Note: Descriptions are shown in the official language in which they were submitted.
W0003/7119
D~D/dpv
2-s-so
1360d
SKYLIGHT CONSTRUCTION
BACK~ROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to an improved
skylight construction and is concerned, more particularly, with
an improved skylight construction employing a rigid plastic
curb frame providing simplified manufacture and improved
temperature resistant and weathering proper~ies. Even more
particularly, the present invention relates to improvements in
skylight features in particular applicable to step flash
skylights.
2. Objects of the Invention
It is a general object of the present invention to provide
improvements to skylights and, in particular, skylights
employing a rigid plastic curb frame.
Another object of the present invention is to provide an
improved skylight construction which is in particular
applicable to a step flash skylight.
A urther object of the present invention is to provide an
improved skylight construction used with a wood base frame,
providing an improved interlocking arrangement for engagement
between the rigid plastic curb frame and the wooden base frame
so as to facilitate convenient assembly of the curb frame to
the wood base frame,
Another object of the present invention is to provide an
improved step flash skylight construction that is of simplifled
construction, can be manufactured relatively easily and at a
relatively low cost and that is simple to install.
Still another object of the present invention is to
provide an improved skylight construction that preferably
employs a PVC curb frame constructed from an extrusion
employing high performance co-extruded weather stripping,
moisture and condensation protection and control, and integral
counterflashing.
Another object of the present invention is to provide an
improved skylight construction having improved gasketing and
flashing features.
SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects, features
and advantages of the invention, there is provided a skylight
construction adapted to be fitted into an opening in a building
such as either a commercial building or a residen~ial
building. The skylight construction comprises a base frame
e~tending about the opening and having means for securing of
the base frame about the opening. A rigid plastic curb frame
means is provided and is firmly secured to the top of the base
.
frame. Transparent or translucent covering means are provided
and retained on the rigid plastic curb frame means. In
accordance with a preferred embodiment of the present
invention, the skylight construction is of step 1ash skylight
type and th~ base frame is preferably a stepped wooden base
frame upon which the rigid plastic curb frame means is
secured. The means for firmly securing the rigid plastic curb
frame includes means for positively interlocking the rigid
plastic curb frame means with the base frame. In an embodiment
disclosed herein, this positive interlocking is carried out by
means of a slot formed in the base frame interlocking in
combination with an interlocking flange of the rigid plastic
curb frame means. A securing screw, bolt or the like passing
through the base frame positively interlocks and secures the
overlying rigid curb frame means with the base frame.
In accordance with another feature of the present
invention, there is provided an improved flashing
construction. In accordance with this feature, the rigid
plastic curb frame means has a peripherally disposed
counterflashing piece extending downwardly from the frame means
and disposed outwardly of the base frame. The counterfla~hing
piece has flashing seal means disposed intermediate the
counterflashing piece and the base frame.
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In accordance with another feature of the present
invention, there is an improved gasket construction,
particularly for a gasket used with a hinged skylight~ The
gasket construction provides four-point gasketing for locking
out air and moisture and provides superior energy efficiency
and weather tightness. The gasket is in the form of a
co-extruded gasket with two-point engagement with the rigid
curb frame means.
BRIEF DESCRIPTION OF THE DRAWINGS
Numerous other objects, features and advantages of the
invention should now become apparent upon a reading of the
following detailed description taken in conjunction with the
accompanying drawings, in which:
FIG. 1 is a prospective view of the skylight construction
of the present invention as secured in a roof;
FIG. 2 is a cross-sectional view taken along line 2-2 of
FIG. 1 showing further details of the skylight construction
illustrated, in particular, in embodiment of the skylight
construction in the form of a step flash skylight;
FIG. 3 is a cross-sectional view through the skylight
construction of FIGS. 1 and 2 as taken along line 3-3 of FIC~ l;
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FIG. 4 is an exploded cross-sectional view showing further
details of components of the skylight construction;
FIG. 5 is a cross-sectional view through a segment of the
skylight construction showing the manner in which the curb
frame is attached to the wooden base frame;
FIG. 6 is an exploded prospective view illustrating th~
components of the skylight construction of the present
invention and the manner in which the components are assembled
including flashing members and the curb frame;
FIG. 7 is a further exploded prospective view showing a
diferent embodiment of skylight components employed in
particular in connection with a roo~ construction employing
roofing tiles;
FIG. 8 is a cross-sectional view of an alternate preferred
construction for the hinge member of the skylight;
FIG. 9 is a cross-sectional view of the hinge of FI~. 8
showing the skylight in an open position;
FIG. 10 is an exploded cross-sectional view showing the
preerred hinge arrangement of FIGS. 8 and 9; and
FIG. 11 is a prospective view of the hinge members used in
FIGS. 8-10.
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DETAILED DESCRIPTION
Reference is now made ~o the drawings for an illustration
of constructions of the present invention. FIGS. 1-6
illustrate a preferred construction for the skylight. FIG. 7
illustrates an alternate embodiment for use with tile roofs.
FIGS. 8~11 illustrate a preferred hinge construction.
It is noted that in the embodiment of the invention as
illustrated in, for example, FIGS. 1-3, the skylight is of a
substantially flat construction employing glaæing panels.
However, in alternate constructions, a domed-type skylight may
also be employed. The skylight is adapted to span an opening
which is generally of square or rectangular shape and the
opening may be defined by upright walls or by headers which are
part of the roof construction. Refer in particular to FIG. 3
for an illustration of part of the roof construction.
Disclosed herein in the illustrated embodiments is an
operable skylight in which the curb frame is constructed of a
base leaf and an operating leaf. However, in alternate
embodiments of the invention the curb frame may be of
substantially single piece construction and still embody one or
more of the concepts of the present invention.
The skylight described herein is characterized by improved
energy performance; thermal air and weather tightness;
simplicity of installation; good weathering properties; and
enhanced durability.
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In the embodiments disclosed herein, it is noted that the
skylight is illustrated as preferably being of step flash
construction. Illustrated herein are various forms of hinge
construction. These hinge constructions have a dual purpose
use of providing both hinying while also functioning as an
impenetratable barrier to water rushing onto the skylight,
particularly at the top thereof. These hinge constructions
eliminate the necessity for separate water diverter flashing
components. The hinge constructions illustrated herein also
permit sash removal during installation.
The skylight construction shown herein includes a pair of
glazing panels 16 and 18, a rigid plastic curb frame 10 for
support of the glazing panels, and a wooden base frame 11. The
rigid PVC curb frame 10 in the embodiment illustrated in FIGS.
1-3, is comprised of two separate sections that are hinged as
illustrated at 13 in FIG. 3. These two separate sections
include a base frame 14 that is adapted to interlock with the
wooden base 11, and an overlying sash frame 20. Refer in
particular to the exploded cross-sectional view of FIG. 4 for
an illustration of the specific cross-section configuration of
the base frame 14 and the overlying sash frame 20.
The two frames 14 and 20 are constructed of a rigid PVC
material and these frames are separately constructed each of
separate co-extruded pieces formed together in a frame
construction.
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The drawings also illustrate the retainer 22 which is
disposed at the very top of the skylight and which is used ^s~
securing the glazing panels 16 and 18 to the sash frame 20.
The retainer 22 is preferably constructed of a lightweight
metal material such as aluminum and has the general L-shaped
cross-section such as illustrated in FIGS. 3 and 4.
Each of the frames 14 and 20 is constructed by a
co-extrusion process in which one or more flexible gaskets are
co-extruded with the rigid main part of the frame. For
example, the ~rame 20 carries a cupped gasket 44 against which
the glazing panel 18 rests. Similarly, the frame 14 carries a
flexible sealing gasket 64. The gasket 64 is adapted for
gasket support between the frames 14 and 20. In this regard,
FIG. 2 illustrates the gasket 64 in its at least partially
compressed state sealing between the frames 14 and 20.
The gasket 64 illustrated herein is of similar general
construction to the gasket illustrated in our related
application serial number 07/283,803 filed December 13, lgB8,
which application is hereby incorporated by reference herein.
The gasket 64 illustrated in this application does differ
somewhat from the ~asket illustrated in the aforementioned
United States serial number 07/283,803 in that it has two
separate attachment points at 64A and 65B to the frame 14. The
gaæket 64 provides multi-point gasketing for locking out air
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and moisture while providing superior energy efficiency and
weather tigh~ness. The gasket 64 is co-extruded with the frame
14 and is thus continuously bonded to the frame for permanent
protection.
The gasket 64 with its two point attachment at 65A an~
65B, as noted in, for example, FIG. 4, is hollow and generally
of tubular construction. It thus provides a space 66 for any
weld upset so that it can flow into the space and thus not
interfere with the function of the gasket, particularly when it
is moved to its compressed stated. In this regard, as noted in
FIG. 4, there is actually a recess at 66.
In connection with both the frames 14 and 20, as indicated
previously, these are constructed of separate co-extruded
pieces that are constructed into a closed frams. At the corner
miters, such as illustrated in, for example, FIG. 6, both the
rigid and flexible parts of the frames are joined by a
technique such as a heat platen sealing technique. This
technique commonly joins the rigid frame sections at the corner
miters for the same time joining the gaskets for providing a
continuous seal above the entire skylight curb frame
construction.
Now, with respect to the gasket 64, there is a multi-point
contact with the glazing. This is provided by the sealing lip
82 along with the oppositely disposed ears 67A and 67B. This
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p~rticular construction with the use of a substantially open
and tubular gasket configuration provides improved weather and
air tightness. Furthermore, there is a reactionary mechanical
action that occurs when the gasket is compressed so as to
enhance tightness of the gasket between the elements that are
being compressed against the gasket.
Reference has been made herein before to the wooden base
11~ In this regard, refer also to FIG. 6 which shows the bas~
11 in place about the opening. It is noted that the base 11 is
provided with mortise and tenon corner joints. This provides a
rugged interlocking wood joint construction that provides
superior strength. Also, this provides a wood curb interior
finish that provides for a very asthetic appearance on the
inside of the skylight.
To enable the curb frame 10 to be secured to the wood~n
base 11, the wooden base 11 is provided with a longitudinal
slot 15 that is dimensioned to properly receive the downwardly
depending leg 24 of the base frame 14.
The wooden base 11 is secured in position about the
opening by means of a series of angle brac~ets 17. The angle
brackets 17 are secured by means of screws 19 as illustrated in
FIG~ 1~. This arrangement secures the wooden frame 11 in
proper position as illustrated in FIG. 4 and with respect to
the roof decking 21.
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In accordance with the present invention, the skylight
construction also employs a unique step flashing arrangement.
The flashing material itself is a superior polyester-based dark
bronze coating provided on a rule ormed aluminum. This is
designed for leak proof installation. The arrangement provides
for an uncomplicated assembly and disassembly saving time and
money. The flashing components are preferably pre-fabricated.
As illustrated in FIG. 6, the flashing includes side step
flashing pieces 31, a sill flashing piece 33 and a head
flashing piece 35.
As far as the sequence of installation is concerned, the
sill flashing piece 33 is installed first ollowed by the
successive installation of side flashing pieces 31. Shingles
37 are laid over th~se flashing pieces such as in the
illustration of FIG. 4 or FIG. 6. In this connection, FIG. 6
also illustrates the curb frame and, in particular, the base
frame 14 positioned over the wooden frame 11.
In the sequence of installation, after the side sill
pieces are installed, then the head flashing piece 3S is
installed at the top end of the skylight. The next step in the
sequence is to install the base frame 14 to the wooden base
11 .
The base frame 14 has, in addition to the leg 24, also a
counterflashing le~ 26 that depends downwardly from the main
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portion of the frame 14. The leg 26 carries co-ex~ruded an
integral weather strips or flashing seals 28. FIG. 4 shows !e
flashing seals 28 in their normal position. FIG. 5 shows the
seals providing their sealing and gasketing function urged
against one of the flashing pieces.
FIG. 4 illustrates the base frame 14 in a position yet to
be installed in the wooden base 11. FIG. 5 on the othPr hand
shows the frame 14 after installation. For this purpose, the
leg 24 is inserted in the slot 15 of the base 11 and a series
of securing screws 29 firmly lock the base frame 14 to the
wooden base 11. For this purpose, at least the wooden base 11
may be pre-drilled with holes such as illustrated at 2S in FIG.
6. The leg 24 may also, at least in one embodiment, be
provided with holes that will align with the holes 25.
Alternatively, the screw 29 may be adapted to simply drill
through the leg 24.
The skylight glazing plates 16 and 18 are supported over
the support frame 20 by means of the retainer 22. The plates
16 and 18 are supported by a glazing frame 79. On the outer
periphery of the frame 79 between the plates 16 and 18 there is
a gasket 77. The gasket 77 may be of a pre-molded butyl
material. As illustrated in, for example, FIG. 3, the frame 79
may be comprised of a metal spacer with an outer seal
comprising a chemically curable two-part polysulfied.
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The lower glazing plate 18 rests upon the cupped sealing
gasket 77 which is co-extruded with the support frame 20. In
FIG~ 3, the gasket 44 is shown in its compressed posi~ion. The
sash frame 2Q also includes means defining a channel for
receiving a securing bolt 56~ The bolt 56 at its end, such as
illustrated in FIG. 3, is received in an internally thxeaded
flange 54 of the retainer 22. A series of bolts 56 are used
spacedly disposed about the frame 20 for securing the glazing
in place. A plurality of these securing bolts or screws are
employed for securing the retainer 22 over the glazing plates
16 and 18.
As also illustrated in FIGS. ~ and 3 herein, there is
provided a glazing cushioning member 75 that forms a cushioning
for the edges of the glazing plates to prevent damage thereto,
as well as to facilitate positioning thereof. For further
details of the glazing cushioning member 75, reference may be
made to our co-pending application serial number 07/283,797
which was filed on December 13, 1988, which is hereby
incorporated by reference herein.
The retainer 22 has a top leg 34 and a side leg 36. The
retainer 22 is generally of L-shaped construction. The top leg
34 of the retainer 22 is adapted to receive a gasket 42 that is
relatively flat and that is interlockQd with the very free end
oE the leg 34. The gasket 42 may be constructed of a
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pr~-molded butyl material and is adapted to engage with and
securely hold the top of the glaæing plates, contacting the
plate 16 as illustrated in FIG. 3. The top leg 34 also has a
slot defined therein for receiving a leg 76 of the cushioning
member 75.
In FIG. 3, the cushioning member 75 is illustrated. It
may be constructed either or a lightweight metal material or a
hard plastic and supports therefrom a somewhat more resilient
and flexible cushioning piece 81. It is the piece 81 that
rests directly against the glazing plates as illustrated in
FIG. 3. FIG. 3 also illustrates in the completed cross-section
part thereof the bolt 56 extending through the frame 20,
through the glazing cushioning member 75 and into the threaded
flange 54. This arrangement positions the cushioning piece 81
adjacent the edge of the glazing plates as illustrated.
The bolt 56, such as illustrated in FIG. 3, also is used
for securing a part of the hinge 13. In this regard, in the
particular embodiment of FIG. 3, the hinge 13 is comprised of
hinge parts 13A and 13B. The hinge part 13B has a recess 13C
for receiving the leg of the hinge part 13A. F~G. 4
illustrates the hinge members separated. FIG. 3 illustrates
the hinge members engaged. The hinge member 13B is secured to
the lower base frame 14 by means of a urther series o
securing bolts 57. The hinge parts 13A and 13B may be
constructed of a PVC material that is somewhat more flexible
than the rigid PVC materials that comprise the ~rames 14 and 20.
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Reference is now made to FIG. 7 for an exploded
prospective view of an alternate construction of the present
invention. In FIG. 7, it is noted that the same reference
characters are used to identify similar parts to those
illustrated in FIG. 6. For example, FIG. 7 illustrates the
wooden base 11 secured to the decking 21 by means of angle
irons 17. The wooden base 11 is provided with ~he peripheral
slot 15. Overlying the wooden base 11 is illustrated the base
frame 14. The base frame 14 may be the same as illustrated in
FIGS. 1-6.
The particular embodiment illustrated in FIG. 7 is for use
in a roofing construction employing roofing tiles 71. The
flashing employed includes a sill flashing piece 68,
illustrated in FIG. 7 as being secured at the bottom end of the
wooden base 11. There is also illustrated in FIG. 7 the side
flashing pieces 69, one on either side of the wooden base 11.
Finally, there is a head flashing piece 70 tha~ is adapted to
mate with the top ends of these side flashing pieces 69.
Reference is now made to FIGS. 8-11 for a preferred
embodiment of the hinge construction that interconnects the
base frame 14 and the sash frame 20. In FIGS. 8-11, the same
reference characters are employed as previously used in
connection with the previous embodiment such as the one
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illustrated in FIGS. 1-5 herein. Accordingly, the skylight
construction includes a wooden base 11, a PVC base frame 14, a
PVC sa~h frame 20, a retainer 22, and glazing plates 16 and
18.
The preferred hinge construction includes hinge members
72A and 72B. The member 72A is constructed in a generally
C-shape having a recess 72C for receiving the member 72B. ~e
member 72B is of partially circular shape constructed with at
least one flat segment 73. When the skylight is closed, these
members interlock in a positive fashion as illustrated in FI~.
8 with segments of the hinge members engaging in a positive
tight interlocking. When the skylight is opened as in FIG. 9,
then the hinge members may be disengaged from each other. In
this way, the sash frame 20 can be removed for installation
purposes and can later be re-engaged with the base frame of ~he
skylight. It is noted that each of the frame members 72A and
72B have legs for support thereof from the respective frames
and for securing by the respective securing bolts 56 and 57.
Having now described a limited number of embodiments of
the present invention, it should 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.
