Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
SUPPORT STRUCTURE FOR USE ON ROOF
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BACKGROUND OF THE INVENTION
Various systems are known for supporting loads on roofs, and for installing
skylights and/or
smoke vents onto, into roofs.
A significant motivation for use of skylights is that the daylighting which
enters the building
through the skylight lenses can reduce or eliminate the need for use of
electrical light fixtures during
the daylight hours. Further, conventionally-known control systems can monitor
the light intensity at
desired, selected locations inside the building and automatically turn on
selected ones of the
electrical light fixtures as needed in order to maintain a desired level of
light intensity at the selected
locations inside the building, or selectively dim, or turn off, such light
fixtures when a desired level of
light intensity is being delivered through the skylights.
The benefits of using skylights to obtain daylighting include lower energy
costs, less use of
fossil fuels for generating electricity, and potentially less worker stress or
fatigue. A significant
problem associated with use of conventionally-available skylight lens
assemblies is that
conventionally-available skylight lens assemblies are known to have high
probability of leaking
during rain events.
Commonly used skylighting systems have translucent or transparent covers, also
known as
lenses, mounted on a support structure, commonly known as a "curb", which is
mounted to building
support members inside the building and wherein such support structure extends
through an
opening in the roof. Ambient daylight passes through the lens and thence
through the roof opening
and into the building.
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Thus, conventional skylight and smoke vent installations use a curb structure
beneath the
exterior roofing panels and inside the building enclosure, and extending
through the roof structure,
in order to provide a support which extends through the roof, past the roof
panels, and which
supports the skylight lens assembly. Conventional skylight curbs, thus, are
generally in the form of
a preassembled box-like structure. Such box-like structure is mounted to
building framing members
inside the building enclosure, and extends through a respective opening in the
roof, and past the
respective elongate metal roof panels. The skylight assembly thus mounts
inside the building
enclosure, and extends through an opening in a corresponding roof structure.
Fitting skylight
assemblies into such roof opening presents problems, both for the installer
and for the user. A
primary problem is that mentioned above, namely that all known types of
installations of
conventional skylight support structures have a tendency to leak water when
subjected to rain.
In light of the leakage issues, there is a need for a more effective way to
support skylights
and smoke vents, thus to bring daylighting into buildings, as well as a more
effective way to support
a variety of other loads, on roofs.
To achieve desired levels of daylighting, conventional skylight installations
use multiple roof
openings spaced regularly about the length and width of a given roof surface
through which
daylighting is to be received. Each skylight lens is installed over a separate
such opening.
Skylight assemblies of the invention are mounted on the ribs defined by metal
roof panels of
standing seam metal roofs. The skylight assemblies are raised above elongate
centralized panel
flats which extend the lengths of the panels, whereby rib elements at the
sides of adjacent such roof
panels are joined to each other in elongate joinders, referred to herein as
the ribs.
The opening for a conventional skylight cuts across multiple such ribs in
order to provide a
wide enough opening to receive conventionally-available commercial-grade
skylight assemblies.
The conventional skylight assembly, itself, includes a curb which is mounted
inside the building and
extends, from inside the building, through the roof opening and about the
perimeter of the opening,
thus to support the skylight lens above the flats of the roof panels, as well
as above the ribs.
Flashing, and conventional pliable tube construction sealants are applied
about the perimeter of the
roof opening, between the roof panels and the flashing, including at the cut
ribs. Typically,
substantially all of such sealant is applied in the panel flats, which means
that such sealant is a
primary barrier to water leakage about substantially the entire perimeter of
the skylight curb.
One of the causes of roof leaks around the perimeter of conventional roof
curbs which
attach primarily through the panel flat at the water line is due to foot
traffic, such as heel loads or
other dynamic loads imposed by workers wheeling gas cylinders or other heavy
equipment on the
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roof panel e.g. with dollies. This type of dynamic loading can cause high
levels of stress and/or
flexing of the adjacent roof panels, adjacent the edges of the curb. Such
joints between the roof
panels and the curb typically rely solely on flashing and tube sealant to
provide seals between the
curb and the roof panels, most notably in the panel flats. Leaks are also
commonly attributed to
areas around fastener locations, as the panels flex under load, causing stress
between the sealant
and the respective curb and/or roof panels; whereby the sealant deforms such
that, with repeated
flexing of the sealant over time, passages develop through the sealant, which
allows for the flow of
water through such passages and into the building.
Such curbs, each extending through a separate roof opening, each sealed
largely in the
panel flats, create multiple opportunities for water to enter the interior of
the building. Such
opportunities include, without limitation,
(i) the number of individual openings in the roof,
(ii) the tendency of water to collect and stay at the upper end of the
curb,
(iii) the disparate expansion and contraction of the roof panels relative
to the skylight-
supporting curb;
(iv) the lengths of sealed seams in the panel flats; and
(v) flexing of tube sealant pursuant to localized loads being exerted on
roof panels
adjacent a such skylight or other opening.
The traditional curb constructions and methods of attachment in most cases
thus require
that a complex support structure be installed below the metal roof panels and
supported from
building framing structure, such as purlins, located inside the building
enclosure, which allows
disparate/discordant movement of the metal roof panels and the skylight
assembly relative to each
other, as associated with thermal expansion and contraction of the metal roof
e.g. in response to
differences in temperature changes outside the building relative to
contemporaneous temperatures
inside the building.
In addition, conventional curb-mounted skylight structures tend to collect
condensation on
inside surfaces of the heated space in the building.
In some known structures, water is diverted to only one side of the structure.
In the case of
heavy rains, it may, in some instances, be desirable to provide a support
structure to divert water to
both sides of the structure in order to effect faster water run-off.
In some instances, it would be desirable to provide a thermal break and/or a
vapor barrier
up alongside the rib and upstanding elements of the support structure in order
to attenuate water
vapor condensation on inside surfaces of the support structure.
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In some instances, it would be desirable to provide a support structure having
a combination
of a thermal barrier and a vapor barrier up alongside the rib, and alongside
upstanding elements of
the support structure, in order to attenuate water vapor condensation on
inside surfaces of the
support structure, as well as to attenuate thermal conduction through the
support structure.
Thus, it would be desirable to provide a skylight system which provides a
desired level of
daylighting in a commercial and/or industrial building while substantially
reducing the
incidence/frequency of leaks occurring about such skylights, as well as
reducing or eliminating the
incidence/frequency of condensate accumulation inside the building in the
areas of such skylights.
It would also be desirable to provide a smoke vent system while substantially
reducing the
incidence/frequency of leaks occurring about such smoke vents, as well as
reducing or eliminating
the incidence/frequency of condensate accumulation inside the building in the
areas of such smoke
vents.
It would further be desirable to provide a support system, suitable for
supporting any of a
variety of roof loads, up to the load-bearing capacity of the metal panel roof
while substantially
controlling the tendency of the roof to leak about such support systems, as
well as reducing or
eliminating the incidence/frequency of condensate accumulation in the areas of
such support
systems.
It would be further desirable to provide thermal break structure which
interrupts the path of
travel of thermal energy otherwise entering the building through the skylight
or smoke vent
structure.
SUMMARY OF THE INVENTION
This invention provides a construction system for installing loads, such as
skylight
assemblies and/or smoke vent assemblies, or other loads, on the major rib
elevations of a metal
panel roof system of a building such that substantially all of the load is
conveyed through a load
support structure, thence through side rails mounted on roof panel ribs,
thence through the ribs and
to underlying building support structure, thereby utilizing the beam strengths
of the standing seams
of the rib elements of the roof panels as the primary support structure
supporting such loads, such
that all, or nearly all, of the overlying load is conveyed, through the ribs,
to the underlying building
support structure.
As used herein "beam strength" refers to the capability of a structural
element to resist a
bending force, as "beam strength" is defined at www.wikipedia.org. Within this
context, the
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standing seams on the ribs, in a standing seam metal panel roof, acting in a
capacity as beam web
structure, provide beam-like strength in supporting/resisting the weight of
overlying vertical loads
imposed on the roof.
In addition, the invention can provide improved control of thermal losses, and
corresponding
condensation on inside surfaces of the load support structure inside the
climate-controlled building
envelope, by providing thermal insulation and thermal break structures, about
the opening in the
roof.
Some embodiments of the invention provide structure diverting up-slope water
to both left
and right opposing sides of the load support structure.
In a first family of embodiments, the invention comprehends, in combination,
an elongate rail
and an elongate rod, for collective use in a rail mounting system on a sloping
metal panel roof, to
support a cover which closes off access to an opening through such roof, the
rail comprising a
lower shoulder adapted and configured to be mounted to the roof, an upstanding
web extending up
from the lower shoulder, to a top of the upstanding web at an upper portion of
the upstanding web,
an upper flange extending laterally from the upper portion of the upstanding
web to a distal end
thereof, and an inner panel extending down from the upper flange to a lower
reach of the inner
panel, the upstanding web, the upper flange, and the inner panel collectively
comprising cavity
walls, and defining a cavity above the lower reach of the inner panel, and a
cavity opening between
the inner panel and the upstanding web, the elongate rod having a cross-
section greater than a
distance between the lower reach of the inner panel and the upstanding web at
the cavity opening,
the rod and the cavity walls defining a combination of manual resilient
compressibility of the rod and
manual resilient deflectability of the cavity walls such that a worker can
manually deform one or
both of the cross-section of the rod or a shortest distance across the cavity
opening so as to insert
the rod through the cavity opening and into the cavity.
In some embodiments, a dominant dimensional change which enables inserting the
rod
through the opening is resilient deformation of the cross-section of the rod.
In some embodiments, a dominant dimensional change which enables inserting the
rod
through the opening is resilient deformation of at least one of the cavity
walls so as to provide a
dominant dimensional change at the cavity opening.
In some embodiments, the cavity walls are not substantially deformed, and
resilient
deformation of the cross-section of the rod is responsible for substantially
all dimensional change
which enables manual inserting the rod through the cavity opening.
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In some embodiments, the cross-section of the rod is not substantially
deformed, and
resilient deformation of one or more of the cavity walls is responsible for
substantially all
dimensional change which enables manual insertion of the rod into the cavity
opening.
In some embodiments, the inner panel extends down from the upper flange at an
included
acute angle of about less than 90 degrees to greater than 60 degrees,
optionally about 70 degrees
to about 80 degrees.
In a second family of embodiments, the invention comprehends a rail mounting
system
configured to be installed about an opening through a metal panel roof, to
support a load, the rail
mounting system comprising a plurality of lateral closure members, having
lengths, and being
adapted to be mounted on such roof and about such opening, the lateral closure
members, when
assembled to each other on such roof, collectively providing an enclosing
wall, and defining an
outer perimeter of the enclosing wall which, with the cover, separates a
surrounded space, over the
opening, from an ambient environment outside the enclosing wall, the enclosing
wall comprising an
upstanding web, an upper flange extending laterally from the upstanding web,
and an inside panel
extending down from the upper flange to a lower reach of the inner flange, the
upstanding web, the
upper flange, and the inside panel collectively comprising cavity walls which
define an elongate
cavity above the lower reach of the inner panel, and a cavity opening between
the inner panel and
the upstanding web; and an elongate rod having a cross-section dimension
greater than a distance
between the lower reach of the inner panel and the upstanding web, and
sufficiently great to, when
in the cavity, resist any resilient return of the inside panel toward the
upstanding web, the cavity
walls being sufficiently resiliently deflectable that a worker can move a
distal edge of the inside
panel a sufficient distance away from the upstanding web so as to enable the
worker to push the
rod into the cavity through the slot, the cross-section dimension, and
compressibility characteristics,
of the rod, and the resilient deflectability of the cavity walls collectively
generating sufficient ongoing
force between the rod and the cavity walls to retain the rod in the cavity
thereby to hold the rod in
the cavity.
In some embodiments, the force between the rod and the cavity walls is
sufficiently great to
hold an element of a layer of insulation in the cavity between the rod and the
cavity walls.
In some embodiments, such rail mounting system is installed about an opening
in a metal
panel roof, the metal panel roof comprising a plurality of metal roof panels,
each having a length
and a width, and being arranged side by side, edges of adjacent ones of the
metal roof panels
meeting at elevated rib structure portions thereof and defining elevated roof
panel ribs, panel flats
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being disposed between the roof panel ribs, cross-section dimension and
compressibility
characteristics of the rod and resilient deflectability of the cavity walls
collectively generating
sufficient ongoing force between the rod and the cavity walls to retain the
rod in the cavity by means
of friction engagement and thereby to hold an upwardly-extending element of a
layer of roof
insulation in the cavity between the rod and the cavity walls.
In a third family of embodiments, the invention comprehends in combination, an
elongate rail
and an elongate thermal break element, for use in a rail mounting system on a
sloping metal panel
roof to support a load which closes off access to an opening through the roof,
the rail having a
length and comprising a lower shoulder adapted and configured to be mounted to
the roof, an
upstanding web extending up from the lower shoulder, to a top of the
upstanding web at an upper
portion of the upstanding web, an upper flange extending laterally from the
upper portion of the
upstanding web to a distal end thereof, an inner panel extending down from the
upper flange to a
lower reach of the inner panel, the upstanding web, the upper flange, and the
inner panel
collectively comprising cavity walls, and defining a cavity above the lower
reach of the inner panel,
and a cavity opening between the inner panel and the upstanding web, the
elongate thermal break
element being mounted to the elongate rail and in proximal contact with the
rail, and extending
along substantially the entirety of the length of the rail, the thermal break,
in combination with the
rail, providing an enhanced thermal barrier proximate the respective portion
of the rail to which the
thermal break is proximate.
In some embodiments, the rail has a first thermal conductivity per unit
thickness, and the
thermal break has a second thermal conductivity per unit thickness, less than
the thermal
conductivity of the rail such that the combination of the rail and the thermal
break, having a given
thickness, provides the enhanced thermal barrier compared to an equal
thickness of only the rail.
In some embodiments, the thermal break is mounted to the rail such that, where
the thermal
break is mounted to the rail, more than half of the thermal break is between
the rail and the
opening.
In some embodiments, the thermal break is mounted to the rail such that, where
the thermal
break is mounted to the rail, more than half of the rail is between the
thermal break and the
opening.
In some embodiments, the rail has an upstanding web, an upper flange extending
laterally
from the upstanding web, and an inside panel extending down from the upper
flange to a lower
reach of the inside panel, the upstanding web, the upper flange, and the
inside panel comprising
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cavity walls and collectively defining a cavity above the lower reach of the
inside panel, the cavity
walls further defining an inside surface of the cavity, facing into the
cavity, the upstanding web, the
upper flange, and the inside panel each further having an outside surface, and
collectively further
defining an outside surface of the cavity, facing away from the cavity, the
thermal break being
disposed primarily on the outside surface of the cavity.
In some embodiments, each rail has an upstanding web, an upper flange
extending laterally
from the upstanding web, and an inside panel extending down from the upper
flange to a lower
reach of the inside panel, the upstanding web, the upper flange, and the
inside panel comprising
cavity walls and collectively defining a cavity above the lower reach of the
inside panel, the cavity
walls further defining an inside surface of the cavity, facing into the
cavity, the upstanding web, the
upper flange, and the inside panel each further having an outside surface, and
collectively further
defining an outside surface of the cavity, facing away from the cavity, the
thermal break being
disposed primarily on the inside surface of the cavity.
As used herein, the lower reach of the inside panel refers to the lowest
elevation to which
the inside panel reaches, which may or may not be the lower distal edge of the
inside panel.
In some embodiments, the thermal break comprises an elongate thermoplastic
extrusion.
In some embodiments, the thermal break overlies the outside surface of the
inside panel
and no more than a minor portion of the upper flange.
In some embodiments, the thermal break overlies the outside surfaces of the
inside panel
and the upper flange, and no more than a minor portion of the upstanding web.
In some embodiments, the thermal break overlies the outside surfaces of the
upstanding
web, the upper flange, and the inside panel.
In some embodiments, the thermal break overlies the outside surface of the
upstanding
web, the upper flange, and a minor portion, if any, of the inside panel.
In some embodiments, the thermal break comprises surface irregularities on an
inside
surface of the thermal break, facing the rail, so as to create thermally
effective dead air spaces
between the rail and the thermal break.
In some embodiments, at least 50 percent of the inside surface of the thermal
break is
spaced from the respective surface of the rail at the surface irregularities.
In some embodiments, the invention comprehends a rail mounting system
comprising a
plurality of lateral closure members configured to be mounted about such
opening and thereby to
close off such opening, the closure members comprising first and second rails,
and end elements,
including a rail as described herein, each of the lateral closure members
having an upstanding web,
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an upper flange extending laterally from the upstanding web, and an inside
panel extending down
from the upper flange to a lower reach of the inside panel, the upstanding
web, the upper flange,
and the inside panel comprising cavity walls and collectively defining the
cavity above the lower
reach of the inside panel, the cavity walls each having an inside surface,
facing inwardly into the
cavity, and an outside surface facing away from the cavity, the thermal break
being disposed
primarily on one of the inside surfaces or the outside surfaces of the cavity
walls.
In some embodiments, the thermal break is disposed primarily on inside
surfaces of the
cavity walls.
In some embodiments, the thermal break extends, from the inside surface of the
inside
panel, about a bottom distal edge of the inside panel and upwardly on an
outside surface of the
inside panel to an upper edge of the inside panel at a corner defined by the
inside panel and the
upper flange.
In some embodiments, the rail mounting system is mounted on a roof of a
building, about
the opening in the roof of the building, the end elements having upstanding
webs, each lateral
closure member having a mounting flange extending from a top of the respective
upstanding web, a
layer of insulation extending upwardly from inside the building, alongside the
lateral closure
members and being held in the cavities in the lateral closure members, the
thermal breaks being
effective to prevent condensation at surfaces of the upper flanges which are
exposed to an interior
environment inside the building.
In some embodiments, the layer of insulation, in combination with the thermal
breaks on
each of the lateral closure members, provides effective thermal break
properties from below the
roof of the building, up through the opening, and up to a top of the rail
mounting system, and about
a full outer perimeter of the rail mounting system on the roof.
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 combination with the accompanying drawings wherein the FIGURES depict
various components
and compositions of support structures of the invention.
FIGURE 1 is a profile of a metal roof of the type known as a standing seam
roof.
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FIGURE 2 is a profile of a metal roof of the type known as an architectural
standing seam
roof.
FIGURE 3 is a roof profile of a metal roof of the type commonly referred to as
an exposed
fastener roof.
FIGURE 4 is a roof profile of a metal roof of the type commonly referred to as
a snap seam
roof.
FIGURE 5 is a roof profile of a metal roof of the type commonly known as a
foam core roof.
FIGURE 6 is a side view showing major components of a skylight system of the
invention,
installed on a metal roof.
FIGURE 7 is a top/plan view of the installed skylight system of FIGURE 6,
showing
placement of the skylights and the direction of water flow around the
skylights.
FIGURE 8 is a cut-away pictorial view showing an upper diverter mounted in a
rib gap.
FIGURE 9 is a cross sectional view showing the relationships of the rails to
the rib
elevations of a metal panel roof where the panel flat has been removed,
including showing
underlying building insulation.
FIGURE 10 is an enlarged end view of a rail mounted on a rib, illustrating a
gap plug in the
space between the upstanding web of the rail and the metal roof standing seam,
under the turned-
over edges of the standing seam.
FIGURE 11 shows a cross-section as in FIGURE 9, after removal of that portion
of the
insulation batt material which was to be removed, and the insulation vapor
barrier layer has been
cut along the length of the aperture in the metal roof.
FIGURE 12 shows a cross-section as in FIGURES 9 and 11 where the insulation
vapor
barrier layer on one side of the opening has been raised and tucked into the
cavity in the rail, and is
being held in the cavity by a retainer rod.
FIGURE 13 shows a cross-section as in FIGURES 9 and 11-12 where the insulation
underlying the roof has been extended up through the aperture in the roof,
where the vapor barrier
layer on both sides of the opening has been tucked into the rail cavity and is
being held in the cavity
by retainer rods such as that shown in FIGURE 12, and where the skylight lens
assembly has been
mounted to the rails, and serves as a cover/closure over the aperture in the
metal roof.
FIGURE 14 is a perspective view, partially cut away, showing structure of part
of a
daylighting system as installed on the rib elevations of a standing seam metal
panel roof.
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FIGURE 15 is a perspective view of an upper diverter showing trailing closure
ears
extending from the ends of the upstanding web of the upper diverter, the
closure ears having been
closed and secured over the upstanding webs of the respective side rails.
FIGURE 16 is a top view of the upper diverter of FIGURE 15 wherein trailing
closure ears
extend from the ends of the upstanding web and define acute angles with
upstanding webs of
respective side rails, before the trailing closure ears are closed over the
upstanding webs of the
side rails.
FIGURE 17 is a front elevation view of the upper diverter of FIGURE 16.
FIGURE 18 is a perspective view of a two-piece lower closure and its panel
stiffener.
FIGURE 19 is a cross-section taken at 19-19 of FIGURE 18, showing the
relationships
between the bottom piece of the lower closure and the upper rail piece,
showing the insulation
vapor barrier layer being held in a flange cavity by a retainer rod, with ends
of the screws which
mount the upper rail piece to the bottom piece being embedded in the retainer
rod, and the panel
stiffener under the flat of the metal roof panel at the lower closure, whereby
the joinder between the
lower flange of the bottom piece of the lower closure and the flat of the roof
panel is supported by
the panel stiffener.
FIGURE 20 is a top view of the lower closure.
FIGURE 21 is an end elevation view of the lower closure.
FIGURE 22 is a perspective view, partially cut away, showing an end joinder
between facing
ends of adjacent skylight assemblies of the system.
FIGURE 23 shows additional detail of the joinder shown in FIGURE 22.
FIGURE 24 shows an exploded pictorial view of a rail connector aligned with
abutting rail
ends and wherein the connector bridges the butt joint between rails which
adjoin each other end-to-
end, providing both reinforcement of the joint and enhanced sealing of the
joint against intrusion of
water.
FIGURE 25 is a perspective view of a second embodiment of the upper diverter,
namely a 2-
way diverter which diverts water in first and second opposing directions
around the respective load
support structure.
FIGURE 26 is a top view of the 2-way diverter illustrated in FIGURE 25.
FIGURE 27 is a front/elevation view of the 2-way diverter illustrated in
FIGURES 25 and 26.
FIGURE 28 is a top view of the 2-way diverter illustrated in FIGURES 25-27,
shown installed
on a roof, with a panel stiffener underlying the diverter, extending from a
first rib next adjacent one
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of the ribs through which the diverter extends, extending underneath the
respective roof panels and
under the diverter, to the next adjacent one of the ribs on the opposing side
of the diverter.
FIGURE 29 is a front elevation view of the diverter installation of FIGURE 28.
FIGURE 30 is a top view of the 2-way diverter illustrated in FIGURES 25-29,
shown installed
on a roof, with a panel stiffener underlying the diverter and having a length
confined generally to
and between the two ribs through which the diverter extends.
FIGURE 30A shows a top view of a 2-way diverter as in FIGURE 30 except that
the panel
stiffener ends on one side at the end of the lower flange and, on the other
side, extends to the next-
adjacent rib beyond the diversion gap.
FIGURE 31 shows an enlarged end view of a rail mounted on a rib, where the
insulation has
been lifted into the opening and its vapor barrier layer is being held in the
cavity by a retainer rod,
and where a thermal break has been installed on the inside surface of the
upper portion of the rail.
FIGURE 32 shows an enlarged end view of a rail mounted on a rib as in FIGURE
31, but not
showing the underlying insulation, and where a serrated thermal break is
installed on the outside
surface of the inside panel of the rail.
FIGURE 33 shows an enlarged end view of a rail mounted on a rib as in FIGURE
32, but
where the serrated thermal break extends across the outside surface of both
the inside panel and
the upper flange.
FIGURE 34 shows an enlarged end view of a rail mounted on a rib as in FIGURES
32-33,
but where the serrated thermal break extends across the outside surface of the
inside panel, across
the outside surface of the upper flange, and across the outside surface of the
upstanding web of the
rail, to the bottom of the upstanding web.
FIGURE 34A shows an enlarged end view of a rail mounted on a rib as in FIGURE
34 but
without full top-to-bottom coverage of the inside panel.
FIGURE 35 shows an enlarged end view of a rail mounted on a rib, and a thermal
break
mounted to the outside surface of the rail as in FIGURE 34, but with full top-
to-bottom coverage of
the inside panel, and where the thermal break is not serrated.
FIGURE 36 shows an enlarged end view of a relatively shortened-height rail
having an
outside thermal break, where the vapor barrier of the lifted insulation is
secured to the standing
seam with a clip, and the space inside the rail cavity, down to the thermal
insulation, is occupied by
a thermally-insulating rod.
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FIGURE 37 shows an end view of a relatively shortened-height lower closure
where the
vapor barrier layer of the lifted insulation is secured to an extension of the
lower flange by a spring
clip.
FIGURE 38 shows a cross-section of a relatively shortened-height upper
diverter where the
vapor barrier layer of the lifted insulation is secured to a flange which
extends from an extension of
the upstanding web.
FIGURE 39 shows an enlarged end view of a relatively shortened-height rail as
in FIGURE
36, but where the space inside the rail cavity, down to the insulation, is
filled with an elongate strip
of thermally-insulating batting material.
FIGURE 40 shows an enlarged end view of a rail mounted on a rib where the
vapor barrier
of the underlying insulation is secured to the standing seam with a clip, the
thermal batting of the
underlying insulation is stuffed into the rib cavity under the rib, and the
space inside the rail cavity,
down to the top of the rib, is occupied by a relatively shape-retaining, but
also resiliently-
compressible, thermal insulation board.
The invention is not limited in its application to the details of
construction, or to the
arrangement of the components set forth in the following description or
illustrated in the drawings.
The invention is capable of other embodiments or of being practiced or carried
out in various other
ways. Also, it is to be understood that the terminology and phraseology
employed herein is for
purpose of description and illustration and should not be regarded as
limiting. Like reference
numerals are used to indicate like components.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
The products and methods of the present invention provide a load support
structure, for use
in installing and supporting various exterior roof loads, including structures
which close off openings
in metal panel roofs. For purposes of simplicity, "support structure" is used
interchangeably herein
to refer to various types of structures which are mounted on ribs of raised-
elevation metal panel roof
structures, such that substantially all of the load passes through the support
structure and through
the ribs on which the support structure is mounted, to the underlying building
framing inside the
building. The support structure typically surrounds an opening in the roof,
including extending
across the flat of a roof panel. Skylight assemblies and smoke vents are non-
limiting examples of
covers which are mounted on such support structures and which extend over, and
which close off,
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such roof openings. Air handling operations such as vents, air intakes, and
air or other gaseous
exchanges to and/or from the interior of the building are non-limiting
examples of operations where
conduits extend through the roof opening. In the case of roof ventilation,
examples include simple
ventilation openings, such as, for example and without limitation, roof fans
and smoke vents, which
are used to allow the escape of smoke through the roof during a fire. The only
limitation regarding
the loads to be supported is that the magnitude of a load must be within the
load-bearing capacity
of the roof panel or panels to which the load is mounted.
The number of skylights or other roof loads can vary from one load, to as many
loads as the
building roof can support, limited only by the amount of support which the
respective roof panels,
namely the ribs to which the load is attached, can provide.
The invention provides structures and installation processes, as closure
systems which
utilize the beam-like bending resistance of the standing seams, in the roof
panel ribs, as a primary
support, supporting e.g. a downwardly-directed load on the roof.
Support structures of the invention do not need to be mounted directly to the
building
framing inside the climate-controlled building enclosure for the purpose of
being themselves
supported, and thereby supporting, an installed skylight system or other load.
Neither does the
skylight system of the invention require a separate curb construction
surrounding each skylight lens
assembly to separately support or mount or attach each skylight lens assembly
to the roof. Rather,
a support structure of the invention, which supports such skylights, is
overlaid onto, and mounted
to, the roof panels, thus exposing the support structure to the same ambient
weather conditions as
the weather conditions which the surrounding roof panels experience.
Accordingly, the support
structure experiences approximately the same, or a similar, rate of thermal
expansion and
contraction as is experienced by the respective roof panel or panels to which
the support structure
is mounted. This is accomplished through direct attachment of the support
structure of the
invention, which supports e.g. a skylight assembly or other load, to the
underlying metal roof
panels. According to such roof mounting, and such ambient weather exposure,
expansion and
contraction of the support structure of the invention generally coincides, at
least in direction, with
concurrent expansion and contraction of the metal roof panels.
Referring now to the drawings, a given metal roof panel generally extends from
the peak of
the roof to the respective eave. Skylight systems of the invention contemplate
the installation of two
or more adjacent skylight assemblies in an end to end relationship along the
major rib structure of a
given such metal roof panel on the building, over a single aperture in the
roof, whereby the
individual skylight assemblies are installed in strips over a continuous,
uninterrupted opening in the
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CA 02895803 2015-06-26
metal roof, the opening extending along a line which extends from at or near
the roof ridge to a
location at or near a corresponding eave.
In the alternative, a single skylight assembly can be installed over each, or
any, such roof
opening.
Skylight systems of the invention can be applied to various types of ribbed
roof profiles.
Figure 1 is an end view showing a roof profile of a metal roof of the type
known as a standing seam
roof. These include the "standing seam" roof, which has trapezoidal elevated
elongate major ribs
32 typically 24 inches to 30 inches on center. Each roof panel 10 also
includes a panel flat 14, and
may include a rib shoulder 16 as part of a rib 32, next to the panel flat. The
elevated rib structures
on a given panel cooperate with corresponding elevated elongate rib structures
on next-adjacent
panels, thus forming standing seams 18. Seams 18 represent the edges of
adjacent such roof
panels, folded one over the other, to form elongate joinders at the side edges
of the respective roof
panels. In the process of forming the standing seams, the edge regions of the
rib elevations on
respective adjacent panels are, together, folded over such that the standing
seam functions as a
folded-over raised joinder between the respective panels, thus to inhibit
water penetration of the
roof at the standing seam/joint.
Figure 2 is an end view showing the roof profile of a metal roof of the type
known as an
architectural standing seam roof, which uses a series of overlapping
architectural standing seam
panels 20. Each panel 20 comprises a panel flat 14, and a rib element of an
architectural standing
seam 28 on each side of the panel.
Figure 3 is an end view showing the roof profile of a metal roof of the type
commonly
referred to as an "R panel" or exposed fastener panel 30. Each panel has
raised shoulder elements
on opposing sides of a panel flat 14 which, with the rib elements of adjacent
panels, form ribs 32.
Adjacent R panels are secured to the roof by fasteners 35. At side lap 38,
overlapping regions of
adjacent panels are secured to each other by stitch fasteners 39. Trapezoidal
major ribs of the R
panel roof are most typically formed at 8 inches to 12 inches on center.
Figure 4 is an end view showing the roof profile of a metal roof of the type
commonly
referred to as a snap rib seam panel 40. Snap rib seam panels 40 have a panel
flat 14 and a
standing seam, also known as a snap seam 48, where the adjacent panels meet.
Figure 5 is an end view showing a roof profile of a metal roof of the type
commonly referred
to as a foam core panel 50. Such roof has a rib 32, a liner panel 53, a panel
flat 14 and a foam
core 57. Overlapping regions 58 of adjacent panels are secured to each other
by a series of
fasteners 59 spaced along the lengths of the overlapped panels.
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CA 02895803 2015-06-26
A skylight/ventilation support structure is illustrative of support structures
of the invention
which close off roof-penetrating openings. Such support structure can comprise
a rail and closure
structure which surrounds an opening in the roof, and which is adapted to be
mounted on, and
supported by, the prominent standing elevations, standing rib structures, or
other upstanding
elements of conventional such roof panels, where the standing structures of
the roof panels provide
the support for the so-mounted support structures. Namely, structure which is
mounted to the roof
panels above the panel flats, e.g. at seams/joints/ribs where adjoining metal
roof panels are joined
to each other, provides the support for supporting respective loads. A such
rail and closure support
structure may be secured to the conventional metal roof panels across a single
panel flat, by
fasteners located above the respective panel flat, and surrounds a roof
opening formed largely in
the intervening flat region of one or more metal roof panels.
Figure 6 shows first and second exemplary support structures 100, mounted to a
standing
seam panel roof 110, and overlain by covers defined by first and second
skylight lens assemblies
130.
Figure 7 shows a portion of the roof 110 of FIGURE 6, in dashed outline. The
roof has
raised ribs 32, panel flats 14, shoulders 16 and standing seams 18. Given that
water seeks the
lowest level available at any given location, any water on a given roof panel
tends to
congregate/gather on the upper surface of the panel flat whereby, except for
any dams across the
panel flat, the water line is generally limited to the panel flat and slightly
above the panel flat,
depending on the quantity of water on the panel flat and the rate at which
rain is falling or water is
otherwise accumulating on the roof. Thus, at any given time, most of shoulder
16, and all of rib 32
above shoulder 16, and all of standing seam 18, are all typically above the
top surface of the water,
colloquially known as the water line. Also depicted in FIGURES 6 and 7 are
ridge cap 120 of the
roof structure, and cutaway regions, or gaps 122 extending through the
respective raised ribs 32.
Skylight lens assembly 130, which is part of the closure system for closing
off the aperture,
generally comprises a skylight lens frame 132 mounted to the load support
structure and extending
about the perimeter of a given load support structure, in combination with a
light-transmitting
skylight lens 134 mounted to frame 132. An exemplary such skylight lens is
that taught in United
States patent 7,395,636 Blomberg and available from Sunoptics Prismatic
Skylights, Sacramento,
California.
Still referring to Figures 6 and 7, and now adding FIGURE 8, support structure
100 of the
invention, as applied to a skylight installation, includes a rail and closure
structure 140. Such rail
and closure structure includes one or more first side rails 142 and one or
more second side rails
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144 (FIGURES 9, 10), an upper diverter 146 disposed adjacent rib gap 122, and
a lower closure
150. As shown in FIGURE 8, a lateral leg 147 of the upper diverter extends
through gap 122,
providing a water-conveying bottom surface of the roof across the gap. Lateral
leg 147 includes
those portions of the lower flange 410, diversion surface 420, and upstanding
web 415 (as rib
sealing plate 450), which extend through gap 122 in the respective rib. The
diverter thus carries
water laterally through the gap, across the width of the respective rib, to
the panel flat 14 of the
adjacent roof panel, thus to convey the water away from the upper end of the
skylight and to
prevent the water from leaking through the roof aperture. Rail and closure
structure 140 also
includes panel stiffeners, connectors, bridging members, and rubber or plastic
plugs to make
various connections to the rail and closure structure elements as well as to
close gaps/spaces
between the various rail and closure structure elements, and between the roof
panels and the rail
and closure structure elements, thus to complete the seals which prevent water
leakage about the
skylight and its associated aperture in the roof.
Figures 7 and 8 show how gap 122 in rib 32, in combination with upper diverter
146,
provides for water flow, as illustrated by arrows 200, causing the water to
move laterally along the
roof surface, over lateral leg 147 of the upper diverter, and down and away
from the roof ridge cap
120 in panel flat 14 of the roof panel which is next adjacent the rib
structures which support the
respective e.g. skylight.
Referring now to Figures 9 and 10, a cross section through rib 32, and
associated support
structures 100 shows securement of support structures 100 to standing rib
portions of the standing
seam panel roof 110. Figure 9 depicts the use of ribs 32 to support side rails
142 and 144 on
opposing sides of the panel flat 14. Each rail 142 or 144 has a lower rail
shoulder 242 and a rail
upper support structure 236. Rail upper support structure 236 has a generally
vertically upstanding
web 238, a generally horizontal rail upper flange or bearing panel 240, and a
rail inside panel 244.
Inside panel 244 extends toward outer web 238 at an included angle, more or
less, of about 75
degrees between upper flange 240 and panel 244. From web 238, shoulder 242
extends laterally
at a perpendicular angle over rib 32 as a shoulder top, and turns at an obtuse
included angle down,
tracking the sloped angle of the side of rib 32. The rail is secured to the
side of rib 32 by fasteners
310 spaced along the length of the rib and above the adjacent panel flat, thus
transferring the
weight of the overlying load to the side of the rib.
As illustrated in FIGURES 9 and 10, in the joinder of each pair of adjacent
panels, the edges
of the two roof panels are folded together, one over the other, leaving a
space 239 between the
bottom edges of the folded over panel edges and the underlying top flat
surface 241 of the rib.
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Where the space 239 faces web 238 of the rail, as at the right side of FIGURE
9, and as shown in
FIGURE 10, a gap plug 243 is disposed in space 239 between the standing seam
and under the
turned-over edge, and upstanding web 238 of the rail. Gap plugs 243 are used
both where the
upper diverter meets the side rails and where the lower closure meets the side
rails.
Where space 239 faces away from upstanding web 238 of the side rail, as at the
left side of
FIGURE 9, the flat surface of upstanding web 238 can be brought into a close
enough relationship
with the standing seam that any space between the standing seam and the
upstanding web can be
closed by pliable tube sealants. Thus, no gap plug is typically used between
upstanding web 238
and the standing seam where the distal edge of the seam is turned away from
the upstanding web.
Gap plug 243 is relatively short, for example about 1.5 inches to about 2.5
inches long, and
has a width/height cross-section, shown in FIGURE 10, which loosely fills
space 239. The
remainder of the space 239, about plug 243, namely between plug 243 and
upstanding web 238,
and between plug 243 and the standing seam, is filled with e.g. a pliable
construction sealant 245.
Such sealant is shown in FIGURE 10 as white space about plug 243. Plug 243
thus provides a
solid fill piece at spaces 239 where there is, otherwise, some risk of water
entry into the roof
opening, and where the space 239 is too large for assurance that a more
pliable sealant can
prevent such water entry.
Gap plug 243 is made of a relatively solid, yet resilient, e.g. EPDM (ethylene
propylene
diene monomer) rubber, which provides relatively solid e.g. relatively non-
pliable mass in space 239
between the folded-over standing seam and upstanding web 238 of the rail, and
relatively pliable,
putty-like, tape mastic and tube caulk or the like are used to fill the
relatively smaller spaces which
remain after the gap plug has been inserted in the respective gap/space. Upper
flange 240, at the
top of the rail, is adapted to support skylight frame 132, seen in FIGURE 13.
Inside panel 244 of
the rail extends down from the inner edge of upper flange 240 at an acute
included angle, illustrated
at about 75 degrees.
Referring back to FIGURE 9, insulation 248 is shown below the opening 249 in
the metal
roof panel. Insulation 248 has a facing sheet/vapor barrier layer 250
underlying a layer of
thermally-insulating, e.g. fiberglass, batt material 252. Dashed line 254
outlines the approximate
portion of the fiberglass batt material which is to be removed. An edge
portion 256 of batt material
is left extending into opening 249 for use described hereinafter.
Rail and closure structure 140 is representative of the perimeter portion of
support structure
100. Rails 142, 144 fit closely along the contours of ribs 32. Upper diverter
146 and lower closure
150 have contours which match the cross-panel contours of the respective ribs
32 as well as
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CA 02895803 2015-06-26
matching the respective panel flats 14, 114. The various mating surfaces of
structure 140 and roof
110 can be sealed in various ways known to the roofing art, including caulk or
tape mastic. Plastic
or rubber fittings or inserts such as plugs 243, and plugs 460, discussed
hereinafter, can be used to
fill larger openings at the rails and ribs.
FIGURE 11 shows the insulation batt material, marked with a dashed outline in
FIGURE 9,
removed from its position under the central portion of the opening in the
metal roof panel, removing
almost all of the batt material from that portion of the facing sheet/vapor
barrier layer. The vapor
barrier layer is then cut along the length of the roof-penetrating opening 249
over which the one or
more skylight lenses are to be installed. At the ends of opening 249, the cut
is spread to the
corners of the opening. A such "Y"-shaped cut 262 is illustrated at the upper
end of the opening in
FIGURE 8, wherein the ends of the "Y" extend to approximately the upper
corners of the opening.
FIGURE 12 shows one side of insulation 248 lifted up into the opening 249. The
vapor
barrier layer and edge portion 256 of the insulation batting have been lifted
into the opening. A
resilient foam retaining rod 260 has been forced into cavity 264 in the rail,
with the vapor barrier
layer captured between the retaining rod and the rail surfaces which define
cavity 264, which draws
the insulation batting of edge portion 256 toward, and against, and into
contact with, the respective
rib 32. Vapor barrier layer 250 enters cavity 264 against upstanding web 238
of the rail, extends up
and over/about rod 260 in the cavity, and thence extends back out of cavity
264 to a terminal end of
the facing sheet outside cavity 264. Thus, rod 260 holds edge portion 256, as
thermal insulation,
against rib 32, and also positions the vapor barrier layer between the climate-
controlled space 266
inside the building and the perimeter of the support structure.
As illustrated, the uncompressed, rest cross-section of rod 260 in cavity 264
is somewhat
greater than the slot-shaped opening 268 between inside panel 244 and
upstanding web 238. Thus
retainer rod 260 is deformable, and the cross-section of the rod is compressed
as the rod is being
forced through opening 268. After passing through opening 268, rod 260 expands
against web
238, upper flange 240, and panel 244 of the cavity while remaining
sufficiently compressed to urge
vapor barrier layer 250 against web 238, upper flange 240, and panel 244 of
the cavity whereby
vapor barrier layer 250 is assuredly retained in cavity 264 over the entire
length of the rail or rails.
A highly resilient, yet firm, polypropylene or ethylene propylene copolymer
foam is suitable for rod
260. A suitable such rod, known as a "backer rod" is available from Bay
Industries, Green Bay,
Wisconsin. Such backer rod can be manually compressed sufficiently to effect
the insertion of the
foam through opening 268 and into cavity 264.
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CA 02895803 2015-06-26
In alternative embodiments, rod 260 can comprise a less compressible material,
whereupon
any or all of the cavity structure elements, namely upstanding web 238, upper
flange 240 and inside
panel 244 are specified to be sufficiently resiliently deflectable that a
worker can deflect inside panel
244 away from upstanding web 238, thus increasing the dimension of slot-shaped
opening 268
enough to allow the rod to be manually pushed through the slot.
Such rod for the alternative embodiments can be any material which can
effectively engage
and hold the vapor barrier sheet when force is applied to the surface of the
rod. Non-limiting
examples of such materials are various non-foamed, or slightly-foamed,
relatively higher density
rubber-like materials, such as EPDM rubbers, styrene butadiene styrene
rubbers, and the like.
Various plastics such as PVC and various ones of the polyolefins, such as
polyethylene,
polypropylene, or the like, can also be used, either unfoamed or modestly
foamed having densities
greater than about 10 pounds per cubic foot, optionally greater than 12 pounds
per cubic foot,
optionally greater than 20 pounds per cubic foot, up to the unfoamed densities
of the respective
materials. In some instances, a wood rod/dowel is acceptable for rod 260.
In any embodiment, the installer deflects panel 244 progressively along the
length of slot
opening 268 while correspondingly inserting respective progressive portions of
the length of rod 260
into the cavity or compresses the rod while correspondingly inserting the
progressive portion of the
length of the rod into the cavity, or both compresses the rod and deflects
panel 244 while inserting
the progressive length of the rod into the cavity. As the installer releases a
respective portion of
inside panel 244 or rod 260, in the process of inserting a respective portion
of the rod 260 into the
cavity, the respective cavity structure or rod resiliently returns toward its
rest position, closing slot
268 and/or expanding the rod to its rest position, which brings inside panel
244 into a holding
engagement with the rod whereby the force being exerted between rod 260 and
panel 244 in
attempting to return to respective unstressed configurations applies an
effective frictional holding
force against vapor barrier 250.
Thus, the function of capturing the vapor barrier layer can be achieved either
by temporarily
compressing the rod enough that the rod can be inserted through slot 268 or by
temporarily
enlarging slot 268 enough that the rod can be pushed through the enlarged
slot, or both
compressing the rod and enlarging slot 268. Accordingly, the vapor barrier can
be captured by rod
260 by any of the following exemplary methods:
(i) selecting/using a rod which is sufficiently compressible that a worker can
manually
compress the rod while pushing the rod through slot 268, or
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CA 02895803 2015-06-26
(ii) making one or more of the cavity walls 238, 240, or 244 of material and
structure
whereby the respective cavity wall is sufficiently resiliently deflectable
that a worker can
manually enlarge slot 268 enough that the worker can push a portion of rod
260, a
length at a time, through the slot, or
(iii) a combination of rod compressibility and resilient deflectability of one
or more of the
cavity walls enables a worker to temporarily enlarge slot 268 and compress rod
260,
enough that the worker can push a portion of rod 260, a length at a time
progressively
through the slot.
In each instance, whether compressing rod or the resiliently deflecting inside
panel 244, or
both, the diameter/cross-section of the rod must be ultimately sufficiently
small that the rod can be
inserted through slot 268 into cavity 264, while being sufficiently large that
a latent force exists
between the rod and inside panel 244 after installation of the rod is
completed/finished.
Thus, in the first instance, the resilient rod applies a constant outwardly-
directed force
against the vapor barrier layer, which is transmitted through the vapor
barrier layer, to inner flange
244. And in the second instance, the resiliency of inside panel 244, once
released, applies a
constant inwardly-directed force against the vapor barrier layer, which is
transmitted through the
vapor barrier layer, to rod 260. Or a combination of outwardly-directed force
and inwardly-directed
force cooperate with each other as the rod holds the vapor barrier layer
against the inner surfaces
of the cavity.
Upper diverter 146 and lower closure 150 extend across the flat of the metal
roof panel
adjacent the upper and lower ends of roof opening 249 (FIGURE 12) to complete
the closure of
support structure 100 about the perimeter of the skylight opening. The upper
diverter and the lower
closure have upper support structures 237 having cross-sections corresponding
to the cross-
sections of upper support structures 236 of rails 142, 144. Those upper
support structures thus
have corresponding flange cavities which are used to capture vapor barrier
layer 250 at the upper
diverter and the lower closure. Thus, the vapor barrier layer is trapped by
frictional engagement in
a cavity at the upper reaches of the rail and closure structure about the
entire perimeter of the rail
and closure structure.
Bridging tape or the like is used to bridge between the side portions and end
portions of
insulation vapor barrier layer 250 at the "Y" cuts at the ends of support
structure 100, such that the
vapor barrier layer and tape, collectively, completely separate the interior
of skylight cavity 274 from
the respective elements of support structure 100 other than inside panel 244.
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FIGURE 13 shows vapor barrier layer 250 trapped/held in the rail cavities on
both sides of
the roof opening. FIGURE 13 further shows the skylight subassembly, including
frame 132 and
lens 134, mounted to rails 142, 144, covering opening 249, and completing the
closure of support
structure 100 over and about opening 249. A sealant 330 is disposed between
upper flange 240
and skylight frame 132, to seal against the passage of water or air across the
respective interface.
A series of fasteners 300 extend through skylight frame 132, through
upstanding web 238 of the
rail, and terminate in rod 260, whereby rod 260 insulates the inside of the
roof opening from the
temperature differential, especially cold, transmitted by fasteners 300,
thereby to avoid fasteners
300 being a source of condensation inside the skylight cavity 274, namely
below the skylight lens.
In Figure 14 a partially cut away perspective view of rail and closure
structures 140 shows
support of the rail and closure structure by standing seam panel roof 110,
particularly the elevated
rib 32 providing the structural support at the standing seams. Figure 14
illustrates how the rail and
closure structures cooperate with the structural profiles of the roof panels
of the metal roof structure
above and below the skylights, including paralleling the rib elevations in
adjacent ones of the
panels, and thereby providing the primary support, by the roof panels, for the
loads imposed by the
skylights. In this fashion, the support structures of the invention adopt
various ones of the
advantages of a standing seam roof, including the beam strength features of
the ribs at the standing
seams, as well as the water flow control features of the standing seam.
Most standing seam roofs are seamed using various clip assemblies that allow
the roof
panels to float/move relative to each other, along the major elevations,
namely along the joinders
between the respective roof panels, such joinders being defined at, for
example, elevated ribs 32.
By accommodating such floating of the panels relative to each other, the roof
panels are free to
expand and contract according to e.g. ambient temperature changes relative to
any concurrent
expansion or contraction of others of the roof panels.
The design of the skylight systems of the invention takes advantage of such
floating features
of contemporary roof structures, such that when skylight assemblies of the
invention are secured to
respective rib elevations as illustrated herein, the skylight assemblies,
themselves, are
supported/carried by the roof panels at ribs 32. Thus, the skylight
assemblies, being carried by the
roof panels, move with the expansion and contraction of the respective roof
panels to which they
are mounted.
Figure 14 shows panel flat 14, rib 32, and shoulder 16, as well as standing
seam 18. Ridge
cap 120 is shown at the roof peak. Gap 122 in a rib 32 is shown adjacent upper
diverter 146.
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As seen in FIGURES 13 and 14, skylight frame 132 is secured to rail and
closure structure
140 at side rails 142 and 144 by a series of fasteners 300 spaced along the
length of the skylight
frame, and rails 142 and 144 are secured to ribs 32 by a series of fasteners
310 spaced along the
length of the respective rail.
In the process of installing a skylight system of the invention, a short
length of one of the ribs
32, to which the closure support structure is to be mounted, is cut away,
forming gap 122 in the
respective rib, to accommodate drainage of water around the rail and closure
structure, at that end
of the rail and closure structure which is relatively closer to ridge cap 120.
Such gap 122 is typically
used with standing seam, architectural standing seam, and snap seam roofs, and
can be used with
any other roof system which has elevated elongate joinders and/or ribs.
In the retained portions of rib 32, namely along the full length of the
skylight as disposed
along the length of the respective roof panel, the standing seams 18 provide
structural support
characteristics which resemble the structural characteristics of the web of an
I-beam. Thus, the
standing seams, in combination with the other upstanding portions of ribs 32,
support side rails 142
and 144 while maintaining the conventional watertight seal at the joinders
between roofing panels,
along the length of the assembly. Portions of ribs 32, inside the enclosed
space of skylight cavity
274, may be removed to enlarge the roof opening, which in turn allows a
further increment of
additional light from skylight lens 130 to reach through the respective roof
opening.
Lower flange 410 of diverter 146 runs along, parallel to, and in general
contact with, panel
flat 14 of the respective roof panel. Fastener holes 430, illustrated in
FIGURE 16, are spaced along
the length of lower flange 410 and extend through lower flange 410 for
securing the lower flange to
a panel stiffener structure 148 in the panel flat, with the roof panel trapped
between the lower flange
and the panel stiffener structure.
Panel stiffener structure 148 is illustrated in FIGURE 7 and follows the width
dimension
contour of the roof panel. Panel stiffener 148 is placed against the bottom
surface of the respective
roof panel at or adjacent the upper end of the opening in the roof. Self-
drilling fasteners, such as
screws 432, illustrated in FIGURE 8, are driven through lower flange 410,
through the metal roof
panel and into panel stiffener structure 148, drawing the diverter, the roof
panel, and the panel
stiffener into facing contact with each other and thus trapping the panel flat
of the roof panel
between the panel stiffener and the diverter and closing/sealing the interface
between the roof
panel and the diverter. Thus, panel stiffener structure 148 acts as a nut for
tightening fasteners
432. In the alternative, nut/bolt combinations, rivets, or other conventional
fasteners, can be used
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CA 02895803 2015-06-26
in place of screws 432. Caulk or other sealant can be used to further
reinforce the closure/sealing
of the diverter/roof panel interface.
Panel stiffener 148 can also be used to provide lateral support, connecting
respective ones
of ribs 32 to each other. Panel stiffener 148 is typically steel or other
material sufficiently rigid to
provide a rigid support to the rail and closure structure at diverter 146 and
to transfer the I-beam
strength characteristics of the standing seam across gap 122 between the
respective lengths of the
standing seam.
Rail and closure structure 140 is configured such that the skylight
subassembly can be
fastened directly to the rails with rivets or other fasteners such as screws
and the like as illustrated
at 310 in FIGURE 13.
Looking now to Figures 8, and 15 through 17, upper diverter 146 extends
between rails 142,
144, and provides end closure, and a weather tight seal, of the rail and
closure structure, at the
upper end of the roof opening/aperture, and diverts water around the upper end
of the
opening/aperture, to the flat portion 14 of an adjacent panel. The upstream
ends of side rails 142
and 144 abut the downstream side of diverter 146 and the height of diverter
146 closely matches
the heights of the side rails. Upper flange 400 of diverter 146 thus acts with
upper flanges 240 of
side rails 142 and 144, and an upper surface of lower closure 150, to form the
upper surface of the
rail and closure structure, to which the skylight lens frame 132 is mounted,
such upper surface
surrounding the space which extends upwardly from the corresponding opening in
the roof panel.
As illustrated, end panel 412 has a diversion surface 420. Diversion surface
420 is, without
limitation, typically a flat surface, and end panel 412 defines first and
second obtuse angles with
lower flange 410 and with an upper web 415 of end panel 412. As indicated in
FIGURE 15,
diversion surface 420 has relatively greater width "W1" on the side of the
closure structure which is
against the rib which is not cut, and a relatively lesser width 'W2",
approaching a nil dimension,
along lateral leg 147 as extending through rib gap 122, thus to divert water
toward and through gap
122.
Diversion surface 420 can, in the alternative, be either concave or convex
whereby the
central portion of the width "W1" and/or "W2" of the diversion surface is
recessed or protruding,
relative to a plane axis extending across the width of the respective roof
panel and along the
lengths of the lines which represent the joint between the diversion surface
and upper web 415, and
the joint between diversion surface and the lower flange, while the top and
bottom edges of the
diversion surface, namely at the respective joints, are typically, though not
necessarily, represented
by straight lines.
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CA 02895803 2015-06-26
Referring to FIGURE 15, at the end of lower flange 410, which is closer to the
closed rib, is
a rib mating structure 440. Rib mating structure 440 is defined by a plurality
of surfaces which
collectively and generally conform the rib mating structure to the profile of
the uncut rib 32. Thus,
structure 440 has a plurality of surfaces which parallel corresponding
surfaces of the respective rib.
At the end of lower flange 410 which is closer to the cut rib is a rib sealing
portion 450 of
upper web 415, which functions as an end closure of the cut rib 32 on the
lower side of gap 122.
Rib sealing portion 450 further functions to divert water across gap 122,
through the respective rib
32, and onto the flat 14 portion of the adjacent roof panel. Rib sealing
portion 450 extends through
gap 122 and across the respective otherwise-open end of the rib, thus closing
off access to the
otherwise-open, down-slope end of the rib. Hard rubber rib plugs 460, along
with suitable tape
mastic and caulk or other sealants, are inserted into the cut ends of the rib
on both the upstream
side and the downstream side of gap 122. The upstream-side plug, plus tube
sealants, serve as
the primary barrier to water entry on the upstream side of gap 122. Sealing
panel portion 450
covers the rib plug 460 on the down-slope side of gap 122, and serves as the
primary barrier to
water entry on the downstream side of gap 122, with plug 460, in combination
with the tube sealant,
serving as a back-up barrier.
The cross-section profiles of plugs 460 approximate the cross-section profiles
of the cavities
inside the respective rib 32. Thus plugs 460, when coated with tape mastic and
tube caulk, provide
a water-tight closure in the upstream side of the cut rib, and a back-up water-
tight closure in the
downstream side of the cut rib. Accordingly, water which approaches upper
diverter 146, from up-
slope on the roof, is diverted by diversion surface 420 and flange 410 and
secondarily by web 415,
toward sealing portion 450, thence through gap 122 in the rib, away from the
high end of closure
support structure 100 and onto the flat portion of the next laterally adjacent
roof panel. Accordingly,
so long as the flow channel through gap 122 remains open, water which
approaches the skylight
assembly from above upper diverter 146 is directed to gap 122, and flows
through gap 122, and
away from, and around, the respective skylight assembly.
FIGURES 8, 15, and 16 show diverter ears 270 on opposing ends of the upper
diverter. An
ear 270 is shown in FIGURE 16, in top view, at an angle a of about 45 degrees
to the end of upper
flange 400 of the diverter. FIGURE 15 shows an ear 270 after the upper
diverter has been
assembled to a rail, and the ear has been bent flat against the respective
upstanding web 238 of
the rail. After the ear has been bent flat against the rail upstanding web,
ear 270 is secured to
upstanding web 238 by driving a screw through aperture 276 and into the
upstanding web.
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CA 02895803 2015-06-26
As illustrated in e.g. FIGURES 8 and 15, lateral leg 147 extends through a gap
122 on the
right end of the upper diverter, at the right side of the support structure,
as viewed from up-slope of
the diverter. Correspondingly rib mating surface 440 engages a rib at the left
end of the diverter, at
the left side of the support structure.
In some embodiments, not shown, the diverter can be the mirror image of the
diverter as
illustrated. Thus, lateral leg 147 extends through a gap 122 on the left end
of the diverter, at the left
side of the support structure, as viewed from up-slope of the diverter.
Correspondingly, the right
end of the diverter is closed off by rib mating surface 440, which engages a
rib at the right end of
the diverter, at the right side of the support structure. Thus, a diverter
which discharges water on a
single side of the support structure, as in FIGURES 8, 14, and 15 can be
specified/designed to
have either a right-directed discharge or a left-directed discharge.
Selection of the discharge side is generally not important where the
respective roof panel is
horizontal across a width of the roof panel perpendicular to the sides of the
roof panel, thus
between the corresponding ribs. However, in some instances, the roof is
pitched down, typically
gently down, across the width of the roof panel, whereby the upper diverter is
selected such that
lateral leg 147 is on the down-slope side of the width of the roof panel.
FIGURES 14, 18, 19, 20, and 21 show lower closure 150. The lower closure is
used to
establish and maintain a weather tight seal at the lower end of rail and
closure structure 140,
namely at the lower end of roof opening 249. As illustrated in FIGURES 14, 18,
and 21, the bottom
of closure 150 is contoured to follow the profiles of ribs 32, thus to extend
up a cross-section of a rib
in surface-to-surface relationship with the rib, as well as to follow the
contour of panel flat 14 across
the width of the panel between the respective ribs. Lower closure 150 abuts
the lower ends of side
rails 142 and 144, and the height of lower closure 150 matches the heights of
side rails 142, 144.
Referring to FIGURES 18 and 19, lower closure 150 has a bottom portion 510,
and an upper
cap 500 secured to the bottom portion. Bottom portion 510 has a lower flange
522, as well as a
closure web 520. Lower flange 522 is in-turned. Namely flange 522 extends
inwardly of closure
web 520, toward the roof opening and includes fastener holes 530. A stiff,
e.g. steel, panel stiffener
532 extends the width of the panel flat under lower flange 522. Legs 533
extend upwardly at the
opposing ends of panel stiffener 532, matching the profile of at least one
upwardly-extending panel
of the respective rib 32 so as to be in surface-to-surface relationship with
the respective upwardly-
extending rib panel. Self-drilling screws 534 extend through holes 530,
through the respective
facing portion of the roof panel, and into the roof panel stiffener. Panel
stiffener 532 acts as a nut
for the respective screws 534, whereby the screws can firmly secure the lower
flange to the roof
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CA 02895803 2015-06-26
panel, both in the panel flat and at upstanding portions of the ribs,
providing stiffening support to the
securement of the lower closure to the roof panel. Tube sealants can be used
to enhance such
closure.
Upper cap 500 is an elongate inverted, generally U-shaped structure. A first
downwardly-
extending leg 524 has a series of apertures spaced along the length of the
cap. Screws 526 or
other fasteners extend through leg 524 and through closure web 520, thus
mounting cap 500 to
bottom portion 510 of the lower closure.
Cap 500 extends, generally horizontally, from leg 524 inwardly and across the
top of closure
web 520, along upper flange 536 to inside panel 537. Inside panel 537 extends
down from bearing
panel 536 at an included angle, between upper flange 536 and inside panel 537,
of about 75
degrees, to a lower edge 538 of the inside panel.
Thus, the upper cap of the lower closure, in combination with the upper region
of closure
web 520, defines a cavity 542 which has a cavity cross-section corresponding
with the cross-
sections of cavities 264 of rails 142, 144. As with cavities 264 of the side
rails, foam retaining rod
260 has been compressed in order to force the rod through slot 544, capturing
vapor barrier layer
250 between the retaining rod and the surfaces which define cavity 542. The
vapor barrier layer
has been lifted into opening 249 in the roof. Vapor barrier layer 250
traverses cavity 542 along a
path similar to the path through cavities 264. Thus, vapor barrier layer 250
enters cavity 542
against the inner surface of closure web 520, extends up and over/about rod
260 in the cavity,
against flange 536 and panel 537, and back out of cavity 542 to a terminal end
of the vapor barrier
layer outside cavity 542. The tension on vapor barrier layer 250 holds edge
portion 256 of the
batting against bottom portion 510 of the lower closure.
The uncompressed, rest cross-section of rod 260 in cavity 542 is somewhat
greater than the
cross-section of slot-shaped opening 544 between inside panel 537 and closure
web 520, whereby
rod 260 is compressed while being inserted through slot-shaped opening 544 and
into cavity 542.
After passing through opening 544, rod 260 expands against panels 520 and 537,
and optionally
flange 536, of the cavity while remaining sufficiently compressed to urge
facing sheet 250 against
panels 520 and 537 optionally against flange 536, whereby facing sheet 250 is
assuredly retained
in cavity 542.
In the alternative, and as with the cavities in rails 142, 144, rod 260 can
comprise a less
compressible material, whereupon the cavity structure such as, without
limitation, inside panel 537
is specified to be relatively more resiliently deflectable. Panel 537 and/or
panel 536, or panel 524,
is e.g. sufficiently resiliently deflectable that slot 544 can be expanded
enough to receive rod 260
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CA 02895803 2015-06-26
with substantially no reduction in the cross-sectional area of rod 260. The
properties of such panel
or panels are such that such panel or panels can be temporarily deflected far
enough that rod 260
can be pushed into cavity 542 by an installer, and sufficiently resilient that
a so-deflected panel
returns, or attempts to return, to its unstressed state with enough force
and/or movement to
securely hold rod 260 in place in the cavity.
Such less-compressible rod can be any material which can effectively engage
and hold the
vapor barrier sheet when force is applied to the surface of the rod. Non-
limiting examples of such
materials are various non-foamed, or slightly-foamed, relatively higher
density rubber-like materials,
such as EPDM rubbers, styrene butadiene rubbers, and the like. Various
plastics such as PVC and
various ones of the polyolefins, such as polyethylene, polypropylene, or the
like, can also be used,
either unfoamed or modestly foamed having densities greater than about 10
pounds per cubic foot,
optionally greater than 12 pounds per cubic foot, optionally greater than 20
pounds per cubic foot,
up to the unfoamed densities of the respective materials. In some instances, a
wood rod/dowel is
acceptable for rod 260.
In any embodiment, the installer deflects panel 537 progressively along the
length of the
slot-shaped opening 544 while correspondingly inserting respective progressive
portions of the
length of rod 260 into the cavity, or compresses the rod while correspondingly
inserting progressive
portions of the length of the rod into the cavity, or both compresses the rod
and deflects panel 537
while inserting progressive portions of the rod into the cavity. As the
installer releases a respective
portion of inside panel 537 or rod 260, in the process of inserting a
respective portion of the rod 260
into the cavity, the respective cavity structure or rod resiliently returns
toward its rest position, which
brings inside panel 537 into a holding engagement with the rod, whereby the
force being exerted
between rod 260 and panel 537 in attempting to return to respective former
configurations applies
an effective frictional holding force against vapor barrier 250.
In each instance, the compressible rod, or the resiliently deflectable inside
panel 537, or
both, the diameter/cross-section of the rod must be sufficiently small that
the rod can be inserted
through slot 544 into cavity 542, while being sufficiently large that a latent
force exists between the
rod and inside panel 537 after installation of the rod is complete/finished.
Thus, in the first instance, the resilient rod applies a constant outwardly-
directed force
against the vapor barrier layer, which is transmitted through the vapor
barrier layer, to inside panel
537 and is resisted by inside panel 537. And in the second instance, the
resiliency of inside panel
537, once released, applies a constant inwardly-directed force against the
vapor barrier layer, which
is transmitted through the vapor barrier layer, to rod 260. Or a combination
of outwardly-directed
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CA 02895803 2015-06-26
forces and inwardly-directed forces cooperate with each other as the rod holds
the vapor barrier
layer against the inner surface of the cavity.
As with screws 300 which mount the skylight assembly to side rails 142, 144,
upper diverter
146, and lower closure 150, screws 526 extend through cap 500, through closure
web 520, and
terminate in rod 260, whereby rod 260 insulates the inside of the roof opening
from temperature
differentials transmitted by screws 526, thereby to avoid the fasteners being
a source of
condensation inside space 274 below the skylight lens.
Upper cap 500 of the lower closure extends inwardly, toward opening 249, of
closure web
520 at a common elevation with upper flanges 240 of the side rails.
Collectively, the upper flanges
of side rails 142, 144, lower closure 150, and upper diverter 146 form a
consistent-height top
surface of the rail and closure structure, which receives the skylight lens
subassembly.
Closure 150 includes rib mating flanges 540 and 550, as extensions of lower
flange 522, to
provide tight fits along ribs 32.
A salient feature of support structures 100, relative to conventional curb-
mounted skylights,
is the reduction in the number of roof penetrations, namely roof openings,
required to provide
daylight lighting to the interior of a building, as multiple skylight
assemblies can be mounted along
the length of a single elongate opening in the roof, whereby fewer, though
longer, openings can be
made in the roof. Namely, a single opening in the roof can extend along
substantially the full length
of a roof panel, if desired, rather than cutting multiple smaller openings
along that same length, and
wherein the single opening can provide for an equal or greater quantity of
ambient light being
brought into the building through a smaller number of roof openings.
Another salient feature of support structures 100, relative to conventional
curb-mounted
skylights, is the fact that the full lengths of the entireties of the sides,
namely the side rails, are
above the panel flats, namely above the typical high water elevations of the
respective metal roof
panels.
Yet another salient feature of support structures 100, relative to
conventional curb-mounted
skylights, is the provision of lateral leg 147 of the upper diverter, which
diverts water laterally away
from the upper end of the support structure while maintaining the integrity of
the rib at full height at
the upper diverter, on the opposing side of the support structure.
Support structures of the invention are particularly useful for continuous
runs of e.g.
skylights, where individual skylights are arranged end to end between the
ridge and the eave of a
roof. Figures 22, 23, and 24 show how the ends of two rails can be joined to
each other end to end,
in a strip of such skylight assemblies and how two adjacent skylights can be
mounted to a standing
- 29 -
CA 02895803 2015-06-26
seam panel roof 110 using a skylight and the rail mounting system in
accordance with the invention.
Instead of using upper end diverters and lower end closures at each end of
each skylight assembly,
in the skylight strip embodiments illustrated in FIGURES 22 and 23, each
skylight frame 132 has a
female end having an upstanding, downwardly opening, female member 622,
typically extending
across the full width of the respective end of the skylight frame, and a male
end having an
upstanding male member 630 extending, optionally intermittently, across the
respective end of the
skylight frame. End-to-end width of the male member across the width of the
skylight frame is less
than the width of female member 622 such that the female member of a next
adjacent, typically
relatively up-slope disposed skylight frame, in a strip of such skylights, can
fit over, and completely
enclose except for a bottom opening, the male member 630 of the next adjacent
skylight frame in
the strip as the skylight frames otherwise generally abut each other end to
end.
As only one non-limiting example, skylights can be produced in units about 10
feet long, and
so connected end to end for as long a strip assembly as is desired or
necessary to achieve the
desired level of light transmission into the building, with each skylight unit
being supported by the
primary rib elevations of the panel roof. The lengths of the rib elevations
extend along the entire
lengths of the side rails of the rail and closure structure, whether one
skylight assembly is used, or a
number of skylight assemblies are used end to end. No water can enter over the
tops of the side
rails of the rail mounting system. No water can enter the top end or bottom
end of such strip of
skylights.
The standing rib elevations are shown underlying and in continuous supporting
contact with
the side rails, providing continuous underlying support to the rails along the
entireties of the lengths
of the rails, and respectively along the entireties of the lengths of the
skylight assemblies.
In the process of installing the closure support structure, the upper diverter
is installed first,
after cutting a small portion of opening 249 near the diverter location. Then,
after the upper diverter
is installed, the remainder of the roof opening is cut in the respective roof
panel and the rails are
installed. The lower closure is then installed, which completes the process of
defining the perimeter
bearing surfaces for the support structure, which are to support the perimeter
of the collective set of
skylight assemblies which overlie opening 249. Insulation 248, as appropriate,
is then drawn up
through the opening and secured in the cavities in the rails, in the diverter,
and in the lower closure.
The skylight assemblies are then mounted on the respective bearing surfaces
and the ends of the
respective skylight assemblies are joined to each other; and the skylight
assemblies are secured to
the rails. Tube sealant and tape mastic are applied, as appropriate, at the
respective stages of the
process to achieve leak-free joinders between the respective elements of the
closure assembly.
- 30 -
CA 02895803 2015-06-26
FIGURE 24 shows an exploded pictorial view of the ends of first and second
rails in abutting
relationship at a joinder of such rails, which abutting joinder relationship
is also illustrated in part in
FIGURE 23, the abutting joinder optionally being co-located with first and
second skylights being
arranged in end-to-end relationship over a single roof opening. Connector 640
is configured to fit
closely inside the cavity cross-sections defined by the respective rails,
against the upstanding webs
238 and against the rail upper flanges 240. Connector 640 is shown aligned
with the abutting rail
ends. The connector is inserted into the cavities in the rails, bridging the
butt joint between the
rails. Apertures 644 in the connector align with apertures 646 in the rails
when the ends of the rails
are in abutting relationship. Screws or other known aperture-to-aperture
fasteners are used to
securely fasten connector 640 to both of the rails. Tape mastic and tube caulk
are used, as known
in the art for water seal closures, to fill the interface between the rail
panels and reinforcing
connector 640. Connector 640 thus provides both reinforcement of the joint and
enhanced seal of
the joint against intrusion of water.
Skylight assemblies of the invention can be connected end to end for as long a
distance as
necessary to completely cover/overlie a roof opening, as each skylight
assembly unit is supported
by the ribs 32 of the respective roof panel through respective rails 142, 144.
The full collective
lengths of the respective rails, regardless of the number of skylight
assemblies which are used to
close off a given opening in the roof, can extend longitudinally along the
standing rib elevations.
And except for the skylight assemblies on either end of a run of skylights,
the entirety of the weight
of the skylight assembly passes through the respective rib and thence to the
underlying building
support structure. Minor portions of the weight of the skylight assembly may
pass through the panel
flat at the upper and lower ends of the rail and closure structure.
Water cannot enter over the tops of the rails because of the sealant at 330 at
the rails, at
diverter 146, and at closure 150. Water cannot enter at the upper diverter at
the uppermost skylight
assembly because of the seal properties provided by the upper diverter, by
panel stiffener structure
148, and by the respective sealants, as well as because the diversion of water
away from the upper
end of the strip of skylights through gap 122 prevents any substantial
quantity of water from
standing on a panel 10 against upper diverter 146 for any extended period of
time. Water cannot
enter at the lower end of the strip of skylights because of the seal
properties provided by the lower
closure and by the sealants between the lower closure and the respective roof
panel. Water cannot
enter between the ends of the skylight subassemblies because of the tortuous
path through the
interface between ends 622 and 630 in combination with the sealants applied at
such end-to-end
interface.
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CA 02895803 2015-06-26
FIGURES 25-36 illustrate additional embodiments of the invention.
FIGURES 25-29 illustrate an embodiment wherein a 2-way upper diverter 146D
diverts
water in opposing lateral directions through first and second rib gaps 122A,
122B, through both of
the next adjacent ribs to which support structure 100 is mounted, and onto the
roof panels on both
sides of the support structure. Referring to FIGURES 25-27, diverter 146D has
an upper flange
400, a lower flange 410, and an end panel 412. End panel 412 includes an
upstanding upper web
415, and first and second diversion panels 420A and 420B.
Each diversion panel stands generally upright while, without limitation,
defining a first obtuse
angle with lower flange 410 and a second obtuse angle with upper web 415,
whereby an imaginary
extension of upper web 415 defines a generally perpendicular angle with lower
flange 410. As
illustrated, diversion panels 420A, 420B meet at an upright dividing line 422
in end panel 412,
midway between rails 142, 144. Each diversion panel 420A, 420B thus has a
relatively greater
width illustrated as width "W1", and thus generally a greater height, at a
generally central location
midway between rails 142, 144; and a generally decreasing width, illustrated
by width "W2", and
generally lesser height, both width and height approaching nil dimensions, as
the respective
diversion panels approach rib gaps 122A, 122B (FIGURE 28). Lateral legs 147A,
147B of the
respective diversion panels extend through the rib gaps, extending onto, and
over, the panel flats of
the next adjacent roof panels, while upper portions of end panel 412 extend
to, but not across, the
respective ribs; and wherein lateral legs 147 extend beyond certain elements
of upper portions of
end panel 412. Diversion panels 420A, 420B thus divert water toward and
through gaps 122A,
122B and onto the next adjacent roof panels while upper portions of upper web
415 are generally
confined to the width of a panel from standing seam to standing seam between
next adjacent ones
of the ribs, across a single panel flat.
FIGURES 28 and 29 illustrate use of diverter 146D on a sloping metal panel
roof. Panel
stiffener 148A underlies diverter 146D. The width "W3" of panel stiffener 148A
extends both up-
slope and down-slope of the roof, relative to lower flange 410. The
combination of the up-slope and
down-slope extensions can at least equal the width dimension of lower flange
410 where such
lower flange width is defined at the locus where lateral legs 147 extend
through gaps 122A, 122B.
Panel stiffener 148A thus underlies and provides vertical support to portions
of the ribs 32 which
support both sides of support structure 100 at rails 142, 144. Such support
underlies both ribs
which support rails 142, 144, in each case both up-slope and down-slope from
the respective gap
122.
- 32 -
CA 02895803 2015-06-26
In addition, panel stiffener 148A extends entirely across the widths of the
panel flats of the
next adjacent roof panels, extending to the uncut ribs at the opposing sides
of such next adjacent
panel flats. Respective portions of the lengths of the panel flats of the next
adjacent roof panels
thus overlie the respective lengths of panel stiffener 148A such that the
panel stiffener generally
interfaces with the panel flats of the next adjacent roof panels.
Legs 533 on panel stiffener 148A extend upwardly at the uncut next adjacent
ribs on the
next adjacent roof panels, matching the upstanding direction of at least one
upwardly-extending
panel of the respective rib 32. Self-drilling screws, or rivets, or other
fasteners 534 extend through
holes 430, through the respective facing portion of the roof panel, and into
panel stiffener 148A.
Panel stiffener 148A acts as a nut for the respective screws 534, whereby the
screws/fasteners can
firmly secure the lower flange to the roof panel. Additional screws/fasteners
534 also secure panel
stiffener 148A to the next adjacent ribs 32 at upstanding legs 533. Panel
stiffener 148A thus
provides vertical support to upper diverter 146D adjacent opening 249, and
also provides lateral
support to lower flange 410 through the attachments of legs 533 to the next
adjacent, uncut ribs
across the panel flats from upper diverter 146D. Still further, panel
stiffener 148A provides a
foundation for bringing together lower flange 410, panel flat 14, and the
panel stiffener in face-to-
face relationships where the lower flange, the panel flat 14, and the panel
stiffener are sufficiently
tightly drawn to each other that a waterproof seal is provided, preventing
water leakage into the
enclosed space at the opening, or directly into the building, at the lower
flange.
FIGURE 30 illustrates use of the same diverter 146D as in FIGURES 28-29, but
with a
shortened panel stiffener 148A. In the embodiment of FIGURE 30, at portions of
the width of panel
stiffener 148A which underlie the uncut portions of ribs 32, both up-slope and
down-slope of gaps
122A, 122B, legs 533 extend up, matching the profile direction of at least one
upwardly-extending
panel of the respective rib 32, and screws or other mechanical fasteners 534
secure the upstanding
legs 533 to such upstanding portions of the ribs. Accordingly, in the
embodiments represented by
FIGURE 30, the stiffness and rigidity of panel stiffener 148A is sufficient to
provide the vertical and
lateral support needed to stabilize the upper diverter 146D relative to the
roof panels and to the
rails, as well as to replace strength lost by cutting away portions of the
ribs in making gaps 122A,
122B. Those skilled in the art will recognize the thickness and/or width
differences in panel stiffener
148A as used in FIGURE 30 to attach to the cut ribs, versus the relatively
longer panel stiffener
148A which can be used in FIGURES 28-29 and which attach to the next-adjacent,
outlying uncut
ribs.
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CA 02895803 2015-06-26
FIGURE 30A illustrates use of the same diverter 146D as in FIGURES 28-30, but
with a
panel stiffener 148A1 of intermediate length. In the embodiment of FIGURE 30A,
at a portion of the
width of the panel stiffener which underlies the uncut portion of the rib on
the left side of the
diverter, both up-slope and down-slope of gap 122B, legs 533 extend up,
matching the profile
direction of at least one upwardly-extending panel of the respective rib 32,
and screws or other
mechanical fasteners 534 secure the upstanding legs 533 to such upstanding
portions of the rib.
On the opposing, right side, of the diverter, panel stiffener 148A1 extends
beyond the end of the
lower flange, to the next adjacent rib 32NA across the panel flat from the
diverter. Those skilled in
the art will recognize the thickness and/or width differences in panel
stiffener 148A1 as used in
FIGURE 30A to attach to the respective ribs, versus the relatively longer
panel stiffener 148A which
is used in FIGURES 28-29.
Referring now to FIGURES 15 and 30, the panel stiffener can be designed such
that, at the
gap end of the stiffener, the stiffener is wide enough to accommodate
upstanding legs 533 on the
panel stiffener at the end of panel stiffener 148 or 148A which underlies rib
plugs 460. Such legs
533 are disposed up-slope of the relatively up-slope rib plug and down-slope
of the relatively down-
slope rib plug.
Rails 142, 144, upper diverter 146, 146D, and lower closure 150 are typically
made of metal.
Given the thermal conductivity of metals commonly used in building structures,
such metal
elements of support structures 100 have the potential capability to conduct
cold and/or heat through
the support structure elements, to the inner surfaces of the support
structure. Such conduction
affects the thermal space heating and/or space cooling needs of the interior
of the respective
building. In addition, the conduction of cold, from the outside environment to
the interior of the
building potentially lowers the temperature of the inside surfaces of support
structure 100. Such
conduction of cold may lower the temperatures of such inside surfaces enough
to cause moisture
from the air inside the building to condense onto such cooled inside surfaces,
which can result in
dripping of such condensed moisture onto building contents below. Such
condensation can thus be
deleterious to the building structure and/or to the contents of the building.
While the thermal insulation illustrated, such as in FIGURE 13, protects lower
portions of the
support structure from thermal conduction, such as at webs 238, end panel 412,
and closure web
520, a cold-conducting path remains potentially available in the embodiment of
e.g. FIGURE 13, at
upper flanges 240, 400 and 536, optionally at the inside panels downwardly
depending from such
upper flanges.
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CA 02895803 2015-06-26
=
FIGURES 31-35 illustrate a variety of thermal break structures 650 which can
be employed
with rails 142, 144, upper diverter 146, 146D, and lower closure 150. Such
thermal break
structures all represent elongate linings which extend the full lengths of the
respective rail, diverter,
or lower closure. Such linings are contemplated to be polymeric extrusions
which, by virtue of the
extrusion processes by which such linings are made, have constant, or
substantially constant,
profiles for the full lengths of such linings. A given such lining extends the
full lengths of each of the
rails 142, 144, diverter, 146, and lower closure 150.
FIGURE 31 illustrates the profile of a first thermal break structure 6501,
lining the inner
surface of rail 144. Thermal break structure 6501 has a first web leg 660 in
surface-to-surface
contact with the inner surface of upstanding web 238, over about 75% of the
upper portion of the
web. Break structure 6501 extends from web leg 660 across the lower surface of
upper flange 240
as flange leg 662, thence down along the inside surface of inside panel 244 as
panel leg 664, about
the distal edge of inside panel 244 and up the outside surface of inside panel
244 as outside panel
leg 666, and terminates at the upper surface of upper flange 240, the end of
the break structure
6501 optionally terminating as an extension of the upper surface of flange
240.
Cold which passes through web 238 by conduction is stopped either by
insulation batt
material 252 or by leg 660 of the thermal break. Cold conducted through upper
flange 240,
optionally through inside panel 244, is stopped by the respective legs 662,
664, and/or 666. Cold
which reaches the joinder between upper flange 240 and inside panel 244 is
stopped by the upper
edge of leg 666.
While thermal space heating efficiency is a consideration, the primary issue
being
addressed by thermal break structure 650 is to maintain the temperature of all
surfaces of the
controlled-temperature space at the opening sufficiently warm as to prevent
condensation of
moisture on the exposed surfaces of the support structure. Thus even though un-
foamed plastic
extrusions, as used for thermal break structures 650, are not generally
considered to be effective
thermal insulators, compared to fiberglass batt material or foamed plastics,
the thermal properties of
many polymer compositions are sufficient to block enough of the thermal
conduction that
condensation can be avoided.
Addressing space heating loss relative to the embodiment of FIGURE 31,
insulation layer
248 protects against major heat loss up through opening 249 and upwardly to
rod 260. Rod 260
protects against major heat loss through cavity 264. The upper end of thermal
break leg 666
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serves as an extension of the corner 668 defined by the joinder of upper
flange 240 and inside
panel 244, thus providing at least nominal protection from heat loss through
upper flange 240.
Addressing condensation prevention, the thermal protection provided by
insulation 248 and
rod 260 is in excess of that needed to prevent condensation while being
effective to control thermal
temperature-control requirements. Given the inventors' recognition that
condensation is a potential
issue at corner 668, by conduction of cold through upper flange 240, thermal
protection against
such condensation is provided by configuring thermal break 650 to cover the
inside surface of
inside panel 244, facing opening 249, at corner 668, and by engineering the
thermal properties of
thermal break 650 so as to prevent condensation at the temperature
differential and humidities
expected to exist in the particular skylight or other application of the
invention.
FIGURE 32 illustrates the structure of a minimalistic thermal break profile
650M. Profile
650M has a leg 666 which covers the outer surface of inside panel 244. Profile
650M extends
about the distal edge of panel 244 and extends a short distance up the inside
surface of inside
panel 244. Profile 650M also extends a short distance across upper flange 240.
The inventors
herein contemplate that the area of the support structure most susceptible to
formation of
condensation is inside panel 244. Thus, profile 650M is limited to providing a
thermal break at
panel 244. The end portions of profile 650M, which extend up the inside
surface of inside panel
244 and a short distance across upper flange 240 are used to provide
mechanical securement of
the thermal break to the rail, upper diverter, or lower closure, as applies,
while the upper end
portion is thin enough to readily accommodate mounting of the skylight
assembly at flange 240.
FIGURE 32 illustrates elongate serrations 670 on leg 666, which may be formed
during the
process of extruding leg 666, or may be subsequently formed, e.g. stamped,
into the respective
surface in any desired surface pattern. A given serration 670 extends the
length of the thermal
break. Multiple serrations are disposed across the width of the thermal break,
and thus the multiple
serrations collectively extend across the height of the outer surface of
inside panel 244 and can
extend onto that portion of profile 650M which overlies panel 240. Serrations
670 are greater in
irregularity than common surface imperfections in extruded thermoforming
polymers. Thus,
serrations 670 space those respective surfaces of the serrations which are
farthest from the cavity
structure surfaces by distances of at least 0.002 inch, optionally at 0.005
inch, further optionally at
least 0.010 inch, at least 0.020 inch, up to about 0.040 inch.
The inventors contemplate that the dead air space in the serrations adds to
the thermal
efficiency of the thermal break. In some embodiments, the serrations are
spaced from the top and
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bottom of inside panel 244 in recognition of stresses which may be
concentrated at such locations,
combined with respective strength requirements at such locations.
FIGURE 33 illustrates the structure of an intermediate-width thermal break
profile 6501W.
Profile 6501W has a leg 666 which covers the outer surface of inside panel
244. Profile 6501W
extends about the distal edge of panel 244 and extends a short distance up the
inside surface of
inside panel 244. Profile 6501W also extends across upper flange 240, as leg
662 and a short
distance down web 238. This intermediate-width thermal break provides
additional thermal break
protection against conduction through upper flange 240. As with the embodiment
of FIGURE 32,
the areas of the support structure away from the corners are serrated. The end
portions of profile
6501W, which extend up the inside surface of inside panel 244 and a short
distance down web 238
are used to provide mechanical securement of the thermal break to the rail,
diverter, or closure.
FIGURE 33 also illustrates elongate serrations 670 on legs 662 and 666, spaced
from the
profile ends of inside panel 244 and upper flange 240.
FIGURE 34 illustrates the structure of a full coverage thermal break profile
650F, which
extends over the entirety of the outer surface of rail 144. Profile 650F has a
leg 666 which covers
the outer surface of inside panel 244, a leg 662 which covers the outer
surface of upper flange 240,
and a leg 660 which covers the outer surface of web 238. Leg 666 extends about
the lower edge of
inside panel 244 and a short distance up the inside surface of the inside
panel. This full-coverage
thermal break provides thermal break protection against conduction through the
entirety of the rail
profile. Thus, thermal protection from condensation is provided irrespective
of whether or not
insulation 248 is used, whether or not a rod 260 is used. As with the
embodiments of FIGURES 32
and 33, the areas of the support structure away from the corners are serrated.
The end portion of
profile 650F which extends up the inside surface of inside panel 244 is used
to provide mechanical
securement of the respective edge of the thermal break to the rail, diverter,
or lower closure.
FIGURE 34 also illustrates the use of the elongate serrations on legs 666, 662
and 660,
spaced from the profile ends of inside panel 244 and upper flange 240, as well
as the lower end of
leg 660.
FIGURE 34A illustrates the structure of a thermal break profile which extends
over the outer
surface of rail 144. The profile of thermal break 650F of FIGURE 34A has a leg
660 which covers
the outer surface of web 238. Leg 662 covers the outer surface of upper flange
240, and extends a
short distance down inside panel 244. Given the full outside coverage of web
238 and flange 240,
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thermal break 650 effectively breaks the thermal impact at inside panel 244
without overlying the
entire top-to-bottom height of panel 244.
FIGURE 35 illustrates the structure of a full coverage thermal break profile
650F as in
FIGURE 34, which extends over the outer surface of rail 144, but which does
not employ serrations,
and which does not wrap around the distal end of panel 244.
Considering the embodiments illustrated in FIGURES 31-39, thermal break
structure can be
deployed on some or all of both the inner surface and the outer surface of
rails 142, 144, as well as
the upper diverter and the lower closure. Thus, a single break structure can
be used to cover some
or all of the respective inner and outer surfaces of the rail. In the
alternative, a combination of
thermal break structures can be used to cover some or all of the respective
inner and outer
surfaces of the rail. FIGURE 31 is instructive regarding use of thermal break
structure on the inner
surface of the rail, where web leg 660 can optionally be extended to the
corresponding upper
surface of standing seam 18. FIGURE 35 is illustrative of use of thermal break
structure on the
outer surface of the rail, showing use of the thermal break structure to cover
effectively all of the
outer surface of the rail, along the full length of the rail which will be
exposed to the ambient
environment. Where different/multiple thermal break structures cover different
portions of the rail
profile, edges of the respective thermal break structures can interface with
each other so as to
avoid thermal leakage at the respective edges or ends. Conventional caulk or
tape mastic can be
used to fill any voids or gaps in the coverage, as needed for achieving an
effective thermal break.
Surface irregularities such as serrations can be used on any or all areas of
any or all of such
thermal break structures which face surfaces of the rails, diverter, or lower
closure, whether the
thermal break structure is applied to the inner surface of the rail, to the
outer surface of the rail, or
both.
FIGURES 36-40 illustrate additional embodiments of how rails can be used in
support
structure 100, along with alternate structures holding insulation 248 in the
opening 249 and
alternate methods of insulating e.g. cavity 264.
Referring to FIGURE 36, rail 144 has an upstanding web 238, upper flange 240,
inside
panel 244, and lower shoulder 242. Inside panel 244 extends from upper flange
240 at an acute
angle 13 of about 75 degrees. Rivets 310 are spaced along the length of the
rail, mounting the rail to
underlying rib 32 above panel flat 14. External thermal break 650 covers
inside panel 244 and
upper flange 240. Short extensions of the thermal break extend down web 238
and around the
distal end of inside panel 244, functioning as retainers holding the thermal
break mounted on the
rail.
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Insulation 248 extends up through opening 249 in the roof and lies against rib
32 up to the
top of the rib at standing seam 18. Vapor barrier layer 250 of the insulation
extends over the top of
the standing seam and down between the standing seam and upstanding web 238 of
the rail. The
vapor barrier layer is held in place over the standing seam by a plurality of
resilient spring clips 676
mounted over the vapor barrier and onto the standing seam, respective such
clips being spaced
along the length of the rail. A variety of clips and/or clamps, or similar
devices can be used in place
of the clip illustrated.
The vapor barrier can be installed using at least two different methods. In
the first method,
shown in FIGURE 36, as a given length of the edge of the vapor barrier is
inserted about the
standing seam, the clips are installed over the vapor barrier layer, thus
securing the respective
length of the vapor barrier to the standing seam. In the second method, the
vapor barrier layer is
wrapped about a spring clip and then the spring clip is mounted over the
standing seam, with an
edge portion of the vapor barrier layer between the spring clip and the
standing seam. With either
method, a portion of the vapor barrier layer is disposed between the spring
clip and the standing
seam, and resilient restoration forces on the spring clips continuously apply
forces urging the vapor
barrier against the standing seam, holding both the vapor barrier and the
spring clip securely
mounted to the standing seam. The plurality of spring clips spaced along the
length of the rail thus
stabilize the insulation in position against the rib, about the perimeter of
opening 249.
At the lower closure, a lower leg of angle bracket 672 overlies the upper
surface of the lower
flange as illustrated in FIGURE 37, and an upper leg 674 extends upwardly,
terminating in a "T"-
shaped top. Fastener holes 530 extend through both the lower flange and the
angle bracket. As
with the standing seam, the vapor barrier layer is extended up over the distal
upper lip of the lower
flange, and spring clips 676 are placed over the vapor barrier layer and
clipped to the e.g. "T"-
shaped top of the lower flange, thus securing the insulation at the top of the
angle bracket.
As illustrated in FIGURE 38, at the upper diverter, a similar upstanding angle
bracket 672
extends inwardly toward the opening, of upstanding web 415, and upwardly as an
upper leg 674 to
an e.g. "T"-shaped top portion. Vapor barrier layer 250 is extended up over
the "T"-shaped top
portion. Spring clips 676 are placed over the vapor barrier layer and clipped
to the "T"-shaped top
portion 674 of the angle bracket, securing the insulation to the angle bracket
at the "T"-shaped top
portion, and thus to the upper diverter.
Returning to FIGURE 36, with the insulation thus stabilized, an e.g.
deformable,
compressible rod 260 is inserted into cavity 264. Rod 260, which is
resiliently compressible, is
compressed as the rod is being inserted through opening 268 into cavity 264.
Rod 260 is inserted
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into cavity 264 far enough that, once the compressed rod is released in the
cavity, and the rod
expands against the cavity walls, the expanded rod reaches, and interfaces
with, at least web 238
and inside panel 244, optionally with upper flange 240. With the rod cross-
section thus extending
across the full width of the cavity between web 238 and inside panel 244, the
frictional engagement
of the rod against the inner surfaces of web 238 and inside panel 244, along
the tapering, narrowing
cross-section of cavity 264, top to bottom, optionally in combination with
engagement of the rod with
the up-turned end of thermal break 650 at the inside surface of inside panel
244, retains rod 260 in
cavity 264, even though a portion 260P of the cross-section of the rod extends
outwardly through
cavity opening 268.
The outwardly extending portion 260P of the rod extends to, and interfaces
with, an upper
portion of insulation 248. Thus, the combination of insulation 248 and rod 260
provides thermal
break properties extending upwardly between opening 249 and the inner surface
of upper flange
240. Thermal break structure 650 provides at least a portion of the thermal
break properties
between the inner and outer surfaces of the upper flange.
FIGURE 39 illustrates a further embodiment, similar to that of FIGURE 36,
except that a
length of e.g. fiberglass batt material is inserted into cavity 264 instead of
a length of rod 260.
Thus, rail 144 has an upstanding web 238, upper flange 240, inside panel 244,
and lower
shoulder 242. Inside panel 244 extends from upper flange 240 at an optional
acute angle 13 of
about 75 degrees; although in this embodiment up to a perpendicular angle 13
is acceptable. Rivets
310 are spaced along the length of the rail, mounting the rail to underlying
rib 32 above panel flat
14. External thermal break 650 covers inside panel 244 and upper flange 240.
Short extensions of
the thermal break extend down web 238 and around the distal end of inside
panel 244.
Insulation 248 extends up through opening 249 in the roof and lies against rib
32 up to the
top of the rib at standing seam 18. Vapor barrier layer 250 of the insulation
extends over the top of
the standing seam and down between the standing seam and upstanding web 238 of
the rail. The
vapor barrier layer is held in place over the standing seam by a plurality of
resilient spring clips 676
mounted over the vapor barrier and onto the standing seam, respective such
clips being spaced
along the length of the rail.
A length of deformable, compressible fiberglass batt material 248C, typically
having no
vapor barrier layer, is inserted into cavity 264. Batt material 248C is
resiliently compressible, and is
compressed as the batt material is being inserted through opening 268 into
cavity 264. Batt
material 248C, is inserted into cavity 264 far enough that, once the
compressed batt material is
released in the cavity, and the batt material expands against the cavity
walls, the expanded batt
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material reaches, and interfaces with, at least web 238 and inside panel 244,
optionally with upper
flange 240. With the cross-section of the batt material thus extending across
the full width of the
cavity between web 238 and inside panel 244, the frictional engagement of the
batt material against
the inner surfaces of web 238 and inside panel 244, along the tapering,
narrowing cross-section of
cavity 264, top to bottom, optionally in combination with engagement of the
batt material with the
up-turned end of thermal break 650 at the inside surface of inside panel 244,
and the relatively
narrow width of opening 268 between panel 244 and vapor barrier 250, retains
bail material 248C
in cavity 264, even though a portion 248CP of the batt material extends
outwardly through cavity
opening 268.
The outwardly extending portion of the batt material extends to, and
interfaces with, an
upper portion of insulation 248 at vapor barrier 250. Thus, the combination of
insulation 248 and
batt material 248C provides thermal break properties extending upwardly
between opening 249 and
the inner surface of upper flange 240. Thermal break structure 650 provides
the thermal break
properties between the inner and outer surfaces of the upper flange and inside
panel 244.
The rail assembly embodiment of FIGURE 39 is assembled generally as follows.
After the
aperture/opening 249 has been cut, the insulation is prepared for extension up
through the
aperture. The insulation batt is stripped away from enough of the vapor
barrier to accommodate
passing the vapor barrier over the top of standing seam 18 and attaching
spring clips 676 over the
vapor barrier and thus mounting the vapor barrier to the standing seam. In the
process of
extending the insulation up through aperture 249, batt material is lifted up
and about shoulder 16 so
as to provide thermal insulation properties to the exposed, inwardly-facing
surface of the shoulder,
as shown in FIGURE 39.
With the insulation thus held in place, and typically after the upper diverter
has been
assembled to the respective roof panels, rail 144 is mounted to the shoulder
of the respective rib,
using rivets 310 as illustrated. Thermal break 650 can be installed either
before or after the rail has
been mounted to the rib. With the rail so mounted to the rib, and with thermal
break 650 mounted
to the rail, insulation batt material 248C is inserted into cavity 264 such
that the batt material
extends down from opening 268 to the top of vapor barrier layer 250, again as
shown in FIGURE
39. Thus the combination of batt material 252 of layer 248 and batt material
248C in cavity 264
collectively provide an upwardly-extending thermal barrier from the inner
surface of flange 240 to
the bottom of the rib cut at aperture 249, interrupted only by vapor barrier
layer 250.
FIGURE 40 illustrates yet another embodiment, similar to that of FIGURE 39. In
the
embodiments illustrated in FIGURE 40, rail 144 has an upstanding web 238,
upper flange 240,
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inside panel 244, and lower shoulder 242. Inside panel 244 is relatively
shorter than the inside
panel illustrated in FIGURES 36-39, and extends down from upper flange 240 at
an angle 13 which
is generally perpendicular to the upper flange. Inside panel 244 in this
embodiment is, for example
and without limitation, about 0.25 inch to about 0.38 inch in height. As in
others of the illustrated
embodiments, rivets 310 are spaced along the length of the rail, mounting the
rail to underlying rib
32 above panel flat 14. The embodiment of FIGURE 40 does not show an external
thermal break;
however an external thermal break, or an internal thermal break, is
contemplated, especially
thermally moderating/protecting the inward end of flange 240 where panel 240
meets inner panel
244.
Vapor barrier 250 extends up through opening 249 in the roof and lies against
rib 32 up to
the top of the rib at standing seam 18. As in the embodiment of FIGURE 39,
vapor barrier layer
250 extends over the top of the standing seam and down between the standing
seam and
upstanding web 238 of the rail. Also as in FIGURE 39, the vapor barrier layer
is held in place over
the standing seam by a plurality of resilient spring clips 676 mounted over
the vapor barrier and
onto the standing seam, respective such clips being spaced along the length of
the rail.
A length of generally rigid, optionally deformable, foam board 678 is shown
having been
inserted into cavity 264. A typical foam board is expanded bead polystyrene
foam having a density
of about 2 pounds per cubic foot (pcf) to about 20 pcf, optionally about 4 pcf
to about 8 pcf. Such
foam is modestly resiliently compressible and generally returns to its
uncompressed configuration
so long as its elastic limit has not been exceeded, and so long as the foam
has not been
permanently damaged such as by tearing or cutting.
Foam board 678 has a notch 680 which extends along the full length of the
board, where
foam material has been removed in order that the board can mount over, and
correspondingly
receive, the combination of standing seam 18, vapor barrier 250, and resilient
spring clips 676.
In the embodiment illustrated, foam board 678 generally fills cavity 264,
typically being in
face-to-face contact with web 238, flange 240, inner panel 244, the top and a
side of spring clip
676, and vapor barrier layer 250 at the top of shoulder 16. When the foam
board is inserted into
cavity 264, the foam may be slightly compressed at one or more of the contact
interface with the
lower surface of upper flange 240, the contact interface with the upper
surfaces of clips 676, the
contact interface with the cavity-facing surface of inner layer 244, and the
contact interface with
vapor barrier layer 250 at the top of shoulder 16.
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The recited minor levels of compression experienced by foam board 678 at such
interfaces
when the foam board is inserted into cavity 264 can create enough friction
between the foam board
and the other facing members to retain the foam board in cavity 264.
The compressibility, deformability of the foam board is such that the board
can be deformed
enough to allow the board to be manually inserted through opening 268, into
cavity 264. Where the
foam board has limited resilient compressibility, such as with expanded bead
polystyrene foam,
opening 268 is expansive as shown, extending almost the full height of web
238, whereby only a
small downward length of inner panel 244 is available to retain the top of
board against
displacement from cavity 264. In such instance, the amount of deformation as
the board is inserted
into cavity 264 is relatively minimal.
Where the board is more compressible, deformable, such as tolerating a
resilient
compressive reduction of e.g. at least about 25 percent in any given
dimension, and readily
recovering from such compressive reduction in dimension, then the dimension of
opening 268,
between the end of flange 244 and the top of rib 32, is reduced accordingly,
and is more like the
opening illustrated in FIGURE 39, or some size between the relative opening
dimensions illustrated
in FIGURES 39 and 40.
Whatever the resilient compressibility of the foam board, opening 268 is sized
accordingly,
in order to both enable the user to insert the board as desired into cavity
264, and to retain the
board in the cavity after the board has been so inserted.
Turning attention now to insulation layer 248 in FIGURE 40, vapor barrier
layer 250 extends
up through aperture/opening 249, up alongside rib 32, under foam board 678,
over standing seam
18, and is captured on, and held to, the standing seam by spring clips 676.
Batt material 252 of
insulation layer 248 has been stripped from that portion of the vapor barrier
layer which extends up
through aperture/opening 249, and has been folded back on itself under rib 32,
and has been
pushed up into the cavity 682 at the underside of rib 32, thus providing a
thermal barrier inside
cavity 682 between the shoulder 16AE which faces the ambient environment and
the shoulder
16BE which faces vapor barrier 250 and the interior building environment.
The rail assembly embodiment of FIGURE 40 is assembled generally as follows.
After the
aperture/opening 249 has been cut, the vapor barrier layer is prepared for
extension up through the
aperture. The insulation batt is thus stripped away from enough of the vapor
barrier to
accommodate passing only the vapor barrier up through the aperture, over the
top and down along
the far side of standing seam 18, and attaching spring clips 676 over the
vapor barrier and thus
mounting the vapor barrier to the standing seam as illustrated. Before the
vapor barrier is so
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extended up through the aperture, the stripped-away edge portion of the e.g.
fiberglass batt
material is stuffed upwardly, as shown in FIGURE 40, into cavity 682 which is
defined by the rib
elevations which define the respective rib 32.
After the edge portion of the insulation batt material has thus been stuffed
up into cavity 682,
the vapor barrier layer is extended up through the aperture/opening, over and
about the standing
seam, and secured in place by clips 676. With the vapor barrier thus held in
place, and typically
after the upper diverter has been assembled to the respective roof panels,
rail 144 is mounted to
the shoulder of the respective rib, using rivets 310 as illustrated. A thermal
break 650 can be
installed on the rail as in e.g. FIGURE 39, if desired, either before or after
the rail has been
mounted to the rib.
With the rail so mounted to the rib, and with thermal break 650, if any,
mounted to the rail,
foam insulation board 678 is inserted into cavity 264 such that the foam board
extends down from
opening 268 to the top of the respective shoulder 16 of the rib elevation.
Thus, the combination of
batt material 252 of layer 248 and foam board 678 in cavity 264 collectively
provide an upwardly-
extending thermal barrier from the inner surface of flange 240 to and through
the bottom of the rib
cut at aperture 249, interrupted only by vapor barrier layer 250 and the
horizontally-extending
portion of rib shoulder 16.
Inserting foam board 678 into cavity 264 may involve a modest amount of manual
compression of board 678 such that the board material expands against the
cavity walls whereby
the expanded foam material reaches, and interfaces with enough of the surface
elements of cavity
264, optionally including upper flange 240, inner flange 244, the tops of
clips 676, and/or the vapor
barrier layer at the top of shoulder 16, whereby certain ones of such
interfaces provide frictional
engagement with board 678, thereby to retain foam board 678 in the cavity,
even though a portion
of the foam board extends downwardly through cavity opening 268.
The downwardly extending portion of the foam board extends to, and interfaces
with, the
upwardly-facing surface of vapor barrier 250.
As an alternative, or supplemental, method of installing foam board 678, two-
sided adhesive
tape 684 can be mounted to the surface or surfaces of web 238 and/or flange
240 which face into
cavity 264. After the tape has been so mounted to such cavity wall surfaces,
the board is inserted
into the cavity and urged against the exposed surfaces of the tape. In some
instances, especially
where the foam board fits closely and with some compression against the wall
surfaces of cavity
264, the tape supplements the frictional engagement of the board with the wall
surfaces, whereby
the board is held in cavity 264 by a combination of friction and tape
adhesion.
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In other instances, foam board 678 is cut to more loosely fit into cavity 264
whereby, while
inner panel 244 and the top of shoulder 16 assist in positioning the board in
the cavity, the two-
sided tape is the primary structure which assures that the board will be
retained inside cavity 264.
Now addressing all of the embodiments illustrated, the weight of a load
received on rails
142, 144 is transferred directly from the rails, to ribs 32 of the respective
underlying roof panels,
optionally along the full lengths of the support structure; and only a minor
portion, such as less than
10%, if any, of that weight is borne by the panel flat, and only at the upper
and lower ends of the
support structure. Thus, the weight conveyed by the rails, or conveyed by the
rail and closure
structure, is borne by those elements of the roof panels which are most
capable of bearing weight
without substantial deflection of the roof panels under load, namely most, if
not all, of the weight is
carried by the ribs.
A wide variety of roof-mounted loads, in addition to skylights and smoke
vents, is
contemplated to be mounted on rails 142, 144, so long as the weight of such
roof-mounted loads
does not exceed the allowable load on the ribs. Where the load does not
overlie an opening of
substantial size in the roof, such as where a roof-mounted load is e.g. an air
conditioner or electrical
panel, the upper diverter and the lower closure can be omitted. Where the
upper diverter and lower
closure are omitted, nominally 100% of the load passes through rails 142, 144
to ribs 32, thence
through the ribs defined by the roof panels, and thence to the building
structural members. While
the rails can extend onto an intervening panel flat, such is not the typical
case. Rather, the rails are
typically confined to the ribs, with the load spanning the panel flat above
the ribs whereby rain water
freely flows down the panel flat between the rails, optionally under the load.
The primary reason why the disclosed rail and closure structures can surround
an opening
without water leakage is that a great portion of the perimeter of the support
structure, namely that
which is defined by side rails 142, 144, is above the panel flat, namely above
the normal high water
line on the roof panel; and all associated roof penetrations, such as screws
310 which mount the
rails to the ribs, are above the water line. With little or no standing water
at the joinders between
the rails and the roof panels, or at any fasteners, even if the sealant fails
at a joinder, no substantial
quantity of water routinely enters such failed joinder because of the heights
of such joinders above
the water line.
Rail and closure structures of the invention close off a roof opening from
unplanned leakage
of e.g. air or water through such roof opening. The rail and closure structure
140 extends about the
perimeter/sides of the roof opening and extends from the roofing panel
upwardly to the top opening
in the rail and closure structure. A closure member, e.g. skylight
subassembly, overlies the top
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CA 02895803 2015-06-26
opening in the rail and closure structure and thus closes off the top opening
to complete the closure
of the roof opening.
Support structure 100 thus is defined at least in part by rail and closure
structure 140 about
the perimeter of the roof opening, and the closure member, such as skylight
assembly 130, or the
like, overlies the top of the rail closure structure and thus closes off the
top of the closure support
structure over the roof opening.
Rail and closure structure 140 has been illustrated in detail with respect to
one or more
variations of the standing seam roofs illustrated in FIGURES 1, 3, and 5. In
light of such
illustrations, those of skill in the art can now adapt the illustrated rail
and closure structures, by
modifying, shaping of the structure elements, to support loads from any roof
system which has a
profile which includes elevations, above the panel flat, using standing
joinders or other raised
elevations, such as, without limitation, those illustrated in FIGURES 2 and 4,
as the locus of
attachment to the roof.
While the figures depict a skylight, the rail structure, with or without end
closures, can be
used to mount a wide variety of loads on such roof, including various types of
skylights, smoke
vents, air conditioning, other vents, air intakes, air and other gaseous
exhausts, electrical panels or
switching gear, and/or other roof loads, including roof-penetrating
structures, all of which can be
supported on rail structures of the invention, and the rails passing the load
to and through ribs 32 of
the metal panel roof, thence directly or indirectly to underlying building
framing members inside the
controlled-environment space inside the building.
Although the invention has been described with respect to various embodiments,
this
invention is also capable of a wide variety of further and other embodiments
within the spirit and
scope of the appended claims.
Those skilled in the art will now see that certain modifications can be made
to the apparatus
and methods herein disclosed with respect to the illustrated embodiments,
without departing from
the spirit of the instant invention. And while the invention has been
described above with respect to
the preferred embodiments, it will be understood that the invention is adapted
to numerous
rearrangements, modifications, and alterations, and all such arrangements,
modifications, and
alterations are intended to be within the scope of the appended claims.
To the extent the following claims use means plus function language, it is not
meant to
include there, or in the instant specification, anything not structurally
equivalent to what is shown in
the embodiments disclosed in the specification.
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