
panel. 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.
[0016] 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
assembly adapted to be supported on a major rib elevation a metal
roof, typically where the elevation has been cut to accommodate
drainage. The balance of the rib is to provide structural support
for the rail assemblies.
[0017] Also in the preferred embodiment, the skylight/smoke vent
system includes a skylight adapted to be supported on the rail and
closure assembly, and a bearing plate structure for supporting and
sealing the portion of the elevations that have been cut away
preventing water accumulation at the surface, thus preventing water
egress into the building.
[0018] In a further preferred embodiment, 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 egress.
[0019] In another preferred embodiment, the invention provides a
skylight system where the metal roof is selected from the group of
roofs comprising a standing seam roof, an architectural standing
roof and a snap seam roof.
[0020] In another preferred embodiment, the invention provides a
skylight system where the rib has been cut in only one
location.
[0021] In a further preferred embodiment, the invention provides a
skylight system where the standing seam roof has trapezoidial rib
elevations.
[0022] In still further preferred embodiment, the invention
provides a skylight system where the ribs are about 24'' to about
30'' on center.
[0023] In a different preferred embodiment, the invention provides
a skylight system where the metal roof is selected from the group
of roofs comprising an architectural standing roof and a snap seam
roof, and where the vertical rib configurations are about 12'' to
about 18'' on center.
[0024] In still further preferred embodiment, the invention
provides a skylight system where the metal roof is an exposed
fastener roof system.
[0025] In one preferred embodiment, the invention provides a
skylight system where the rib has been cut in two locations.
[0026] In a different preferred embodiment, the invention provides
a skylight system having a trapezoidial or rectangular rib
elevation 8'' to 12'' on center.
[0027] In another preferred embodiment, the invention provides a
skylight system where the exposed fastener roof is of the type
having roof panels fastened directly to the roof purlin from the
top side of the roof panel.
[0028] In a further preferred embodiment, the invention provides a
skylight system where the system comprises two or more skylights
supported end to end.
[0029] In a different preferred embodiment, the invention provides
a skylight system (including smoke vents) where each of the
skylights are about 10 feet in length.
[0030] In one preferred embodiment, the invention provides a
skylight system where the rail and closure assembly moves with the
rib elevation.
[0031] In different preferred embodiment, the invention provides a
skylight system further comprising a ridge cap configured to fit
over the standing rib elevations at the ridge of the roof.
[0032] In a further preferred embodiment, the invention provides a
skylight system where a lower closure of the skylight rail and
closure assembly extends across the top of the metal roof panel
profile.
[0033] In one preferred embodiment, the invention provides a
skylight system where the closure is configured to match the roof
panel surface adjacent rib elevations for sealing.
[0034] In a further preferred embodiment, the invention provides a
skylight system where the closure is pre-cut to match the roof
surface and adjacent rib elevations for sealing.
[0035] In a still further preferred embodiment, the invention
provides a skylight system where the rail and closure assembly is
fastened directly to the rib elevations using screws or rivets.
[0036] Where an extension is attached to the upper flange of the
rail and closure assembly to effectively raise the height of the
skylight or smoke vent to accommodate snow conditions and the
like.
[0037] In a preferred embodiment, the invention provides a skylight
system further comprising a safety security guard attached to the
rail assembly.
[0038] In a still further preferred embodiment, the invention
provides a skylight system where the rail and closure assembly
comprises an extended down leg on the inside of the roof cut away
segment.
[0039] In another preferred embodiment, the invention provides a
skylight system where the rail and closure assembly forms a water
tight seal with the rib elevation.
[0040] In a preferred embodiment, the invention provides a skylight
system where a side rail elevation attaches to the interior of the
rib elevation.
[0041] In a further preferred embodiment, the invention provides a
skylight system where the side rail elevation attaches to the
anterior of the rib elevation.
[0042] In a different preferred embodiment, the invention provides
a skylight system where a portion of the adjacent rib elevation is
cut away to accommodate drainage along the roof surface.
[0043] In a still further preferred embodiment, the invention
provides a skylight system where a portion at only one adjacent rib
elevation is cut away to accommodate drainage along the roof
surface.
[0044] In another preferred embodiment, the invention provides a
skylight system where a portion at two or more adjacent rib
elevations is cut away to accommodate drainage along the roof
surface.
[0045] 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
[0046] 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
conjunction with the accompanying drawings wherein various figures
depict the components and composition of the multiple skylight
system.
[0047] FIG. 1 is a view showing the roof profile of a metal roof of
the type known as the standing seam roof panel.
[0048] FIG. 2 is a view showing the roof profile of a metal roof of
the type known as an architectural standing seam roof.
[0049] FIG. 3 is a view showing the roof profile of a metal roof of
the type commonly referred to as a snap seam roof.
[0050] FIG. 4 is a view showing the roof profile of a metal roof of
the type commonly referred to as an exposed fastener roof
panel.
[0051] FIG. 5 is a view showing the roof profile of a metal roof of
the type commonly known as foam core panel.
[0052] FIG. 6 is a side view showing the major components of the
system as installed on a metal roof.
[0053] FIG. 7 is a top plan view of the installed system, showing
the placement of skylights and the direction of water flow over the
roof.
[0054] FIG. 8 is a cross sectional view showing the connections of
the skylight frame to the rail and closures structure, and the
latter affixed over the outer surfaces of adjacent rib elevations
of the metal roof.
[0055] FIG. 9 is a cross sectional view showing an alternative
arrangement for the elements shown in FIG. 8, only with the rail
and closure structure connecting along the inner faces of adjacent
rib elevations.
[0056] FIG. 10 is a perspective view partially cut away showing
internal structure of the system as installed on the rib elevations
of a metal roof.
[0057] FIG. 11 is a perspective view of the upper rain pan or
diverter of the rail and closure structure.
[0058] FIG. 12 is a top view of the upper rain pan or diverter of
the rail and closure structure.
[0059] FIG. 13 is a front plan view of the upper rain pan or
diverter of the rail and closure structure.
[0060] FIG. 14 is a perspective view of the lower rain pan or lower
closure of the rail and closure structure.
[0061] FIG. 15 is a top view of the lower rain pan or lower closure
of the rail and closure structure.
[0062] FIG. 16 is a front plan view of the lower rain pan or lower
closure of the rail and closure structure.
[0063] FIG. 17 is a perspective and partially cut away view showing
a connection of adjacent skylights of the system.
[0064] FIG. 18 shows detail of how the batten connects adjacent
skylights and prevents water egress between them.
DETAILED DESCRIPTION OF THE INVENTION
[0065] The products and methods of the present invention provide a
skylight rail and closure system for use in installing various roof
penetrating structures in metal 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.
[0066] The number of skylights can vary from one to many structures
connecting end to end be from one to as many as the building roof
structure will support, limited only by the amount of support
provided by the roof surface structure, which is left largely
intact during the installation process.
[0067] The system utilizes the major rib structure in the roof as
the primary support structure and water barrier to fasten the
skylight assembly. Typical skylight installations do not allow for
continuous runs, but use a curb construction that is typically 2-3
times wider than the present system.
[0068] The present skylight system does not require a complex
structure underneath the panels or a separate curb construction to
support or attach the skylight. The rail and closure assembly is
overlaid onto the roof system and allows for thermal expansion and
contraction by utilizing the major profiles of the metal roof panel
for support. This is accomplished through direct attachment of the
rail assembly and a combination of the panel flat and major ribs
for support and attachment of the closure assembly.
[0069] 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.
[0070] The skylight system may be applied to various types of
ribbed roof profiles. FIG. 1 is a view showing the roof profile of
a metal roof of the type known as the standing seam roof panel 10.
These include the "standing seam" roof, which 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.
[0071] 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.
[0072] 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, panel flat 34. Adjacent
R panels are secured to the roof through a structural fastener 35,
and at the shoulder 36 which is formed from overlapping regions, or
side lap 38, the adjacent panels are secured through a stitch
fastener 39. The trapezoidal major ribs of the R panel roof are
most typically formed at 8'' to 12'' on center.
[0073] 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 40. Snap
seam panels 40 have a panel flat 44 and a standing seam or snap
seam 48 at adjacent panels.
[0074] FIG. 5 is a view showing the roof profile of a metal 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. This panel is typically
installed from the interior of the building.
[0075] The system includes a rail and closure assembly adapted to
be supported onto the major elevations, seams, rib structures, or
other structural elements of such roof profiles, where the standing
structure provides the support, and the skylight is secured through
an opening formed in the intervening, non-structural roof flat
region.
[0076] 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.
[0077] 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 a series of cutaway
regions, or gaps 122 formed to accommodate the structure, as
described more fully as follows.
[0078] 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 assembly
system.
[0079] Again in reference to FIGS. 6 and 7, the system includes a
rail and closure structure 140, generally comprised of side rails
142 and 144, and upper diverter 146 disposed at the rib cutaway
section, or gap 122. At this gap 122 a plate 148 may be located
under the gap 122 to prevent water leakage from roof. In assembling
the rail and closure structure to a roof, the plate 148 may be
sealed and fastened securely to the roof panel supports.
[0080] Looking more particularly to FIG. 7 it is shown 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.
[0081] The rail and closure assembly structure 140 may also include
a lower closure 150 to seal the system from the elements.
[0082] In reference now to FIG. 8, there is shown a cross section
through the skylight 130 region of the rail and closure structures
100, showing the securement of the assembly 100 to the standing
seam panel roof 110. In particular, FIG. 8 depicts the use of the
rib 112 to support the side rails 142 and 144. It is seen that 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 the a fastener 300.
[0083] The rail shoulder 242 is shaped to fit closely over outside
of the roof rib 112, and is secured to roof rib 112 by a rivet 310.
The rail bearing surface 240 supports the skylight frame 132, where
a sealant 330 can be applied to seal against the passage of water
or air.
[0084] FIG. 9 depicts a variation of the rail and closure assembly
100 shown in FIG. 8, only where the rail shoulder 242 is shaped to
fit closely along the inside of the roof rib 112, and is secured to
roof rib 112 by rivet 310. As for FIG. 8, the rail bearing surface
240 similarly supports the skylight frame 132, where a sealant 330
can be applied.
[0085] 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 provided be used to seal
the open area of the panel roof.
[0086] In FIG. 10 a partially cut away perspective view of the rail
and closure structure 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.
In FIG. 10 it is seen how the rail and closure system incorporates
the structural profile of the upper panels of metal roof structure,
the elevations and ribs used in sealing adjacent panels, to provide
the support of adjacent skylights. In this fashion, the system
adopts various advantages of a standing seam roof.
[0087] 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 eave and allowed to expand and
contract over at ridge. Very wide roofs can be fixed at midspan and
expand towards both the cave and ridge. The design of the skylight
system takes full advantage of the floating features of
contemporary roofing structures, and when a skylight is so secured
to the elevations, the skylight assemblies themselves are able to
draw strength from the structural load bearing capacity of the roof
profile.
[0088] Shown in FIG. 10 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 in the roof 122.
[0089] The skylight 130 is supported on the rail and closure
structure 140, as previously described.
[0090] 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.
[0091] In application, from each structure 140 a single rib 112 is
typically cut away to accommodate drainage at the high 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 may be cut for roofs having an "R" panel profile.
[0092] The retained portions of rib 112 serve as a beam 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 may be
removed to allow additional light from the skylight 130.
[0093] 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.
[0094] 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 fasteners such as screws and the like.
The rail and closure structure 140 may also be designed to accept a
safety security guard before the skylight is installed.
[0095] Looking now to FIGS. 11 through 13, an upper or high end
diverter 146 provides closure and diversion of water around the top
of the assembly to an adjacent panel flat. Diverter 146 also
provides a weather tight seal at the upper end of the assembly,
with the plate 148 (not shown). In reference to the side rails 142
and 144 of 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 actually acts with upper
flanges 240 of the side rails 142 and 144 to form the bearing
surface of the skylight frame.
[0096] The diverter 146 lower flange 410 runs along the panel flat
114. The diverter 146 also has a diversion surface 420 and fastener
holes 430 along the lower flange.
[0097] At one end is a rib mating surface 440 and at the other a
rib sealing plate 450 is formed.
[0098] FIGS. 14 through 16 shows the low end closure 150 that is
used to maintain a weather tight seal at the lower end of the
assembly. Shown again in reference to the side rails 142 and 144 of
a standing seam panel roof 110, the closure 150 is adapted to fit
the profile of the rib 112. The side rails 142 and 144 abut the
closure 150 and the height of the closure 150 matches them in
height.
[0099] Looking to the closure 150, it is seen to have an upper
flange 500 and a lower flange 510, as well as a closure web 520.
The lower flange 510 includes fastener holes 530.
[0100] The closure 150 also includes rib mating surfaces 540 and
550 to provide a tight fit along the ribs 112.
[0101] Looking now to FIGS. 17 and 18, 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. These minimized openings can be maintained
along a single rib, if desired, with one continuous opening versus
many smaller ones permitting an equal or greater amount of ambient
light into the building.
[0102] In the case of standing seam roofs the system provides the
ability to remove only a portion of the bottom flat 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 cave requiring water to be diverted only once near
the ridge of the roof plane and only across one panel flat.
[0103] 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.
[0104] The rail system is designed to install to either the inside
or outside of the major rib elevation for any of the aforementioned
roof panel profiles.
[0105] The rail and closure assembly 100 is particularly useful for
continuous runs of skylights end to end. FIG. 17 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 curb 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.
[0106] FIG. 18 is a side elevational view of the batten 620,
showing how it fits over the adjacent upper and lower standing rib
frames 600 and 610.
[0107] As only one example, skylights can be produced in units of
up to 10 feet long, and connected in this fashion for as long as
necessary, as each skylight unit is supported by the primary rib of
the profile. The standing rib elevation (the major corrugation)
runs longitudinally along the length of the assembly and mates
along the entire assembly 100, regardless of the number of adjacent
structures 140. No water can enter over the top of the rail and
closure assembly.
[0108] Where it is desired that the skylight starts at the ridge of
the roof, a simple flashing can be inserted under the ridge
cap.
[0109] 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 on to the next panel.
[0110] If desired, a simple rail enclosure extension could be used
to increase the height or distance between top skylight frame and
the roof panel, and can be adapted to simply lay over or attach to
the top of the rail and closure assembly. Such an extension could
be produced to rest along the upper flange of the rail and closure
assembly, 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 varying extensions used to elevate the
overall height of the structure for such varied purposes. Various
forms for such an extension would be suitable, and the skilled
artisan will understand various ways and means of designing and
manufacturing these to accomplish the goal of added height to the
skylight.
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.
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