Note: Descriptions are shown in the official language in which they were submitted.
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1 STANDING SEAM ROOF SKYLIGHT
3 ACKGRO~ND OF THE INVENTION
1. Field of the Invention
7 The present invention relates to skylight
8 systems for standing seam roofs, shingle roofs and
9 sun rooms, and more particularly to a skylight
systems providing simple and leakproof installation
11 thereof~
12
13 2. Description of the Prior Art
14
The use of skylights in residences as well as
16 commercial buildings has become widespread in
17 recent years with the advent of low cost and rugged
18 plastic dome skylights. Self flashing plastic
19 skylights are popular, partly due to economies in
eliminating extensive curb construction. However,
21 some skill is required if a leakproof installation
22 is to be achieved and some customer dissatisfaction
23 has occurred from poor installation practices.
24 Certain types of roofs have not been suitable
for skylight installation. For example, it is
26 common in the southern parts of the United States
27 to construct patios, porches and the like using
28 sheet metal standing seam roofing. A typical roof
29 of this type utilizes long panels having upturned--
edges. The panels are laid side by side with the
31 upstanding edge of one panel contiguous with the
32 upstanding edge of adjacent panels. The upper
33 edges of the upstanding portions may be bent at
34 right` angles or rolled. In either style, an
interlocking bead is provided which snaps over the
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1 contiguous upstanding portions of the panels. This
2 type of roof also is widely used for metal
3 industrial buildings.
4 Although it is desirable in many installations
to install skylights in a standing seam roof,
6 difficulty has been experienced in adapting
7 standard plastic dome type skylights to the
8 standing seam metal roofs. Self flashing skylights
9 have been used which must be screwed to the metal
and require caulking compound to prevent leaking.
11 However, due to the differing expansion
12 coefficients of the plastic and sheet metal, it has
13 been found very difficult to prevent leaks.
14 Furthermore, openings must be cut into the metal
which reduces the strength of the roof and adds to
16 the labor cost.
17 There have been attempts to overcome these
18 problems. For example, it is known to form a
19 narrow continuous panel of acrylic plastic or the
like which will simply replace a standard metal
21 roof panel and which runs the entire length of the
22 roof. It is apparent that this type of unit must
23 be narrower than a standard roof panel since the
24 plastic lacks the required strength for a full
width panel.
26 Problems have also arisen in installing self
27 ~lashing plastic skylights in shingled roofs and
28 care must be taken to ensure freedom from leaks.
29 This problem is compounded when a so-called
sunroof, formed by joining a plurality of plastic
31 skylights together, is desired.
32 There is a need for a plastic dome type
33 skylight which can be installed at any point along
34 a metal roof panel without cutting an opening in
the metal panel, which will not experience
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1 difficulties with leakage and which can be
2 installed in a shingled roof with the same
3 watertight integrity that is obtainable with curb
4 type installations. Additionally, there is a need
for a self flashed skylight which can be
6 interlocked with others to form a leakproof
7 sunroof.
9 SUMMARY OF THE INVENTION
11 The present invention includes a plastic
12 skylight formed from acrylic sheet, CAB plastic
13 sheet, polycarbonate sheet or the like havinq a
14 conventional skylight dome formed therein and a
self flashing flange which may be installed in a
16 metal standing seam roof. The skylight is formed
17 to have the same width as a standard metal rooE
18 panel. The side flanges are bent upward to the
19 same height as the metal roofing standing seam and
2a the end edge flanges are formed in the same manner
21 ~s those of the metal roofing panels. The width of
22 the skylight is the same as that of the metal roof
23 panels. As may now be understood, the upstanding
24 edges of the skylight of the invention will mate
with the adjacent upstanding edges of the metal
26 panels of the roof. A standard metal seam clip and
27 batten are utilized and are clamped over the
28 standing seam. Other types of upper edges such as
29 a rolled edge can also be provided to be usable
with other roof seam designs. A flange is provided
31 at each end of the dome of the skylight which is
32 formed to overlap the ends of metal roof panels in
33 the same run with the skylight. The skylight
34 flanges are formed to make a snug fit with a metal
35 panel roof panel. The joint between the skylight
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1 and the adjacent panels in the same run may be
2 sealed with any suitable compound. Preferably, a
3 flat plastic sheet is bonded to a lower perimeter
4 of the skylight dome so as to provide a dead air
space for insulation properties. In an alternative
6 embodiment r an inverted dome may be bonded to the
7 flat sheet thereby providing two insulating air
8 spaces.
9 Some seam roofs have a flat upstanding seam.
One implementation of the invention is formed by
11 folding a flat self flashing flange of an all
12 plastic skylight up at 90 to fit against a flat
13 seam of a metal roof panel. A snap on seam cap is
14 installed over the plastic to metal seam.
The flat seam version of the invention is
16 suitable for installation on a shingled roof using
17 step flashing coupled to the upstanding seam by a
18 seam cap. The step flashing solves the leakage
19 problem experienced with prior art self flashing
plastic skylights.
21 In another embodiment of the invention used
22 for forming sloping sunroofs, an upstanding flat
~3 seam is provided along the sides of a plastic
24 skylight. The upper and lower edges are formed by
folding the lower edge and under the ~h~ upper edge
26 over, thereby producing means for interlocking
27 similarly formed skylights. A sun roof can be
28 produced by mounting a multiplicity of such
29 skylights with the lateral edges coupled by seam
caps and the folded edges by forming interlocking
31 joints. A grid of extruded metal rafters and
32 purlins can be used to support the skylights which
33 have suitable metal seam clips and C-clips to
34 secure the skylight edges and joints to the grid.
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Sealants are applied at all joints to prevent leaking.
As will be understood, the provision of the above
plastic skyliohts will permit fast and accurate assembly
and installation of skylights and sunroofs by relatively
unskilled workers, and will provide leakproof joints with
the roof.
Broadly speaking, therefore, the present
; invention provides a skylight molded from sheet plastic for
installation in a metal roof formed from a plurality of
metal roof panels, each of the metal panels having a pair
of parallel upstanding edges with means for joining such
edges with adjacent abutting upstanding edges comprising:
an essentially rectangular first sheet of plastic having a
~` pair of essentially parallel edges thereof folded upward to
form a right angle with the sheet of plastic, the upward
folded edge formed to match the upstanding seam edges of
the metal roof panels; and a dome formed in and projecting
upward from the sheet of plastic.
These and other features and advantages of the
invention will become apparent from the following detailed
description when read in conjunction with the drawings.
BRIEF DESCRIPTION O~ Tn~ DRAWINGS
Figure 1 is a perspective view of a typical
skylight dome in accordance with the invention.
Figure 2 is a top view of the dome skylight of
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Figure 1;
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Figllre 3 is a cross-sectional view of the
skylight of Figure 1 through the plane 3-3;
Figure 4 is a cross-sectional view of a double
skylight similar to that of Figure l;
Figure 5 is a cross-sectional view of a triple
skylight similar to that of Figure lo
'. Figure 6 shows a fragmentary perspective view of
a metal roof system having a skylight in accordance with
the invention installed therein;
Figure 7 is a cross-sectional view of the
skylight of Figure 1 in cross section showing the manner of
joining to two adjacent metal panels;
Figure 8 is a perspective view of a skylight in
accordance with the invention for use on shingled roofs and
the like;
Figure 9 is a partial cross-sectional view of a
skylight of Figure 6 installed on a shingled roof;
Figure 10 i9 a perspective view of a shroud
showing the manner of installing on the skylight of Figure
9;
Figure 11 is a perspective view of a skylight in
: accordance with the invention that is suitable for forming
sunroofs;
Figure 12 is a typical sunroof shown in
- perspective view using the skylights of Figure 11;
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1 Figure 13 is a partial cross sectional view of
2 the skylight of Figure 11 showing a standing seam
3 thereof;
4 Figure 14 shows in partial view the ends of
the skylight of Figure 11;
6 Figure 15 shows a cross sectional view of a
7 perimeter rafter of the sunroof of Figure 12
8 showing in partial view the installation of the
9 standing seam edge of the skylight thereof;
Figure 16 is a cross sectional view of an
11 interior rafter of the sunroof of Figure 12 showing
12 partially two abutting standing seams of the
13 skylight of Figure 11;
14 Figure 17 is a cross sectional view of the
front perimeter rafter of the sunroof of Figure 12
16 showing the manner of attaching the skylight end
17 thereto;
18 Figure 18 is a cross sectional view through a
19 purlin showing the manner of coupling the ends of
two of the skylights of Figure 11 and attaching to
21 the purlin;
22 Figure 19 is a perspective view of an anchor
23 clip util.ized with the standing edge seams of the
24 skylights of a sunroof of Figure 12; and
Figure 20 is a cross sectional view of the
26 rear perimeter rafter of the sunroof of Figure 12
27 showing the attachment to a building.
28
29 DETAILED DESCRIPTION OF TH~ PREFERRED EMBODIMENT
31 The present invention is an improved all
32 plastic skylight design that is applicable to
33 several types of roof structures~ In one
34 embodiment of the invention, a plastic dome type
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1 sky light is provided for use with metal standing
2 seam roof panels. Standing seam roof panels of
3 metal are generally found in a rectangular shape
4 having a flat or corrugated roof section with
standing seam portions bent upward at 90 along
6 each longitudinal edge. The standing seam height
7 may be on the order of two inches. Various designs
8 of the standing seam are available. In Figure 1,
9 one embodiment of the invention is shown for use
with metal standing seam roof panels in which the
11 top edge of the standing seam is bent inward at
12 90 and a seam is formed by a batten cap disposed
13 over the abutting standing seamO Thus, the
14 skylight 10 shown in Figure 1 has longitudinal-edge
upstanding seams 20 with a folded-over edge 16 to
16 match the metal standing seam roof panel with which
17 the sky light 10 will be used. It is to be
18 understood that other standing seam designs may
19 also be applied to the skylight 10 to match the
particular metal standing roof panel. This
21 implementation of the invention will be disclosed
22 with reference to the right angle edge 16 as shown.
23 Plastic sky light 10 may be made of any suitable
24 plastic sheet; however, a preferred material is
polycarbonate sheet such as General Electric
26 Lexan~. A dome or bubble 14 is formed in the
27 center of the plastic sheet leaving a flat poxtion
28 18 at one end and a flat portion 12 at the opposite
~9 end. Preferably~ a trough area 15 is provided
between seam 20 and dome 14 to insure water
31 drainage.
32 In Figure 2, a design feature of skylight
33 element 10 is indicated. As shown in somewhat
34 exaggerated form, the seam portions 20 are not
parallel but taper slightly longitudinally. This
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l produces a spacing A at one end of skylight lO and
2 a spacing B at the opposite end with respect to
3 parallel edges of metal roof panelsO This
4 deviation from a straight line may be on the order
of l/8 inch. This permits the narrow end 12 to be
6 inserted between the upstanding seams of an
7 abutting metal standing seam panel and the end of
8 the abutting steel panel at the opposite end will
9 slide inside of wide end 18. As will now be
recognized, dimensions A and B need only be
ll approximately the thickness of the sheet metal of
12 the metal roof panels. A cross section of the
13 skylight 10 of Figure l through the plane 3-3 is
14 shown in Figure 3. Although a single dome skylight
10 may be utilized, it is preferable to add a
16 rectangular plastic sheet 22 bonded to the edges of
17 dome 14. Plastic sh~et 22 serves two purposes: it
18 adds additional strength to the dome; and it
19 provides a dead air space for insulation purposes.
Another advantageous construction is shown in
21 the cross-sectional view of a double air space
22 slcylight of Figure 5. The skylight in accordance
23 with Figures 3 and 4 has an inverted plastic dome
24 23 bonded to the edges of plastic sheet 22 thus
forming two dead air spaces for additional
26 insulation.
27 A typical installation is shown in Figure 6.
28 Here, a roof structure is shown utilizing metal
29 standing seam panels 30 having standing seams 32.
As may be noted, metal panels 30 are secured
31 together by a batten strip 34 best seen in cross
32 section in Figure 7. Normally, a sealant is
33 applied to the mating surfaces of standing seams 32
34 and 30 and may also be applied to the inside of
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1 batten strip 34 before installing. Batten strip 34
2 is crimped about the edges formed in standing seams
3 32 and 20.
4 In Figure 6, a skylight 10 in accordance with
the invention has been installed between metal roof
6 panels 30A and 30B and adjacent metal roof panels
7 30C and 30D. As best noted in the cross sectional
8 view through skylight 10 and roof panels 30C and
9 30D of Figure 7, batten strip 34 is crimped around
skylight standing seam 20 and metal roof panel
11 standing seam 32. Sealant may be applied between
12 the seams 20 and 32 prior to installation. End 12
13 of skylight 10 has been inserted between standing
14 seams 32 of roof panel 30A at the lower end while,
at the upper end 18, the lower end of panel 30B has
16 been inserted between standing seams 20. Sealant
17 is placed across the entire length of the flat seam
18 formed at both the upper and lower edges. The
19 installation is made such that the pitch of the
roof is as shown by the arrow.
21 As may be recognized, skylight 10 can be the
22 full width of a metal roof panel 30 and may be
23 installed at any place in the roof desired.
24 Similarly, the length of skylight 10 may be
selected in accordance with the amount of exposure
26 desired.
27 An embodiment of the invention which is
28 suitable for use in shingled roofs, either during
29 new construction or in modification of e~isting
roofs, is shown in Figure 8. Skylight 60 is formed
~`'3 31 from sheet pl~/stic having a dome 64 and upper and
32 ~ lower edges ~ and 66. The longitudinal edges are
33 bent up at 90 to ~orm straight standing seams 62.
34 As will be explained hereafter, it is desirable to
cut the corners of seams 62 at an angle as shown.
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The method of installation of skylight 60 is
2 shown in the partial cross sectional view of Figure
3 9. Here a rafter or truss element 78 is shown
4 supporting roof sheathing 76. A space indicated at
77 is left which is open to the interior of the
6 building over which the skylight dome will be
7 installed. The skylight is held in place by a
8 plurality of anchor clips 68 shown in more detail
9 in the perspective view of Figure 19. Anchor clips
are nailed to sheathing 76 and spaced along the
11 skylight seams 62. As may be noted, one clip end
12 59 is folded over standing seam 62. A plurality of
13 step flashing elements 70 having the same height as
14 standing seam 62 are abutted to standing seam 62
and anchor clips 68. One clip end 67 in each
16 anchor clip 68 is folded over an adjacent step
17 flashing 70. Step flashing 70 is nailed to roof
18 sheathing 76 beneath roofing 74 and over roofing
19 felt 75. As is well known in the ark, the step
flashing is suitably overlapped to prevent water
21 leakage. After installation of the skyliyht 60,
22 anchor clips 68 and step flashing 70, the standing
23 seam is covered with a seam cover or batten 72.
24 Th i s batten may be formed of sheet metal and
crimped over the standing seam, in which instance
26 sealant is used to insure a water tight seam.
27 However, it is pre~erred to use a snap on seam
28 having an extruded vinyl weather seal such as is
29 available from Berridge Manufacturing Company.
3û This snap on seam device presents an attractive
31 appearance and forms a weathertight seal.
32 At the upper and l~wer ends of skylight 60,
33 skylight ends ~ and ~ are nailed to the roof
34 sheathing in conventional fashion. To prevent
leakage at the ends of the standing seams, a shroud
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1 65 seen in Figure 10 is provided. Shroud 65 may be
2 formed from sheet metal or the like. An angular
3 recess 63 is formed which matches the ends of
4 skylight standing seams 62. The step flashing 70
5 i5 trimmed to match this angle and shroud 65 is
6 placed over flashing 70 and standing seam 62. It
7 is then nailed to the roof sheathing. Thereafter,
S snap on seam cover 72 is installed on seams 62 and
9 70 producing a watertight seam.
As will now be recognized, this embodiment of
11 the invention permits a low cost and watertight
12 installation of a skylight in either an existing
13 roof or in new construction without the time, labor
14 and materials required to construct a curb in the
roof opening for a curb type skylight. It also
16 eliminates the problems heretofore found with self
17 flashing skylights due to separation and cracking
18 of sealant after exposure to the weather and
19 provides a desirable low profile skylight.
A third embodiment of the invention is shown
21 in Figure 11 in which a skylight 40 is provided
22 having standing seam edges 42 similar to that of
23 skylight 60 of Figure 8. However, the lower edge
24 46 and upper edge 48 are formed such that these
edges of adjacent skylights 40 can be joined
26 together. Thus, skylight 40 is usable to form sun
27 roofs as will be described hereinafter. For
28 examplel a typical sun roof is shown in Figure 12
29 formed from six skylights 40. The sun roof of
Figure 12 has a pitch as indicated in the direction
31 of the arrow. To permit the upper edge of one
32 skylight 40 to be joined to the lower edge of
33 another skylight 40, these edges are formed as
34 indicated in Figure 14. Here, the lower edge of
skylight 40A is shown which is formed by folding
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1 the edge 46 under itself to form a narrow first U
2 shaped edge. Similarly, lower skylight 40B has its
3 upper edge 48 folded over itself to form a narrow
4 second U shaped edge. As will be noted, edge 46
may be interlocked with edge 48 in a manner as will
6 be described below. Figure 13 shows the cross
7 section through plane 13-13 in Figure 11
8 illustrating the standing seam edge 42.
9 A sunroof as shown in Figure 12 can be formed
with multiple skylights 40 mounted on a rafter and
11 purlin system. A side perimeter rafter 82 is shown
12 with the system having a similar rafter along the
13 opposite side, a front perimeter rafter 85l and a
14 pair of interior rafters 83, not seen in this view.
Purlins 100, seen in phantom view, run between the
16 rafters 82 and 83. Details of the joints between
17 the skylights 40 and the manner of connecting the
lB skylights to the raters and purlins are shown in
19 Figures 15 through 18. Figure 15 shows a
cross-section through plane 15-15 of Figure 12.
21 Although the rafters and purlins may be o~ wood or
22 other material, it is preferred to use rectangular
23 extruded aluminum tubing. In Figure 15, a side
24 perimeter rafter 82 is seen having an anchor clip
68 fastened to rafter 82 by screws 67. Flashing 80
26 is butted with side seam 42 of skylight 40 and the
27 upper clip ends of anchor clip 68 are bent over the
28 skylight standing seam and the flashing 80 to hold
29 these elements securely in place. Sealant is
applied to this seam prior to assembling. A seam
31 cover 84 is then placed over the seam and sealant
32 92 installed to insur~ against leakage~ As will be
33 understood, anchor clip 68 may be installed every
34 foot or so along the seam.
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1 In Figure 16, the standing seam between two
2 adjacent skylights is shown in cross-section
3 through plane 16-16 of Figure 12. An interior
4 rafter 83 has anchor clips 68 fastened to it by
screws 67O Anchor clips 68 are bent over standing
6 seams 42 of the adjacent skylights and a seam cover
7 84 installed with sealant 92.
8 Along the front perimeter rafter 85, the lower
9 folded edge 46 of skylight 40 is attached thereto
as shown in the cross-sectional view 17-17 of
11 Figure 17. Front rafter flashing 87 runs the
12 length of rafter 85 and is attached thereto by
13 screws 91. Flashing 87 has its upper edge folded
14 over on itself to engage the folded portion 46 of
skylight 40. Sealant 92 is provided to insure a
16 leakproof joint. The manner in which the upper and
17 lower edges of two skylights 40 are joined is
18 indicated in Figure 18 through cross-section 18-18.
19 Lower edge 48 of the lower skylight is interlocked
with upper edge 46 of the upper skylight. A
21 plurality of C-clips 48 is installed along purlin
22 100 and coupled into the joint formed between edges
23 4 6 and 4~ to secure the joint to the purlin.
24 Sealant 92 is applied to prevent leakage. A
typical joint between the skyroof and a building
26 106 is shown in cross-sectional view 20-2Q in
27 Figure 20. The rafter assembly 83 and 85 is
28 attached to a hangar bracket 104 which is fastened
29 to wall 106. The upper edge 48 of skylight 44 is
held against rear perimeter rafter 85 by clips lOB.
31 A closure channel 110 is fastened by suitable
32 screws to rafter 85~ A plurality of Z-clips 112
33 along the top of channel 110 is used to hold
34 flashing 114 in place. The assembly is sealed with
sealant 92.
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It will be understood that in the figures, the
2 thicknesses of the materials and the spacing
3 therebetween are somewhat exaggerated for clarity.
4 In actual use, the interlocking joints are formed
to i n terlock tightly with a minimum of space
6 between the materials forming the joints. Prior to
7 joining the interlocking edges, sealant is applied
8 to fill any voids.
9 Although speci f ic implementations ana
conf igurations of the skylights of the invention
11 have been disclosed and aescribed herein, the
12 invention is not to be considered limited to such
13 examples. Various modifications to the exemplary
14 disclosures will be obvious to those of skill in
the art and are considered to fall within the
16 spirit and scope of the invention.
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