Abstract:
A smoke vent including a curb and door assembly utilizing a continuous hinge assembly that extends an entire length of a door. Hinge members of the door assembly and curb define continuous, extruded hinge members such that the door is supported across the entire length of the hinge members, whereby localized deflection of the curb is avoided. By supporting the door across the entire length of the hinge member, a door seal can be evenly compressed against the curb so as to prevent moisture/water intrusion when the door is in a closed disposition. The door assembly can further include a dome member that substantially defines an upper and lower surface of the door(s). Each door can comprise a plurality of retainer clips that positively couple the dome member to extruded members that define a door frame while providing a moisture resistant seal between the dome member and the door frame.

Description:
RELATED APPLICATION 
       [0001]    The present application claims the benefit of U.S. Provisional Application No. 62/332,190 filed May 5, 2016, which is hereby incorporated herein in its entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is generally directed to roof mounted smoke vents. More specifically, the present invention is directed to a roof mounted smoke vent having an improved curb and door design to simplify manufacturing and installation. 
       BACKGROUND OF THE INVENTION 
       [0003]    Building codes for large buildings, for example warehouses and factories generally require the installation of one or more smoke vents on the roof. In the event of a fire emergency, one or more doors on the smoke vent are opened, either automatically or at the direction of emergency personnel, to release heat, smoke and or noxious fumes from an interior of the building. Generally, opening of the door(s) is accomplished through activation of a heat trigger or alternatively, using a manual release that is located on an exterior of the smoke vent. 
         [0004]    In order to successfully open the door(s), the door(s) must be hinged to an exterior curb of the smoke vent. The exterior curb mounts to the roof and projects upward from the roof surface. Generally, two or more hinges are mounted to the exterior curb whereby the hinges are attached to the door(s) so as to allow the doors to rotate between a closed/covering disposition and an open/venting disposition. Due to the size and weight of the doors, these hinges generally must be of a heavy duty design and require various operations including, for example, drilling, welding, fastening and the like to properly install the doors. Furthermore, due to the weight of the doors, the amount of localized torque at each hinge can cause localized deflection of the exterior curb which can lead to sealing issues and potential moisture leakage. 
         [0005]    In view of the costs and potential mounting issues associated with conventional hinged smoke vents, it would be advantageous to improve upon current designs. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention is generally directed to a smoke vent including a curb and door assembly utilizing a continuous hinge assembly that extends an entire length of a door. Generally, the continuous hinge assembly can comprise a pair of corresponding hinge members that are rotationally engageable across a rotation range of between 0 and 90 degrees, measured in relation to a door position relative to the curb. Beyond 100 degrees, the door can be lifted into position relative to the curb and subsequently rotated to an orientation less than 100 degrees, whereby the door is positively, hingedly connected to the curb. The corresponding hinge members of the door assembly and curb can comprise continuous, extruded hinge members such that the door is supported across the entire length of the hinge members, whereby localized deflection of the curb is avoided. By supporting the door across the entire length of the hinge member, a door seal can be evenly compressed against the curb so as to prevent moisture/water intrusion when the door is in a closed disposition. In some representative embodiments, the door(s) can further comprise a polymeric dome member that substantially defines an upper and lower surface of the door(s). Each door can comprise a plurality of retainer clips that positively couple the dome member to the door while providing a moisture resistant seal between the polymeric dome member and a door frame. 
         [0007]    In one aspect of the present invention, a smoke vent can comprise a curb member and one or more door assemblies, wherein a hinge assembly for mounting the door assemblies to the curb member is integrally formed into the curb member and door assembly. Generally, the curb member can include a hinge wall side including a continuous hinge mount that is continuously defined along en entire length of the hinge wall. The continuous hinge mount can include a projecting member having an arcuate hinge surface. Each door assembly can include a door frame formed of an extruded assembly about the perimeter of the door frame. The extruded assembly can include a lower hinge engagement portion including a hinge tab having an arcuate hinge channel. The door assembly can be positioned so as to engage the arcuate hinge surface with the arcuate hinge channel whereby the door assemblies can be rotated between open and closed positions relative to the curb member. In some embodiments, the lower hinge engagement portion can include a projecting drip edge extending below and out from the continuous hinge mount to assist in preventing moisture intrusion into the smoke vent. 
         [0008]    In yet another aspect, a door assembly can comprise a door frame, a cover panel and a plurality of panel retainer clips. The door frame can be formed by coupling a plurality of extruded assemblies that form each side of the door frame. The cover panel can then be positioned above an upper engagement surface on each of the extruded assemblies. Along each side, a panel retainer clip can be positioned over the cover panel and then snapped into position relative to the extruded assembly with a latching member on the panel retainer clip positively engaging a receiving channel on the extruded assembly. In this manner, the door assembly can be fabricated with a minimum of fasteners and fastener operations to reduce both material and labor costs. In some embodiments, a 
         [0009]    In yet another aspect, the present invention is directed to methods of fabricating a smoke vent assembly. 
         [0010]    In another aspect, the present invention is directed to methods of assembly for a smoke vent door assembly. 
         [0011]    In another aspect, the present invention is directed to a reduced cost smoke vent assembly in which forming operations, fasteners and labor costs are reduced through the use of extruded assemblies to form a curb member and door frame. 
         [0012]    In yet another aspect, the present invention is directed to a reduced cost roof hatch assembly in which forming operations, fasteners and labor costs are reduced through the use of extruded assemblies to form a curb member and door frame. 
         [0013]    In still another aspect, the present invention can be directed to a detachable hinge mount that allows the benefits of a continuous hinge to be added or retrofitted to conventional or existing curb walls. 
         [0014]    The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  FIG. 1  is a top perspective view of a smoke vent according to a representative embodiment of the present invention. 
           [0016]      FIG. 2  is a section view taken at line  2 - 2  of  FIG. 1 . 
           [0017]      FIG. 3  is a detailed section view of a hinge mount wall of the smoke vent of  FIG. 1  in a fully closed position. 
           [0018]      FIG. 4  is a detailed section view of a hinge mount wall of the smoke vent of  FIG. 1  in an open position. 
           [0019]      FIG. 5  is an exploded section view of a door frame according to a representative embodiment of the present invention. 
           [0020]      FIG. 6  is a section view of the door frame of  FIG. 6 . 
           [0021]      FIG. 7  is a section view of a door frame and hinge mount wall with a cover portion removed according to a representative embodiment of the present invention. 
           [0022]      FIG. 8  is an exploded section view of a door frame according to another representative embodiment of the present invention. 
           [0023]      FIG. 9  is a section view of a detachable hinge mount according to a representative embodiment of the present invention. 
           [0024]      FIG. 10  is an exploded section view of a hinge mount wall using the detachable hinge mount of  FIG. 9 . 
           [0025]      FIG. 11  is a section view of the hinge mount wall of  FIG. 10 . 
           [0026]      FIG. 12  is a side view of a hinge mount wall including the detachable hinge mount of  FIG. 9 . 
       
    
    
       [0027]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0028]    As shown in  FIG. 1 , a smoke vent  100  according to the present invention is mounted directly to a roof  52  of a building  50 , for example, a warehouse or factory. Generally, smoke vent  100  comprises a curb member  102  and one or more door assemblies  104 . Depending on the size and application, smoke vent  100  can include a pair of door assemblies  104  as shown in  FIGS. 1 and 2  or alternatively, smoke vent  100  can comprise a single door assembly. In the case of a smoke vent  100  utilizing a pair of door assemblies  104 , it will be understood that each door assembly  104  is essentially equivalent in design and components with the exception of a reversed mounting arrangement. Though not illustrated, it will also be understood that smoke vent  100  includes the necessary safety components including a latch assembly, latch release and lifting members to allow for the door assemblies  104  to open in the event of an emergency or as dictated by emergency or maintenance personnel. Furthermore, it will be understood to one or ordinary skill that the concepts disclosed with respect to the construction of smoke vent  100  can be similarly applied to other roof accessories, including for example, root hatches. 
         [0029]    Generally, curb member  102  is formed of a moisture resistant metal or alloy such as, for example, aluminum. Curb member  102  generally defines a square or rectangular curb perimeter  110 . Curb member  102  comprises a pair of opposed hinge mount walls  112   a ,  112   b , a pair of end walls  114   a ,  114   b  and a gutter member  116 . Generally, the hinge mount walls  112 , end walls  114   a ,  114   b  and gutter member  116  all comprise individually extruded members that are welded together to define the curb member  102 . Hinge mount walls  112   a  and  112   b  are essentially the same member except for being oriented in the opposite direction. End walls  114   a  and  114   b  are also essentially the same member except for being oriented in opposite directions when coupled together to form the curb member  102 . Curb member  102  is generally mounted between the end walls  114   a ,  114   b  at a midpoint position between the hinge mount walls  112   a ,  112   b.    
         [0030]    As seen in  FIGS. 2, 3 and 4 , the curb member  102 , and more specifically the opposed hinge mount walls  112   a ,  112   b  and end walls  114   a ,  114   b  generally define a curb wall  120  having a roof mounting end  121 , an upwardly projecting wall  122  and an upper end  124 . Roof mounting end  121  can comprise any of a variety of configurations depending upon roof design without departing from the spirit and scope of the present invention. For example, roof mounting end  121  can comprise an apron mount style  125  to allow for connection to an apron flange (not shown) that projects upward from a roof. Apron mount style  125  can comprise an angled surface  126 , a projecting surface  128  and an apron flange  130 . 
         [0031]    The design of upper end  124  varies between the opposed hinge mount walls  112   a ,  112   b  and the end walls  114   a ,  114   b . For end walls  114   a ,  114   b , the upper end  124  terminates in a sealing flange  132  as shown in  FIG. 4 . For hinge mount walls  112   a ,  112   b , the upper end  124  defines a hinge flange  133  and a continuous hinge mount  134  as seen in  FIGS. 2, 3 and 4 . The continuous hinge mount  134  is continuously defined along an entire hinge wall length  136  of the hinge mount walls  112   a ,  112   b  as shown in  FIG. 1 . Continuous hinge mount  134  comprises a lateral surface  138 , an upper arcuate surface  140  and a downwardly projecting hinge member  142 . Downwardly projecting hinge member  142  has a generally circular hinge cross-section  144  defining an arcuate hinge surface  146 . 
         [0032]    Door assembly  104  generally comprises a cover panel  158  defining an upper exterior surface  160  and a lower interior surface  162  as shown in  FIGS. 1 and 5 . Cover panel  158  can comprise a flat or generally flat panel or alternatively, a domed or double domed design. Door assembly further includes a door frame  163  having a hinge side  164 , a latch side  166  and a pair of opposed end sides  168   a ,  168   b . The door frame  163 , and more specifically, the hinge side  164 , the latch side  166  and the opposed end sides  168   a ,  168   b  are each generally defined by an extruded assembly  170  that forms the entire length of each side of the door frame  163 . Extruded assembly  170  serves to perform a hinge function along the hinge side  164  but also serves to couple the cover panel  158  to the door assembly  104  on each of the hinge side  164 , the latch side  166  and the pair of opposed end sides  168   a ,  168   b . Extruded assembly  170  generally defines an upper dome engagement surface  174  and a lower hinge engagement portion  176 . Upper dome engagement surface  174  includes a serrated seal surface  178 , a receiving channel  180  and a projecting tab  182  having a tab lip  184 . Lower hinge engagement portion  176  includes a lower arcuate surface  186  having an arcuate profile  188  that matches and corresponds to the upper arcuate surface  140 . Lower hinge engagement portion  176  further includes a hinge tab  190  including an arcuate hinge channel  196 . Lower hinge engagement portion  176  is generally only utilized along the hinge side  164  but is present and unused along the latch side  166  and the opposed end sides  168   a ,  168   b.    
         [0033]    Door assembly  104  further comprises a panel retainer clip  200  as shown in  FIG. 5 . Panel retainer clip  200  generally comprises an extruded retainer body  202  including a retainer portion  204  and a latching portion  206 . Retainer portion  204  generally defines an upper surface  208  and a lower surface  210 . Lower surface  210  includes a plurality of downward barbs  212  and a seal channel  214 . Latching portion  206  comprises a latch member  216  and a biasing member  218 . Latching member  216  includes an engagement face  220  and a latching surface  222 . Latching surface  222  includes a latch recess  224 . 
         [0034]    In assembling door assembly  104  as shown in  FIG. 6 , a seal member  230  is positioned on the serrated seal surface  178  on each extruded assembly  170  along the entire length of the hinge side  164 , the latch side  166  and the opposed end sides  168   a ,  168   b . Next, the cover panel  158  is placed so as to rest on top of the seal member  230  that is present on each of the hinge side  164 , the latch side  166  and the opposed end sides  168   a ,  168   b . A clip seal member  232 , for example liquid silicone, can be applied within the seal channel  214 . The panel retainer clip  200  is then positioned such that the latching portion  206  is positioned proximate the receiving channel  180 . The latching portion  206  is inserted into the receiving channel  180  such that the engagement face  220  contacts the receiving channel  180  with the latching surface  220  becoming captured and retained by the by the tab lip  184  of the projecting tab  182 . This locks the panel retainer clip  200  to the extruded assembly  170  with the cover panel  158  captured between the upper dome engagement surface  174  and the lower surface  210  of the retainer portion  204 . The process of coupling the panel retainer clip  200  to the extruded assembly  170  for capturing the cover panel  158  is the same and is repeated for each of the hinge side  164 , the latch side  166  and the pair of opposed end sides  168   a ,  168   b  to define the door frame  163 . 
         [0035]    Once door assembly  104  is assembled, door assembly  104  can be positioned above the curb member  102  with the hinge side  164  positioned proximate hinge mount wall  112   a . In order to hingedly attach the door assembly  104  to the curb member  102 , door assembly  104  should be positioned such that the hinge tab  190  is positioned below the projecting hinge member  142 . The door assembly  104  is then manipulated to bring the arcuate hinge channel  196  into contact with the arcuate hinge surface  146 . With the hinge tab  190  and the projecting hinge member  142  engaged, the door assembly  104  can begin to rotate about the projecting hinge member  142  whereby the arcuate profile  188  of the lower arcuate surface  186  begins to interface with the upper arcuate surface  140 . The door assembly  104  can then be rotated to a fully closed position  230  as shown in  FIG. 1 . Because of the interaction of the hinge tab  190  and the projecting hinge member  142  as well as the engagement of the lower arcuate surface  186  and the upper arcuate surface  140 , the door assembly  104  remains coupled to the curb member  102  as the door assembly is rotated to an open position  232  as shown in  FIG. 4 . More specifically, the door assembly  104  remains positively coupled to the curb member  102  across a rotation angle α of 0 degree (closed position  230 ) all the way to a rotation angle α of 90 degrees (open position  232 ). Only after the door assembly is rotated past a rotation angle α of approximately 100 degrees, dictated by the engagement of the lower arcuate surface  186  and the upper arcuate surface  140 , is the door assembly  104  capable of being removed from the curb member  102 . 
         [0036]    As the hinge tab  190  and projecting hinge member  142  extend the entire length of the extruded assembly  170  and the hinge mount wall  112   a  respectively, the hinge engagement is continuous along the entire length of the hinge side  164 . As such, there is no localized deflection at specific hinge locations as found in typical designs, and instead, even pressure is applied to the hinge flange  133  and against a curb seal  240 . 
         [0037]    With the present design, manufacturing and assembly of the smoke vent  100  is simplified and costs are reduced through the use of extrusion techniques and by removing the number of fastener and welding operations necessary to fabricate the smoke vent  100 . For example, extruded assembly  170  is used on each side of the door frame  163 . In addition, cover panel  158  is coupled to the door frame  163  using a single, full length panel retainer clip along each side of the door frame  163  so as to remove the necessity for multiple fasteners. In addition, by extruding the projecting hinge member  142  as part of the hinge mount walls  112   a ,  112   b  and the hinge tab  190  as part of the extruded assembly  170 , no separate hinge parts are required to be purchased nor are they required to be separately installed on the curb member  102  and the door frame  163 . The use of the disclosed extruded assemblies can be applied across other roof components including, for example, roof hatches. 
         [0038]    With reference to  FIG. 8 , additional features can be incorporated into extruded assembly  170  to form an extruded assembly  250  that similarly engages with the panel retainer clip  200  in assembling the door assembly  104  as well as rotating about the projecting hinge member  142 . As shown in  FIG. 8 , the lower hinge engagement portion  176  and more specifically, the hinge tab  190  can further comprise a projecting drip edge  252  that extends outward from and below the arcuate hinge channel  196 . In this way, projecting drip edge  252  adds additional protection from moisture intrusion into the curb member  102   
         [0039]    Finally, in an alternative embodiment as shown in  FIGS. 9-12 , the advantages of the continuous hinge engagement and the assembly techniques for door assembly  104  can be added or retrofitted to existing designs and installed curb members  102  through the use of a detachable hinge mount  260 . Generally, detachable hinge mount  260  can couple to an existing curb member  102  so as to impart similar functionality and structure to the curb member  102  as is provided by continuous hinge mount  134 . Detachable hinge mount  260  generally comprises a body member  262  having a mount length  264  that is equal to the length of the hinge mount wall  112   a . Body member  262  includes a mount surface  266  that can be placed directly against the curb wall  120  or against curb flashing  268  as shown in  FIGS. 10-12 . Generally, a plurality of fasteners  269  can be utilized for coupling the mount surface  266  to the curb wall  120 /curb flashing  268 . Extending from the mount surface  266  is a hinge portion  270  including lateral surface  138 , upper arcuate surface  140  and downwardly projecting hinge member  142 . Downwardly projecting hinge member  142  has a generally circular hinge cross-section  144  defining an arcuate hinge surface  146 . Hinge portion  270  is defined along the full mount length  264  such that the use of door assembly  104  and detachable hinge mount  260  imparts the previously described benefit of continuous hinge engagement as described previously with respect to curb wall  120  that includes the continuous hinge mount  134  as part of an integral, extruded assembly. 
         [0040]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. Furthermore, while the present application has been described with respect to a smoke vent, the principles associated with the continuous extruded hinge as well as the use of a panel retainer clip in door assembly can be similarly applied to other roof components including, for example, roof access hatches and the like.