U.S. patent number 10,385,570 [Application Number 15/884,000] was granted by the patent office on 2019-08-20 for supporting a load on a roof.
This patent grant is currently assigned to T&M Inventions, LLC. The grantee listed for this patent is T&M Inventions, LLC. Invention is credited to Michael J. McLain, Timothy Pendley.
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United States Patent |
10,385,570 |
Pendley , et al. |
August 20, 2019 |
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) |
Applicant: |
Name |
City |
State |
Country |
Type |
T&M Inventions, LLC |
McFarland |
WI |
US |
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Assignee: |
T&M Inventions, LLC
(McFarland, WI)
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Family
ID: |
44787048 |
Appl.
No.: |
15/884,000 |
Filed: |
January 30, 2018 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20180202164 A1 |
Jul 19, 2018 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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14482471 |
Sep 10, 2014 |
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13771746 |
Sep 16, 2014 |
8833009 |
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12932892 |
May 14, 2013 |
8438798 |
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12572176 |
Oct 1, 2009 |
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61102333 |
Oct 2, 2008 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D
3/24 (20130101); E04D 3/30 (20130101); E04D
3/364 (20130101); E04D 3/36 (20130101); E04D
13/03 (20130101); E04D 13/0315 (20130101); E04D
13/031 (20130101); E04D 13/0305 (20130101); E04D
3/365 (20130101) |
Current International
Class: |
E04D
3/30 (20060101); E04D 3/24 (20060101); E04D
3/36 (20060101); E04D 3/367 (20060101); E04D
13/03 (20060101); E04D 3/365 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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981948 |
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Feb 1965 |
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GB |
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2000-336859 |
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May 2000 |
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JP |
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2001-214577 |
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Aug 2001 |
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JP |
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2008-202372 |
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Sep 2008 |
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JP |
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WO 2010/040006 |
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Apr 2010 |
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WO |
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Other References
Cross-section and pictorial views of SSR-TUF-LITE daylighting
panels, 1 sheet. cited by applicant .
Cross-section of VP TUF-LITE Panel--attached to the side of SSR
rib, 1 sheet. cited by applicant .
Cross-section of Butler LITE Panel--attached to the side of MR24
rib, 1 sheet. cited by applicant .
FAA Facility, photos of skylight installation, 3 pages, Sacramento,
CA, prior to 2007. cited by applicant .
Siemens Building, photos of skylight installation, 6 pages, prior
to 2007. cited by applicant .
R & S Manufacturing and Sales Company, Inc., Standing Seam 24
Light, Quick Installation Instructions, Under/Over Seam Clip, 12
pages, Newbury Park, CA, Aug. 2012. cited by applicant .
R & S Manufacturing and Sales Company, Inc., SS 24 Light, The
First Truely Thermally Broken Metal Building Skylight,
informational sheet, 1 page, Newbury Park, CA, Aug. 2012. cited by
applicant .
R & S Manufacturing and Sales Company, Inc., Enlarged sketch of
metal roof showing the down slope, 1 page, Newbury Park, CA, Aug.
2012. cited by applicant .
Daljcon, LLC., Butler Manufacturing, www.daljcon.com, Example of 6
Layer Standing Seam, printed Dec. 11, 2012. cited by applicant
.
Side Rails, used with thermal break, some showing thermal breaks,
Technical Drawings, 15 pages, release and revision dates Jan. 10,
2014 to Apr. 30, 2014. cited by applicant .
Front Diverter and Diverter Assemblies, Technical Drawings, 10
pages, release and revision dates Jan. 13, 2014 to Jan. 30, 2014.
cited by applicant .
Front and Rear Closures, Technical Drawings, 5 pages, release and
revision dates Jan. 13, 2014 to Apr. 30, 2014. cited by applicant
.
PVC Thermal Break (for Extruded Side Rail), 2 pages, release and
revision dates Jan. 10, 2014 to Mar. 26, 2014. cited by
applicant.
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Primary Examiner: Triggs; Andrew J
Attorney, Agent or Firm: Wilhelm; Thomas D. Northwind IP
Law, S.C.
Parent Case Text
REFERENCE TO RELATED APPLICATION
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.
Claims
What is claimed is:
1. A metal panel roof, said metal panel roof comprising a plurality
of elongate metal roof panels arranged side by side, such metal
roof panels having lengths and widths, edges of adjacent such metal
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 respective elevated roof panel ribs, having
rib lengths, panel flats being disposed between such elevated roof
panel ribs, said panel flats having panel flat widths extending
between respective ones of said elevated roof panel ribs, a load
being mounted on said roof, a rail and closure structure underlying
and supporting said load, said load having a first end and a second
end, and a load length between the first end and the second end,
and extending in a same direction as the lengths of said elevated
roof panel ribs, said rail and closure structure comprising first
and second rails, separate and distinct from said load, said rails
having rail lengths extending substantially the full length of said
load, said rails directly contacting underlying ones of said ribs
and extending upwardly from said underlying ribs, said rails
supporting said load, said underlying ribs supporting said rails
between the first end of said load and the second end of said load,
substantially all downwardly-directed force of said load passing
downwardly through said rails, and passing from said rails
downwardly to said underlying ones of said ribs.
2. A metal panel roof as in claim 1, 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 rail and closure structure, said end
closures extending between said first and second rails, said load,
in combination with said rail and closure structure comprising a
rail and closure assembly, said rail and closure assembly forming a
water tight seal with the rib elevation.
3. A metal panel roof as in claim 2, said end closures comprising
an upper diverter at the up-slope end of said rail and closure
structure and a lower closure at the down-slope end of said rail
and closure structure.
4. A metal panel roof as in claim 3, a lower portion of an end
panel of said upper diverter defining a downwardly-directed slope
extending across the width of the respective panel flat thereby to
direct water, flowing by gravity toward said rail and closure
structure, laterally across the respective metal roof panel at said
upper diverter.
5. A metal panel roof as in claim 1, said load being disposed above
respective elevations of the panel flats which are next adjacent
said rail and closure structure.
6. A metal panel roof as in claim 1, 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.
7. A metal panel roof as in claim 1, aid rail and closure structure
surrounding an area on said roof and extending, from the underlying
roof panels, upwardly to a top of said rail and closure structure,
and wherein said rail and closure structure spans an entirety of
the width of a said panel flat between said first and second
rails.
8. A metal panel roof as in claim 1, all downwardly-directed force
of said load passing downwardly through respective ones of said
roof panels.
9. A metal panel roof as in claim 1, said load passing from said
ribs downwardly to structural support members of said building.
10. A metal panel roof as in claim 1, upper bearing surfaces of
said rails supporting said load above said ribs.
11. A metal panel roof as in claim 1, substantially all
downwardly-directed force of said load passing downwardly through
said rails, including along substantially the full length of said
load.
12. A metal panel roof, said metal panel roof comprising a
plurality of elongate metal roof panels arranged side by side, such
metal roof panels having lengths and widths, edges of adjacent such
metal roof panels meeting at elevated rib structure portions
thereof, ones of said rib structure portions being joined to each
other and thereby defining elevated roof panel ribs, having rib
lengths, panel flats being disposed between such elevated roof
panel ribs, said panel flats having panel flat widths extending
between respective ones of said elevated roof panel ribs, a load
being mounted on said roof, said load being supported by a rail and
closure structure, said rail and closure structure having a length
and a width, and comprising first and second rails, separate and
distinct from said load, said rails having lengths extending in
same directions as the lengths of said elevated roof panel ribs,
said rail and closure 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 rail and closure structure, said
second rail defining a second opposing side of said rail and
closure structure, said first and second rails being mounted
directly to said first and second ribs, said rail and closure
structure defining a plurality of support flanges interfacing with
said load at a common elevation above the panel flat of a
respective next adjacent said first roof panel along the width and
the length of said rail and closure structure, said load exerting a
downwardly-directed force on said rail and closure structure at
said support flanges, said rail and closure structure being
disposed between said load and one or more of said roof panels,
substantially all downwardly-directed force of said load passing
downwardly through said rails, and passing from said rails
downwardly to underlying ones of said ribs.
13. A metal panel roof as in claim 12, said rail and closure
structure further comprising an upper diverter at an up-slope end
of said rail and closure structure and a lower closure at a
down-slope end of said rail and closure structure, said rail and
closure structure surrounding an area on said roof and extending,
from the underlying roof panels, upwardly to said support flanges,
each of said first and second rails, said upper diverter, and said
lower closure defining elements of said support flanges, and
defining upwardly-facing load bearing surfaces on said support
flanges.
14. A metal panel roof as in claim 12, further comprising end
closures at up-slope and down-slope ends of said rail and closure
structure, said end closures extending between said first and
second rails, said load, in combination with said rail and closure
structure comprising a rail and closure assembly, said rail and
closure assembly forming a water tight seal with the rib
elevations.
15. A metal panel roof as in claim 14, said end closures comprising
an upper diverter at the up-slope end of said rail and closure
structure and a lower closure at the down-slope end of said rail
and closure structure.
16. A metal panel roof as in claim 15, a lower portion of an end
panel of said upper diverter defining a downwardly-directed slope
extending across the width of the respective panel flat thereby to
direct water, flowing by gravity toward said rail and closure
structure, laterally across the respective metal roof panel at said
upper diverter.
17. A metal panel roof as in claim 12, all of the
downwardly-directed force of said load passing downwardly through
respective ones of said roof panels.
18. A metal panel roof as in claim 12, 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.
19. A metal panel roof as in claim 12, said load passing from said
ribs downwardly to structural support members of said building.
20. A metal panel roof as in claim 12, all downwardly-directed
force of said load passing downwardly through respective ones of
said metal roof panels.
21. A metal panel roof as in claim 12, upper bearing surfaces of
said rails supporting said load above said ribs.
22. A metal panel roof as in claim 12, substantially all
downwardly-directed force of said load passing downwardly through
said rails, including along substantially the full length of said
load.
Description
BACKGROUND OF THE INVENTION
Field of the Invention
The field of the invention is skylights systems.
Description of Related Art
Various systems are known for using curb construction for inserting
skylights and smoke vents into roofs.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
This invention provides for supporting a load on a roof. In one
aspect, 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.
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.
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.
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.
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.
In another preferred embodiment, the invention provides a skylight
system where the rib has been cut in only one location.
In a further preferred embodiment, the invention provides a
skylight system where the standing seam roof has trapezoidial rib
elevations.
In still further preferred embodiment, the invention provides a
skylight system where the ribs are about 24'' to about 30'' on
center.
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.
In still further preferred embodiment, the invention provides a
skylight system where the metal roof is an exposed fastener roof
system.
In one preferred embodiment, the invention provides a skylight
system where the rib has been cut in two locations.
In a different preferred embodiment, the invention provides a
skylight system having a trapezoidial or rectangular rib elevation
8'' to 12'' on center.
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.
In a further preferred embodiment, the invention provides a
skylight system where the system comprises two or more skylights
supported end to end.
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.
In one preferred embodiment, the invention provides a skylight
system where the rail and closure assembly moves with the rib
elevation.
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.
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.
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.
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.
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.
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.
In a preferred embodiment, the invention provides a skylight system
further comprising a safety security guard attached to the rail
assembly.
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.
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.
In a preferred embodiment, the invention provides a skylight system
where a side rail elevation attaches to the interior of the rib
elevation.
In a further preferred embodiment, the invention provides a
skylight system where the side rail elevation attaches to the
anterior of the rib elevation.
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.
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.
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.
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
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.
FIG. 1 is a view showing the roof profile of a metal roof of the
type known as the standing seam roof panel.
FIG. 2 is a view showing the roof profile of a metal roof of the
type known as an architectural standing seam roof.
FIG. 3 is a view showing the roof profile of a metal roof of the
type commonly referred to as a snap seam roof.
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.
FIG. 5 is a view showing the roof profile of a metal roof of the
type commonly known as foam core panel.
FIG. 6 is a side view showing the major components of the system as
installed on a metal roof.
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.
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.
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.
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.
FIG. 11 is a perspective view of the upper rain pan or diverter of
the rail and closure structure.
FIG. 12 is a top view of the upper rain pan or diverter of the rail
and closure structure.
FIG. 13 is a front plan view of the upper rain pan or diverter of
the rail and closure structure.
FIG. 14 is a perspective view of the lower rain pan or lower
closure of the rail and closure structure.
FIG. 15 is a top view of the lower rain pan or lower closure of the
rail and closure structure.
FIG. 16 is a front plan view of the lower rain pan or lower closure
of the rail and closure structure.
FIG. 17 is a perspective and partially cut away view showing a
connection of adjacent skylights of the system.
FIG. 18 shows detail of how the batten connects adjacent skylights
and prevents water egress between them.
DETAILED DESCRIPTION OF THE INVENTION
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 loads or other ventilating
structures, which can all be adapted to be supported on the rail
and closure assembly system.
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. FIGS. 6 and 7, collectively, show the rail 142 being
mounted to the rib by rivets 310 at leading, intermediate, and
trailing portions of the length of the rail. 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.
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.
The rail and closure assembly structure 140 may also include a
lower closure 150 to seal the system from the elements.
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. FIGS. 6 and 7 illustrate the skylight load length
extending in the same direction as the roof ribs 112. FIG. 8
illustrates the skylight load width. FIGS. 6-8 show the skylight
load being separate and distinct from the rail and closure
structure 140. FIGS. 6 and 7 also show the rails extending
substantially the full length of the skylight load. FIG. 8 shows
rails 142, 144 contacting respective underlying ones of the ribs
and extending upwardly from the underlying ribs, and supporting the
skylight load; and the underlying ribs supporting the rails along
substantially the full length of the skylight load.
In particular, FIG. 8 depicts the use of the ribs 112 to support
the side rails 142 and 144 on opposing sides of panel flat 14. It
is seen that each of rail 142, rail 144, and upper diverter 146,
has an upper support flange defining an upper bearing surface 240
at a common elevation above the panel flat of a next adjacent roof
panel, supported by a generally vertically upstanding web. Rails
142, 144 have lower shoulders 242 supporting the upstanding webs.
FIG. 11 shows the upper bearing surfaces of the diverter and the
rails at a common elevation.
FIG. 6, in combination with FIG. 8, shows that rails 142 and 144
extend substantially the full length of the overlying skylight
load, and that the skylight load is secured to the underlying rails
by fasteners 300 spaced along the lengths of the rails. The rails
142 and 144 extend upwardly from and above the ribs in contacting
and supporting the load, whereby substantially all of the
downwardly-directed force of the load passes downwardly through the
rails at the vertically upstanding webs, as elements of the rails,
and from the rails downwardly to the underlying ones of the ribs,
and from the ribs downwardly to structural support members of the
building. Particularly as illustrated in FIG. 7, as supported by
FIGS. 6, 8, and 10, all of the downwardly-directed force of the
skylight load passes downwardly through respective ones of the roof
panels, ultimately through the respective roof panel ribs, along
substantially the full length of the load, to underlying elements
of the building support structure. As illustrated in FIG. 7, the
load extends between the first and second rails across the entire
width of the respective panel flat.
The rail shoulder 242 is shaped to fit closely over the outside of
the roof rib 112, and FIG. 8, in combination with FIG. 6, shows the
rail secured directly to roof rib 112 by a rivet 310. A rail
support flange supports the skylight frame 132, where a sealant 330
can be applied to seal against the passage of water or air.
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.
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.
In FIG. 10 a partially cut away perspective view of the rail and
closure structure 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.
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.
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.
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.
The skylight 130 is supported on the rail and closure structure
140, as previously described.
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.
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.
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.
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.
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.
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 support
flange 400 of the diverter 146 actually acts with upper support
flanges 240 of the side rails 142 and 144 to form the bearing
surface of the skylight frame.
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.
At one end is a rib mating surface 440 and at the other a rib
sealing plate 450 is formed.
FIGS. 14 through 16 show 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 flange matches the in height of
flanges 240 of the side rails and the diverter, whereby the rail
and support structure defines a plurality of support flanges having
bearing surfaces all interfacing with said load at a common
elevation above the panel flat of a respective next adjacent roof
panel.
Looking to the closure 150, it is seen to have an upper support
flange 500 and a lower flange 510, as well as a closure web 520.
The lower flange 510 includes fastener holes 530.
The closure 150 also includes rib mating surfaces 540 and 550 to
provide a tight fit along the ribs 112.
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.
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.
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.
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.
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.
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.
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.
Where it is desired that the skylight starts at the ridge of the
roof, a simple flashing can be inserted under the ridge cap.
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.
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.
* * * * *
References