Rooftop enclosure

The present invention relates to an improved commercial rooftop enclosure that utilizes a roof and wall panel design incorporated with structurally bent rails connecting the panel assemblies to each other and to a corrugated panel steel base. This forms the enclosure into a torsion box style building wherein the strength of the enclosure is derived from its overall “unibody” style construction. With this design the rooftop enclosure offers a lower overall profile, reduced weight and increased structural strength over its conventional counterparts.

FIELD OF THE INVENTION

The present invention relates to an improved commercial rooftop enclosure. More specifically, it relates to a new torsion box design for a rooftop enclosure that adds additional strength while minimizing the overall height and weight of the unit.

BACKGROUND

Commercial rooftop A/C units, chillers and pre-fabricated penthouses have enclosures that house, protect, support and integrate the A/C and/or mechanical components into the building structure. These enclosures are quite large. These enclosures must be light enough to fall within building roof loading limits and seismic regulations, strong enough to withstand distortion under craning operations and wind loads, and maintain as low a profile as possible to minimize wind loads as well as the visual impact of the monstrous eyesores.

The conventional enclosure designs attach a paneled wall and roof structure, made from a plurality of mechanically connected flat panels and corner panels, atop a planar base platform. The base platform is made of steel deck plate affixed atop a frame of thick structural steel members and cross members. Since these huge enclosures must be raised onto a rooftop by a crane, distortion is a problem. Because of the square footage of the enclosure's sides, distortion from wind loading is also a problem. The base, to serve as the strength to unify the enclosure and resist distortion, requires thick structural members having substantial height below the deck plate, increasing the overall enclosure height and weight. This type of construction is in direct opposition with the roof loading/seismic requirements and the overall aim of a lowered enclosure height. Simply stated, height and weight must be minimized in these structures and strength must be maximized.

The present invention utilizes a roof and wall panel design that has corrugated or formed and bent “C” profile panels with increased structural strength. The present invention also has a corrugated panel metal base that eliminates the massive structural steel requirement. Rails that are adapted for the connection of the walls to the base, and the roof to the walls, allow for the strength of the enclosure to derive from its overall “unibody” style construction rather than from connection to a stout base. The present invention enclosure forms a strong torsion box that has a lower overall profile, reduced weight and increased strength.

Such design innovations as the present invention provides, overcome the pitfalls of the prior art and is a cost effective, simple solution that avoids the aforementioned pitfalls of the prior art.

SUMMARY OF THE INVENTION

The general purpose of the present invention, which will be described subsequently in greater detail, is to provide an economical, lightweight, rigid, low profile, rooftop unit enclosure that will be easily located onto a building rooftop while withstanding the stresses and strains of such relocation without encountering any non-elastic deforamtion of the enclosure.

It has many of the advantages mentioned heretofore and many novel features that result in a new, lightweight, strong, height minimized outdoor enclosure which are not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.

In accordance with the invention, an object of the present invention is to provide an improved outdoor enclosure that has a lowered height profile to minimize wind load.

It is another object of this invention to provide an improved enclosure that offers substantial structural rigidity while minimizing weight.

It is a further object of this invention to provide an improved lightweight outdoor or indoor enclosure that is simple and economical to construct.

The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. Other objects, features and aspects of the present invention are discussed in greater detail below.

DESCRIPTION

The present invention relates to a commercial rooftop enclosure that utilizes a new unibody, torsion box design that offers significant increases in strength while reducing the overall weight and height.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings.

The improvements and innovations of the present invention can best be seen in relation to the existing limitations of the prior art.FIGS. 1-4illustrate the construction and assembly of a conventional commercial rooftop A/C enclosure.

Conventional enclosure2has a base made of two structural “C” channels4mechanically affixed, generally by welding, to a plurality of structural cross members6so as to form a support structure for planar floor8. Channel4, cross member6and floor8are made of steel. Wall panels10carry the weight of roof panels12down onto channels4and are connected to the base by lower “Z” rails14. First mechanical fasteners16attach wall panels10to lower “Z” rail14and second mechanical fasteners18connect lower “Z” rail to channel4. Roof panel12is connected to wall panel10in a similar fashion using top “Z” rail46with third mechanical fastener48. Electrical conduits50are run along the roof/wall interface and held there unprotected by an appropriate means of attachment. Roof panels12are of an overlapping rainproof design which is well known in the art. Multiples of the wall panels10are connected to form the walls. Adjacent wall panel assemblies are connected by corner wall panels32. The roof panels12and wall panels10are of a box style steel construction having a hollow centrally enclosed cavity54. The floor8is of steel deck plate. The coupling of multiples of wall panels10and roof panels12can be accomplished by any of a number of mechanical fastening means, most commonly though, is by crimping, screws or nuts and bolts.

Since these enclosures2have to be raised onto the building roof by crane, they are subject to a plethora of unbalanced forces in this process. This requires the enclosure2to have a suitable level of rigidity. The strength of the conventional enclosure arises from its base and the heavy structural members that are used. The floor8serves to strengthen the base's rectangularity, preventing the base from “racking” into a trapezoid. The strength required for conventional enclosure bases requires that the “C” channels4and structural cross members6are thick. This raises the overall height of the enclosure2thereby subjecting it to higher wind loads, adds additional mass to the roof, affects seismic considerations, and increases visibility of what can be generally considered an eyesore. The number and spacing of cross members6varies with the actual floor8.

The present invention of a rooftop enclosure utilizes a system of structural base, wall and roof panels tied together by structural rails. The overall structure forms a torsion box, unibody construction with at least two top rails connecting the roof panel system to the wall panel system and four bottom rails connecting the floor panel system to the wall panel system. The following description details each of the floor, wall and roof panel systems as well as the rails that join these systems and give strength to this torsion box design.

Looking atFIGS. 5,6and7the general arrangement of a floor panel20and the manner of joining two or more floor panels can be best seen. Floor panel20is a linear member formed from a longitudinally symmetrical “C” channel22, and a corrugated top panel24, that are adhered together after the injection of an expanding, adhesive foam core26between these panels. Top panel24has a concave configuration with two flanges extending normally outward from the top linear edge of its parallel sides38. Channel22has a concave configuration with two substantially similar flanges34extending internally and normal from the top linear edge of its parallel sides36. The concavity of top panel24resides inside the concavity of “C” channel22. Insulating adhesive foam26holds channel22and top panel24together.

Top panel24is not symmetrical about its longitudinal axis. It has a depth of corrugation and a raised profile28along its longitudinal axis to impart strength and rigidity. First side38of top panel24has a flange32extending outward and normal. The opposing second side40of top panel24has a cap flange30also extending outward and normal but is formed into an interlocking cap that is dimensioned so as to reside atop of first flange32of an adjacently positioned floor panel20. Adjacent floor panels20are connected by mechanical fasteners42that pass through abutting sides36. These fasteners42are applied before panel20is fully assembled and foam26installed. Although not illustrated, it is known that the method of mechanical fastening by crimping together the metal of adjacent panels is an acceptable, commonly used alternative to the use of nuts and bolts, screws, rivets, pins etc.

FIG. 8shows a perspective side view of three connected floor panels20prior to the injection of insulating adhesive foam26. It is a notable distinction between the base of the present invention (formed from connected multiple floor panels) and the base of a conventional rooftop unit, that the base of the present invention has a smooth, planar bottom surface44and a corrugated upper surface which is shaped into folds or parallel and alternating ridges and grooves. This design is an inversion of the conventional bases, which have smooth, planar upper surfaces and ribbed or corrugated bottom surfaces. This smooth bottomed configuration allows for flexibility when installing and locating A/C enclosures on rooftop curbs. It is known that the floor panel assembly may be installed upside down as required in certain configurations. Still in other configurations the corrugation may be incorporated onto channel22, or the smooth surface may be incorporated onto top panel24.

Insulating adhesive foam26, as used in the ceiling and floor panel systems, is well known in the industry and commonly known as polyurethane foam. It has a volatile fluorocarbon content, is best suited for applications not exposed to sunlight and generally has a closed cell content of 85 to 95%.

As can be seen inFIG. 9, a cross section of a wall panel taken through its longitudinal axis, steel wall panel56has been formed into a “C” shape so as to have two sidewalls58that extend normally from a planar outer face60. Flanges62extend inward toward the concavity created by the panel56. Bat insulation63is placed within the panel's concavity and a panel plate64is friction fit into the assembly so as to form a planar panel56which is rectangular in cross section. The outer face60of each panel is longer than the sidewalls58and the panel plate64so as to form a connecting and weatherproofing lip116(FIG. 16).

Looking atFIG. 10the top cross sectional view of the rooftop enclosure without panel plates installed, can be seen. Wall panels56are mechanically fastened together at their adjacent sidewalls58by mechanical fasteners66. Corner panels68differ from panels56only by the introduction of a 90 degree bend70.

Looking atFIG. 11the method of joining floor panel20to wall panel56can best be seen. Bottom rail72is an extruded steel member of a bottom plate74with a flange76projecting normally from its lower face bottom edge78and a riser plate80projecting normally from the approximate midpoint of its upper face82. The riser plate80has a secondary plate84extending normally therefrom that resides parallel to bottom plate74. Floor panel20resides between bottom plate74and secondary plate82while abutting to riser plate80. It is held in this position by mechanical fastener86. Wall panel10is mechanically fastened to flange76by fastener110. In this way wall panel10is held secured and normal to floor panel20. There are four bottom rails72utilized as can be seen in FIG.11's end view cross section and FIG.16's partial cutaway sections.

The roof panel system can best be seen and explained by reference toFIGS. 13,14and15. The roof panel system is made of corrugated end panels88and corrugated center panels90. Each of these panels is made of numerous extruded plates held together by adhesive insulating foam26. All panels are of an interlocking design so as to be connected between their nestled inner96, middle98and outer drip flanges108by any of a plethora of mechanical fasteners93including but not limited to screws, nuts and bolts, pins, rivets and cinchlocks. The design incorporates three waterproof lips to retard rain ingress between joined roof panels, between the end walls and the roof panels, and between the side walls and the roof panels.

End panel88has bottom corrugated plate92held in a spaced, parallel planar configuration with first top plate95by adhesive insulating foam26. First top plate95has a short inner drip flange96at a proximate edge, extending normally from its top surface, that resides adjacent to and abuts long middle drip flange98which projects normally from the proximate edge of bottom corrugated plate92. The distal edge of top plate95has a cap flange100extending normally from its bottom surface. Cap flange100has a flared lip101to direct away rain. Cap plate102is a “C” shaped channel that bridges the gap between cap flange100and the distal edge104of bottom corrugated plate92. The trough formed by cap flange100accommodates the end wall panels56and68, thereby forming a drip proof end wall to roof enclosure.

Center panel90has bottom corrugated plate92held in a spaced, parallel, planar configuration with second top plate106by adhesive insulating foam26. Second top plate106has a short inner drip flange96at a proximate edge, extending normally from its top surface, that resides adjacent to and abuts long middle drip flange98which projects normally from the proximate edge of bottom corrugated plate92. This drip flange design is identical on both the end panel88and the center panel90. Outer drip flange108abuts the distal edges of second top plate106and bottom corrugated plate92so as to reside parallel to long middle drip flange98.

Adhesive insulating foam26serves to strengthen and insulate the roof panels88and90as well as adhesively affixing all plates, cap flanges and drip flanges into their spaced configurations.

Looking atFIG. 15it can be seen how inner drip flange96, middle drip flange98and outer drip flange108nestle to form a rainproof seal. Mechanical fastener93connects the adjacent panels. This fastener93may be any of a multitude of mechanical fasteners, including but not limited to screws, bolts, pins, rivets and cinchlocks.

Looking atFIG. 11end view cross section, it can be seen how first top plate95of end panel88extends beyond the length of corrugated panel92to form side drip flange107so as to prevent rain ingress between the roof panels and the side wall panels111. Second top plate106of center panel90has a substantially similar side drip flange. Mechanical fasteners although not necessary to affix side drip flange107to top rail94and wall panels56or68, may be used. Cap flange100and cap plate102require mechanical fasteners to affix them to end wall panels113. Here it can also be seen that top rail94is a box tubular member with a “C” shaped channel projecting normally from one face and away from the edge of that face so as to form a cavity101adapted for insertion of an end wall panel. The area enclosed by the box tubular member of top rail94is used as a wire raceway eliminating the need for separate conduit.

The overall assembly is best explained by reference to end view partial cutawayFIG. 16. Enclosure115is a three dimensional enclosure having six planar, rectangular outer faces. Enclosure115is comprised of a series of connected corrugated, floor panels20that have a smooth bottom surface44adapted for direct placement upon a rooftop curb forming a peripheral boarder around a rooftop opening. This smooth bottom surface44allows for installation of the enclosure onto a variety of different sized curbs. Bottom rails72are fastened by mechanical fastener86onto all four sides of the floor panel assembly. These bottom rails72are shorter in length than the overall length of the sides of the floor panel assembly they are connected onto. All wall panels56are connected to one bottom rail72, while corner panels68are connected to two, perpendicular bottom rails72. Mechanical fasteners16are used to connect the wall panels56and68to the bottom rail72through the connecting and weatherproofing lip116. The wall panels56and68are affixed substantially normal to the floor panels20.

Wall panels56and corner panels68are mechanically fastened to whichever type of wall panel is adjacent by mechanical fasteners66passing through the sidewalls58. Two top rails94are mechanically affixed with mechanical fasteners110to the top of the series of wall panels56and corner panels68that make up the two longest and parallel walls. This serves to align the wall panels in the same manner as the bottom rail72does and serves as a support for the roof panels88and90.

The roof is made of a series of connected roof panels having end panels88at the end of a series of connected center panels90. Adjacent roof panels are connected to each other by fastener93passing through the inner drip flange96, middle drip flange98and outer drip flange108, which nestle to form a rainproof seal. The wall panels56and68on the ends of the enclosure115fit into cap plate102and the wall panels56and68on the long wall sides of the enclosure115fit into the cavity101of the top rail94. Side drip flange107partially resides atop top rail94so as to form another rain proof seal for the roof to wall interface. Mechanical fasteners110may be used to secure the roof panels88and90to the wall panels56and68and to top rail94.

With this style of construction, a lightweight planar torsion box rooftop enclosure is established that offers exceptional strength and stability against non elastic deformation.

The above description will enable any person skilled in the art to make and use this invention. It also sets forth the best modes for carrying out this invention. There are numerous variations and modifications thereof that will also remain readily apparent to others skilled in the art, now that the general principles of the present invention have been disclosed.