Note: Descriptions are shown in the official language in which they were submitted.
37~3
The present invention relates in general to skylights
and the like, and is concerned, more particularly, with an
improved technique for sealing the skylight about a roof or
other building opening.
At the present time, a skylight is conventionally
secured to a roof or other appropriate part of the building
with the use of a roofing mastic. In an existing building,
after the roof opening has been made, the roofing mastic is
applied on the deck around the opening to provide a seal
between the deck and the flange of the skylight. Once the
roofing mastic is applied, then the skylight is positioned
over the opening and the flange is then pressed firmly
into the mastic to provide a water tight seal. The skylight
flange is then nailed to the roof and additional mastic
applied. Shingling is then completed about the~entire
skylight.
Now, there are a number of dlsadvantages associated with
this conventlonal;well knowD~procedure for seallng a skyllght.
There is extra expense associated in purchasing the roofing
~ .
:
:
~ ~ :
:
:
`
::
~ ~ :
. ~
mastic and there is associated expense of th~ labor
involved in applying the mastic. The application of a
roofing cement also adds to the ins-talJatlon time of
the skylight unlt. The roofing mastic product is
extremely messy, particularly for an inexperienced
remodeler or one involved in a do-it-yourself project.
Furthermore, the success of the installation, parti-
cularly as it relates to resisting water leakage, is a
function of steps that are taken that take place in
the field and have nothing to do with the manufacturing
of the unit. Because of this, there are many uncer-
tainties that are involved. Also, the resistance of
the unit to leakage involves the proper performance of
the mastic. Because there are a large number of
different mastics that are available, this introduces
great variables into the desired performance.
Reference is also made to U. S. Patent No.
4,527,368, dated July 9, 1985, commonly owned by the
assignee herein and which describes a sealing technique
for skylights. Although this technique is effective
in the preferred embodiment, it uses one or more nails
for piercing the flange. This may have the effect of
causing further leakage problems at the flange.
Reference is also made herein to U. S. Patent
No. 4,589,238, issued May 20, 1986, in which there is
described a curb frame having a co-extruded peripheral
flexible flashing flange extending thereabout with the
bottom surface of the flange being substantially flat
and having a plurality of elongated spaced upstanding
ribs that form flow diverters extending peripherally
about the curb frame. While this arrangement functions
quite satisactorily, it has been found that improved
flow diversion is possible by providing the upstanding
ribs in spaced~sets.
: : :
; - 2 -
~,3 :
. ,
,
~, .., .
.: . . . : . . .
37,~
Accordingly, it is an object of the present invention to
provide an improved technique for the sealing of a skylight
about a building opening, and in which the sealing flange is
secured preferably without requiring ~he piercing by nails or
other fasteners therethrough.
Another object of the present invention is to provide a
sealing technique as in accordance with the previous object,
particularly adapted for sealing skylights and which is a dry
seal technique.
A further object of the present invention is to provide an
improved sealing technique as set forth hereinbefore and in
which the sealing is provided by a dry seal, co-extruded
element.
Still another object of the present invention is to provide
a technique for sealing a skylight to a building about an
opening in the building and without requiring the use of messy,
expensive and time consuming roofing cements or mastics.
Still a further object of the present invention is to
provide an improved skylight sealing,technique that eliminates
uncertainties when the unit is installed in the field due to
inherent invariables associated with field installation.
Still another obiect of the present invention is to provide
an improved skylight sealing technique that is particularly
useful in skylight installations wherein skylights are butted
closely together. Adjacent skylight flanges are adapted to
overlap without the required use of caulking or mastic
therebetween.
A further object of the present invention is to provide an
improved skylight sealing technique in which the fastening of
the skylight curb is carried out by separate means whereby the
structural securing of the skylight curb frame does not rely
~36~
upon a securing of the flange itself directly to the
building.
Still a further object of the present inven-
tion is to provide an improved skylight sealing tech-
nique employing a co-extruded flexible flashing flange
having a series of upwardly directed flow diverter
ribs for assuring proper sealing and water deflection.
Another object of the present invention is
to provide an improved skylight sealing technique in
which the fastening of the skylight curb frame may be
carried out by alternate means permitting securing
either on the inside or outside of the curb frame.
Still another object of the present inven-
tion is to provide an improved skylight sealing tech-
nique employing a simplified means for securing the
curb frame without requiring the use of a separate
securing clip.
A further object of the present invention
is to provide an improved skylight sealing technique
that is particularly useful in skylight installations
wherein skylights are~butted closely together~ and in
which instance, there is provided a common fastener
for adjacent skylight curb frames. The common fas-
tener is preferably in the form~of an elongated
securing clip that extends between adjacent curb
frames.
Summary of the Invention
To accomplish~the foregoing and other ~ ;
objec~ts, features and~advantages of the invention,
there is provided a~skylight for covering an opening
in a building having a curb frame with a co-extruded
peripheral flexible flashing flange~extending there-
about.
Preferably, this flashing flange is made of
a flexible plastic material and is co-extruded with
the curb~frame. The bottom surface of the flashing
flange is preferably substantially flat
-4-
: : , : : :'
:
,, : .
, : . : . .
,
.
3~7S3
while the upper surface thereof has closely spaced upstanding
ribs that form flow diverters so as to divert water away from
the building. In accordance with the installation of the
skylight, the skylight curb frame itself is secu~ed by separate
clip means so that the securing of the curb frame does not have
to rely upon a securing through the flashing flange itself. As
a matter of fact, in a preferred embodiment of the present
invention, the flashing flange itself is adapted to have no
nails or other fasteners passing therethrough. This thus
minimizes any chance for water entering the building about the
skylight through the flashing flange membrane. 1~ the
installation of the unit, the flashing flange is simply lifted
and the clip means is inserted into a slot in the curb frame.
The clip means is then secured by nails or other fasteners and
the flashing flange is then placed thereover. The shingles
that are adapted to fit adjacent to the skylight are then
placed over the co-extruded flexible flashing flange and it is
preferred that in nailing these shingles that no nails be
directed through the shingle and through the flashing flange.
The nailing of the shingles simply occurs outside of the
co-extruded flexible flashing flange.
In accordance with the present invention the aforementioned
plurality of elongated spaced upstanding ribs are preferably
provided in spaced sets with the spacing between sets of ribs
being on the order of the width of each set. This has been
found to provide enhanced flow diversion. Also, it is
preferred to have a flashing cap extending upwardly from the
flashing flange, generally of L-shape and adapted to receive
the roofing shingles therein. An alternate to the
aforementioned securing clip is the provision of a peripheral
rigid base extension from the curb frame through which a
.
~3~()7f3
fastening means such as a roof nail may extend for the purpose
of securing the curb frame. This securing is carried out
beneath the sealing flange so as no~ to interfere therewith.
An integral sealing element i5 also provided and one element
secured to one of the domes of the skylight and in the second
embodiment integral with the curb frame itself. The curb frame
in an alternate embodiment may also be provided with a pair of
base recesses for having the capability of receiving securing
clips either on the inside or outside of the curb frame.
In accordance with the invention, there is also provided an
improved flexible flange mulling concept in which'skylights may
be essentially supported in adjacent position. In this
embodiment of the invention, the peripheral flexible flashing
flange of each curb frame is disposed in an overlapping
position. The underlying flexible flashing flange may be
trimmed to provide proper joining and there is provided a
continuous seal between these overlapping flexible flashing
flanges. The continuous seal is preferably provided with a PVC
glue or cement. A common support is provided between the
adjacent curb frames in the form of a continuous metallic hold
down clip having opposite ends that are adapted to be received
in slots of the respective spaced curb frames. A fastener such
as a nail may be employed to secure the clip to the building.
Within each slot that receives the clip, there are preferably
provided sealing ribs co-extruded with the curb frame for
providing a seal between the end of each clip and the
corresponding curb frame.
'; '
.
.
7~
Brief Description of the _Drawings
Numerous other objects, features and advantages of the
invention should now become apparent upon a reading of the 3
following detailed description taken in conjunction with the
accompanying drawing, in which:
FIG. 1 is a cross-sectional view through a curb frame of a
complete skylight unit illustrating the rigid curb frame and
the co-extruded flexible flashing flange;
FIG. 2 is a fragmentary plan view illustrating in
particular the miter connection of the curb frame and
associated co-extruded flexible flashing flange; '
FIG. 3 is a perspective view illustrating the securing clip
employed in connection with the invention;
FIG. 4 is a fragmentary cross-sectional view illustrating
the manner in which skylights can be arranged in adjacent
position with the flashing flanges in an overlapping
arrangement;
FIG. 5 is a perspective view showing the preferred
embodiment of the present invention as secured in a roof
opening;
FIG. 6 is a cross-sectional view through the curb frame
showing further details at the side thereof and taken along
line 6-6 of FIG. 5;
FIG. 7 is a cross-sectional view taken thro~gh the skylight
at the top thereof and taken along line 7-7 of FIG. 5;
FIG. 8 is a cross-sectional view showing further details of
the skylight taken at the bottom of the curb frame and taken
along line 8-8 of FIG. 5;
FIG. 9 is a cross-sectional view of an alternate embodiment
to that illustrated, for example, in FIG. 6 showing the use of
an alternate securing means for the curb frame and also an
alternate arrangement for the sealing element between domes of
the skylight;
:, , " . ' . ' , ,
.. ' '
:
. :
:~
1~3~j~37~ -
FIG. 10 is a cross-sectional view similar to the view of
FIG. 6 showing a slightly different rib pattern, and
furthermore illustrating sealing ribs in the curb frame
securing slot;
FIG. 11 is a fragmentary enlarged view illustrating the
sealing ribs in the curb frame slot;
FIG. 12 is a cross-sectional view illustrating the flexible
flange mulling concepts of the present invention, and
furthermore illustrating the continuous securing clip that is
used between curb frames; and
FIG. 13 is a plan view of the elongated metallic securing
clip shown in FIG. 12.
Detailed Description
FIGS. 1-4 show one embodiment of the present invention. A
preferred embodiment of the invention is illustrated in FIGS.
5-9 to be discussed in further detail hereinafter. FIGS. 10-13
illustrate further details regarding the mulling of skylight
units and the associated technique of sealing;between flanges.
FIG. 1 is a cross-sectional view through one embodiment of
the curb frame of the invention. FIG. 1 also illustrates the
co-extruder flexible flashing flange of the invention. This
integral peripheral flashing flange provides a much simpler
alternative in the installation of skylights not requiring the
use of roofing cement or step flashing kits. This embodiment
of the invention also offers the additional benefit and
flexibility of ofering an installer the convenience of
arranging adjacent units together in a cluster by simply
trimming and gluing overlapping flashing pieces so as ~o
essentially form a one-piece, self-flashing skylight. At the
presene time, clusters of skylights are interconnected by more
-- .
:
: '
.
. ~ . .. .. . .
, ` , . ' ' ,
' ,, , , : :
07~
complex techniques requiring complex mulling kits or are made
in custom factory built units~ In accordance with the present
invention, the unit itself and the method of installation are
extremely simple requiring fewer pieces and relatively simple
instructions to be described in further detail hereinafter.
~ eferring now to FIGS. 1 3, there is shown a skylight curb
frame 10 that is constructed of a rigid plastic material,
preferably a rigid PVC. The rigid curb frame 10 has a top wall
12 that is adapted to support the co-extruded glazing gasket
14. The curb frame 10 also has an inwardly directed wall 16
defining a condensation gutter 18. With regard to the glazing
gasket 14, it is noted that this is co-extruded with the curb
frame 10 but while the curb frame 10 is of a rigid PVC
material, ~he gasket 14 is of a more flexible material~
FIG. 1 also illustrates the acrylic domes which comprise an
acrylic inner dome 20 and an acrylic outer dome 22. The outer
flange of the dome 20 rests upon the co-extruded glazing gasket
14. The outer dome 22 has its flange overlying the flange of
the inner dome. In between these two flanges there is provided
an extruded and welded dome seal gasket 24. The inner and
outer acrylic domes along with the respective gaskets are
maintained in place by means of the aluminum retainer 26 which
includes a horizontal leg 27 and a vertical leg 28. A screw
fastener 30 passes through the leg 27 and is secured
appropriately in a receiving hole at 32 in the curb frame 10.
At the bottom of the curb frame 10 there is provided a leg
34 defining a slot 36. The slot 36 may extend about the entire
periphery of the curb frame. The slot 36 is provided primarily
for the purpose of securing the curb frame 10 itself directly
to the building member 38. In order to carry out this
securing, there is provided a securing clip 40. Depending upon
_g_
.
.
,
,-
,
3~ 7~
the size of the skylight, four more of these securing clips may
be disposed along the sides of the skylight.
Reference is now made to the perspective view of FIG. 3
which shows one version of the securing clip 40. The clip 40
has one end 41 that is adapted to fit within the slot 36 in the
curb frame. The securing clip 40 also has another end 42 that
is adapted to lie upon the building member 38 for securing
thereto. For this purpose, the end 42 has a hole 43 for
receiving a nail 44 or other fastener. The hole 43 may be
prepunched. The securing clip 40 may be constructed of plastic
or metal.
The flashing flange 50 is preferably constructed of a
flexible PVC plasticO The flange 50 is co-extruded with the
rigid curb frame 10 in the same manner as the co-extrusion of
the glazing gasket 14. The co-extruded flexible flashing
flange 15 may have a length on the order of 6 inches and has a
flat bottom surface 52. The top surface 54 is provided with a
series of upstanding ribs 56. FIG. 1 shows the flange 50
secured at end 58 thereof. This is secured within the rigid
.
curb frame as illustrated in FIG. 1. The upstanding ribs 56
extend longitudinally as noted in FIG. 2 and form a series of
flow diverters so that should any water enter under the shingle
16 between the shingle and these ribs, then the water will
simply run down the roof and be diverted away from any area
where the water might enter under the flashing flange. It is
noted that there are a number of these ribs provided in
relatively closely spaced relationship so that should the water
pass one rib, there are a number of adjacent ribs to provide
flow diversion. Also, because of the substantial number of
ribs that are employed, there are also a number of contact
points between the shingle that is disposed over the flashing
t.
;
--10--
.. . ..
~, ,, . , ~ . :
, , ~ . ' ' . ' '
, ', . . ' ' .
3~)7~3
flange and the flashing flange itself. ~ith regard to the flow
diversion, even at the bottom of ~he skylight where the ribs
will tend to run substantially horizontally, these ribs are of
very small height and thus any water directed from the side
disposed ribs simply for the most part deflected off of the
bottom flange.
In accordance with the installation of the skylight
illustrated in FIGS. 1-3, there is provided the usual opening
in a building illustrated at 62 in FIG. 1 and the curb frame is
adapted to be positioned about this opening on the building
member 38. Between the base of the curb frame and the member
38 there may be some form of an asphalt paper. This asphalt
paper is not illustrated in FIG. 1.
After placement of the curb frame in the proper position
about the skylight opening, then a series of the clips 40 are
used for securing the curb frame in place. FIG. 1 illustrates
one of these clips. FIG. 3 illustrates the clip in a
perspective view and FIG. 2 illustrates what might be a typical
placement of clips near to the,mitered corner.
The flashing flange 50 is flexible and thus readily lifted
upwardly, essentially pivoted at its end 58 so as to provide
access to the base of the curb frame for insertion of the clips '
40. The clips 40 as indicated previously are secured by means
of a nail 44 or the like fastener. Thereafter, the flashing
flange 50 is then moved downwardly to the position illustrated
in FIG. 1 for covering the roof or other structure.
Preferably, a plurality of these clips are used on each side of
the skylight. The number of clips that are used are the
function of the size of the skylight with the larger number of
clips being used on larger skylights.
After the co-extruded flexible flashing flange has been
,
--11--
.
. .
':' ', ` . :'
,
. ~: '~ ' , ' . ' ' , : , .
placed in the manner illustrated in FIG. 1, then
shingles 60 are placed thereover in the usual manner.
In a preferred method of installation, the shingles 60
are disposed over the flange as illustrated. These
shingles are arranged in the usual manner overlapping
each other such as illustrated in U. S. Patent No.
4,527,368. However, in accordance with the preferred
procedure of installation, the shingles are not to be
secured through the flashing flange 50. It is pre-
ferred not to pierce the flashing flange 50 with anynails. Instead, the nailing of each shingle occurs
outside of the flashing flange. This minimizes any
chance of water diversion through a hole created by a
nail piercing the shingle and flashing flange.
With regard to FIG. 2, it is noted that the
curb frame and the flashing flange are both jo~ined at
the miter 66. Because the curb frame and the flashing
flange and glazing gasket are all formed integrally as
'a c-o-'extrusion,"'these'elements' can also be cut at a
bevel and remain at a co-extrusion. The individual
parts once mltered are then heat welded to form a one-
piece rectangular curb frame with an integral welded ''
flashing skirt or flange about the entire~curb peri-
meter as illustrated in the fr~agmentary vi'ew~of FIG. 2.
Reference is now made to the cross-sectional
view of FIG. 4 whlch shows ln a fragmentary view the
joining essent~ially of adjacent skylights without ~
requiring the use of any coverlng shingles. In this '~ ~ '
way, there can be an installation of~a cluster of sky-
lights without~requiring complex custom units~. This
is carried~out by simply trimming the flanges 50A and
50B in~FIG. 4 if necessary.~ Trimming occurs depending
upon the'~closeness with which the skylights are to be ~-
arranged. The glue is then applied at 51 between the
overlapplng portions of
~ 12
~, ~, :: : , ~
:
.
' ' . ... : ' '` ~ , , . . ' ` .
~: ' . ' ' ' ' .
' ~ ' ~ ' . ' . ..
. .
',
, ' , ' , .
?607~3
the flanges 50A and 50B. Once the flanges are glued, then
there is formed an integral ~lexible flashing arrangement
essentially providing a one-piece connection between skylights.
In connection with the method of installation of the
present invention, it has been noted previously that shingles
are provided over the flashing flange with instructions being
provided not to pierce the flashing flange. In addition to
that, it may also be preferred to provide a row of shingles
under the flashing flange at the bottom of the skylight along
with a row of shingles over the top of the flashing rlange at
the bottom of the skylight.
FIG. 5 is a perspective view of the preferred embodiment of
the present invention illustrating a curb frame 70 that is
constructed of a rigid plastic material, preferably a rigid
PVC. Also refer to FIGS. 6-8 which show respective
cross-sectional views taken at the side, top and bottom of the
skylight curb frame. The rigid curb frame 70 has a top wall 72
(see FIG. 6) that is adapted to support the co-extruded
cup-shaped gas~et 74. ~The cur-b frame 70 also~has an inwardly
directed wall 76 defining a condensation gutter 78 as
illustrated in FIG. 6. With regard to the gasket 74, it is
noted that this is co-extruded with the curb ~rame 70.
However, while the curb frame 70 is of a rigid PVC material,
the gasket 74 is of a more flexible material.
FIGS. 5 and 6 also illustrate the acrylic domes which
comprise an acrylic inner dome 80 and an acrylic outer dome
82. The outer flange of the dome 80 rests upon the co-extruded
gasket 74. The outer dome 8~ has its ~lange overlying the
flange of the inner dome S0. In between these two flanges
there is provided a gasket 84 having a turned end 85 that is
adapted to fit about the flange of the dome 80 essentially
-13-
. .
., ' ',:
...
securing the gasket 84 in place so that it is easier to then
dispose the dome ~2 thereover. The gasket 84 with its turned
end 85 essentially slips onto the edge of the flange of the
dome 80.
The inner and outer acrylic domes 80 and 82, along with the
respective gaskets, are maintained in place by means of the
aluminum retainer 86. The retainer 86 includes a horizontal
leg 87 and a vertical leg 88. A screw fastener 90 passes
through the leg 87 and is secured appropriately in a receiving
h~ole at 92 in the curb frame 70.
At the bottom of the curb frame 70 there is provided a leg
94 defining a slot 9S. The slot 96 along with the leg 94 may
extend about the entire periphery of the curb frame. The slot
96 is similar to the slot 36 illustrated in FIG. 1 and may be
used for the purpose of securing the curb frame 70 itself
directly to the building member 980 However, rather than the
use of the securing clips 40 illustrated in FIG. 1, a more
simplified arrangement is shown in FIG. 6 in which the leg 94
has an outwardly.extending integral e-x.tension 95 that may be
drilled to receive the securing nail 97. In this way there is
no need for a separate securing clip as illustrated in FIG. 1. -
It is noted in FIG. 6 that the extension 95 extends beyond the
outer wall 71 of the curb frame so as to provide access to the
extension 95. When installing the curb frame, the sealing
flange may simply be lifted to provide access to the extension :
so that the extension can be nailed down to secure the curb
frame in its proper position.
The flashing flange 100 is provided as illustrated in the
perspective view of FIG. 5 and is furthermore illustrated in
the cross-sectional views of FIGS. 6-8. The flashing flange
100 is preferably constructed of a flexible PVC plastic. ~ ::
-14-
~3~()7~
Flange 100 is co-extruded with the rigid frame 70 in the sa~e
manner as the co-extrusion of the gasket 74. ~he co-extruded
flexible flashing flange 100 may have a length on the order ~of
6 inches and has a flat bottom surface 102. The top surface
104 of the flange is provided with a series of upstanding ribs
106. The ribs 106 are provided in spaced sets. In the
particular embodiment disclosed herein, each set comprises four
elongated ribs. The sets of ribs are separated by valleys 1~7
in which there is ~n abs~nce D~ any ribs. It has been found
that by providing an open valley area the water diversion is
improved. As illustrated in FIG. 8, each of the sets may have
a width W that is comparable to th~ width of the valley 107
illustrated in FIG. 8 as the width X. Actually, the width of
the set of ribs is perhaps slightly less than the width of ~he
valley.
Also, each of the upstanding ribs 106 is preferably not
totally vertical but is hooked, such as illustrated in FIG. 8,
at 105.
FIGS. 6-8 illustrate the flange 100 secured at end 108
thereof. This is secured within the rigid curb frame s~ch as
illustrated in FIG. 6. The ribs 106 extend longitudinally as
noted in FIG. 5 and form a series of flow diverters so that
should any water enter under the shingle 109 between the
shingle and these ribs, then the uater simply runs down the
roof and is diverted away from any area where the water might
enter under the flashing flange.
In connection with the illustration of FIG. 5, it is noted
that cross-sectional views have been taken at the side of the
curb frame as well as at the top and bottom, all~illustrated in
respective FIGS. 6-8. In FIG. 6, as well as in FIGS. 7 and 8,
it is noted that the flashing flange 100 has a flashing cap 110
.
!-
.
-15-
: . . , , , :
.
.. . . :
,
~3607f3
that in FI~. 6 includes a substantially vertical leg 112 and a
substantially horizontal leg 114. FIG. 8 shows the flashing
cap 110 in its normal non-deflected position. It is noted that
in FIG. 6 the shingles 109 are disposed inside of the flashing
cap 110 and rest upon the flow-diverting ribs 106.
In ~IG. 7, which is a cross-sectional view taken at the top
of the skylight, the shingles los extend over the ribs 106 and
likewise also extend to cover the flashing cap 110. FIG. 8 is
a cross-sectional view at the bottom of the curb frame and in
this instance it is noted that the shingles 109 are disposed
under the flashing flange 100. In addition, there also may be
a row of shingles disposed over the flashing flange 100,
although this is not illustrated in FIG. 8.
In accordance with the installation of the skylight
illustrated in FIGS. 5-8, there is provided the usual opening
in a building illustrated at 120 (see FIG. 6). In the drawing
the curb frame is adapted to be positioned about this opening
on the building member 98. Between the base of the curb frame
and the member g8 there may be some form of an asphalt paper.
This asphalt paper is not ilIustrated in the drawings.
After placement of the curb frame in the proper position
about the skylight opening, then a series of nails 97 are used
for securing the curb frame in place by passing through the
extension 95 of the leg 94. With this arrangement, unlike the
arrangement of FIG. 1, there is no separate securing clip thus
making the securing task easier.
The flashing flange 100 is flexible and thus readily lifted
upwardly, essentially pivoting at its end 108 so as to provide
access to the base of the curb frame for securing of the nails
97. A hammer may be used for that purpose. Thereafter, the
flashing flange lO0 is then moved downwardly to the position
,
-I6-
i(37~
illustrated in, for example, FIG. 6, for covering the roof or
other other structure. Preferably, a plurality of nails is
used on each side of the skylight. The number of nails that
are used are a function of the size of the skylight with a
larger number of securing nails being used of course on larger
skylights.
After the co-extruded flexible flashing flange has been
placed in the manner illustrated in FIGS. 5-8, then shingles
109 are placed thereover in the usual manner. In a preferred
method of installation, the shingles 109 are disposed over the
flange such as illustrated in FIG. 6 and on the sides under the
flashing cap 110. These shingles are arranged over the
flashing cap at the top, as illustrated in FIG. 7. These
shingles are arranged in the usual manner overlapping each
other such as illustrated in co-pending application Serial
Number 06/453,339, filed December 27, 1982 now United States
Patent No. 4,527,368, dated July 9, 1985. However, in
accordance with the preferred procedure of installation, the
shingles are not to be secured through the flashing flange 50.
It is preferred not to be secured through the flashing flange
100. It is preferred not to pierce the flashing flange with
any nails. Instead, the nailing of each shingle preferably
occurs outside of the flashing flange. This minimizes any
chance of water diversion through a hole created by a nail
piercing the shingle and flashing flange.
With regard to FIG. 5, it is noted that the curb frame and
the flashing flange are both joined at the miter 125. Because
the curb frame and the flashing flange and glazing gasket are
all formed integrally as a co-extrusion, these elements can
also be cut at a bevel and remain as a co-extrusion. The
individual parts once mitered are then heat-welded to form a
!
17
.
: - . , . ' .
.
3~(~7f3
one-piece rectangular curb frame with an integral welded
flashing skirt or flange about the entire curb perimeter as
illustrated herein.
FIG. 9 illustrates a cross-sectional view similar to the
view of FIG. 6 but for an alternate embodiment of the
invention. In FIG. 9 there is shown the curb frame 130 having
co-extruded therewith the flashing flange 132. The flashing
flange 132 may be of the same construction as illustrated in
FIGS. 5-8. The curb frame 130 includes a top wall 134 for
supporting the cup-shaped gasket 136. There are also provided
a pair of domes including an inner dome 138 and an outer dome
140. These domes are retained in place by the retainer 142
which may be an aluminum retainer, such as illustrated in FIG.
9. The curb frame 130 is also provided with an external wall
144 forming a condensation gutter 146 at the inside of the curb
frame.
There are basically two alternate featured illustrated in
FIG. 9 that require consideration. First, integral with the
curb frame 130 at the top wall 134 is an upright member 148
that is integral with a sealing gasket 150. The gasket 150 is
adapted to be disposed between the flanges of the respective
domes 138 and 140. The integral nature of the member 148 and
gasket 150, being integral with the curb frame 130, provides an
improvement in that there is no need any longer for a separate
gasket to be installed. The lower dome 138 is simply inserted
between the gasket 136 and the gasket 150 and then the upper
dome 140 is disposed thereover. The retainer is then secured
in place to hold the domes in place against the peripheral curb
frame.
The second feature illustrated in FIG. 9 has to do with the
fact that the curb frame 130 now has a dual means of securing
.
-18-
:` :
S)7,~3
and for this purpose is provided with an outer slot 154 and an
inner slot 156. A clip such as illustrated in FIG. 1 o~ this
application may be used in the slot 1~ for securing the curb e
frame at its outer side. However, an alternate means of
securing is illustrated in FIG. 9 in which there is provided a
clip 160 ha~ing a substantially vertical leg 162 and a
substantially horizontal leg 164. The leg 164 is adapted to
fit in the slot 156. The vertical leg 162 is adapted to rest
against a side surface of the member 98. A securing nail 166
is used, which passes through a hole in the vertical leg 162 of
the clip 160 for securing the clip in place and likewise also
securing the curb frame itself in place about the skylight
opening.
FIG. 10 is a cross-sectional view through one embodiment of
the curb frame of the invention illustrating the co-extruded
flexible flashing flange of the invention. In this particular
embodiment, as also illustrated in FIGS. 11 13, there is the
additional benefit and flexibility of offering an installer,
the convenience of arranging adjacent units together in a
cluster by trimming and gluing the overlapping flashing flanges
so as to essentially form a one-piece, self-flashing skylight
as indicated previously. Presently clusters of skylights are
interconnected by more complex techniques requiring complex
mulling kits or are made in custom factory built units.
In FIG. 10 there is shown the skylight curb frame 210 that
is constructed of a rigid plastic material, preferably a rigid
PVC. The rigid curb frame 210 has a top wall 212 that is
adapted to support the co-extruded blazing gasket 214. The
curb frame 210 also has an inwardly directed wall 216 defining
a condensation gutter 218. With regard to the glazing gasket
214, it is noted that this is co-extruded with the curb frame
!
'
--19-
- . ,.
' : , . , '
.', , .
- : . ' ! ,
210, but while the curb frame 210 is of a rigid PVC material,
the gasket 214 is of a more flexible PVC material.
FIG. 10 also illustrates the base 220 of the curb frame
210. Defined just above the base 220 are inner and outer slots
identified in FIG. 10 as an inner slot 222 and an outer slot
224. The slots 222 and 224 may extend about the entire
periphery of the curb frame. These slots are provided for the
purpose of securing the curb frame 210 directly to the building
structure.
FIG. 10 also shows the flashing flange 250 which is
preferably constructed of a flexible PVC plastic. The flange
250 is co-extruded with the rigid curb frame 210 basicall~ in
the same manner as the co-extrusion of the glazing gasket 214.
The co-extruded flexible flashing flange 250 may have a length
on the order of 6 inches and has a flat bottom surface 252.
The top surface 254 of the flashing flange is provided with
upstanding ribs 256. The ribs 256 are provided in spaced
sets. In the embodiment of FIG. 10, most of the sets comprise
two elongated ribs with the exception of the outer set which
comprises four elongated ribs. The sets of ribs are separated
by valleys 257 in which there is an absence of any ribs. It
has been found that by providing an open valley area, the water
diversion is improved. Also, each of the upstanding ribs 256
is preferably not totally vertical but is hooked, such as has
been previously illustrated in FIG. 8.
FIG. 10 also illustrates the flashing cap 260 which
basically is of the same construction as illustrated previously
in FIG. 6.
Reference is now made to FIG. 11 which shows an enlarged
detail of the slot 224 further illustrating the sealing ribs
225 that may extend peripheralIy about the entire frame. These
- ! :
-20-
'
7~
ribs 22S are adapted to sealing against the securing clip 230.
In this regard, also note the securing clip 230 shown in FIG.
12. It is the end 232 thereof that actually is inserted into
the slot 224 and that comes into contact with the sealing ribs
225. Should any water for any reason get under the flashing
flange, then a further seal is provided between the clip and
the sealing ribs 225.
Reference is now made to FIG. 13, which shows one form of a
hold down clip 230 as used in practicing the mulling
arrangement of FIG. 12. It is noted that the clip 230 has an
elongated center section and also has opposite ends 231 and
232. As illustrated in FIG. 11, one of the ends 232 was shown
in one of the receiving slots of a curb frame. In a preferred
embodiment of the invention, the hold down clip 230 extends
alony an entire side of the curb frame between adjacent curb
frames. It is also noted in FIG. 13 that the clip 230 has at
least one center hole 233 for receiving a fastener such as the
nail 235 illustrated in FIG. 12. The hold down clip 230 is
preferably. me.tallic,..such..as al:um~inum.~ ~As. indi.cated.
previously, the hold down clip 230 preferably extends along the
entire side of the curb frame. At the top and bottom of the
clip, an epoxy adhesive may be used for providing a proper seal
between the ends of the clip and the skylight curb frame. --
Again, the clip 230 that extends the entire length of the curb
frame provides a second water tight sealing barrier by virtue
of contact of the end 232 of the clip with the sealing ribs 225
as illustrated in FIG. 11. Thus, there is a sealing joint
provided by the overlapping of the flanges as well as the
sealing provided as indicated in FIG. 11 between the clip 230
and the base of the curb frame at the ribs 225.
'
.
~ -21-
:
- : .
. ~
.
': ~
: . ' ''' ' ~, ' ' :. ;
S07is3
Reference is now made to FIG. 12 which shows the Jnulling
concepts of the present invention, in which two skylight curb
frames are adapted for positioning relatively close to each
other. In FIG. 12, these curb frames are illustrated by curb
frame A on the left and curb frame B on the riyht. The curb
frame A has associated therewith, a flexible sealing flange C
and similarly the curb frame B has an associated flexible
sealing flange D. Once again, the elongated hold down clip 230
is used for positioning the curb frames A and B in the manner
illustrated in FIG. 12. A fastener such as the nail 235 is
used for holding the clip 230 in position. It is noted that
the ends 231 and 232 of the clip are held in the slots provided
above the base of each of the curb frames, in the manner as
illustrated in FIG. 11. Of course, each of the curb frames on
their opposite sides also have clips that may be like the clip
230 if there is a further skylight being assembled therewith,
or they can be a clip of the type illustrated previously, such
as in FIG. 1.
When ove-rlapping the flanges C and D in FIG. 12, it is
noted that with regard to the underlying flange D the flashing
cap 260 lS to be removed so that it does not interfere with the
upper flange. This is shown in dotted outline in FIG. 12.
Similarly, some of the ribs 256 may also be removed so that the
top surface of the flange D is flat. In this connection, it is
noted that with reference to FIG. 10, the flanges are each
trimmed at about location 240.
In order to provide a seal between the overlapping flanges,
there is provided a PVC cement at 244. This may be coated onto
the lower flange and then the upper flange is overlapped and
pressed against the lower flange.
:
. . ~
-22-
:
.
'
'
- :
1~36t~7,~
Having now described a limited number of embodiments of the
present invention, it should now be apparent to those skilled
in the art that numerous other embodiments and modifications
thereof are contemplated as falling within the scope of the
present invention as defined by the appended claims.
~; :
,
.
,
: : .
. .
