Abstract:
A roof scuttle safety railing system is provided for an existing or new roof scuttle which railing may be installed on the roof scuttle by unskilled labor without compromising the integrity of the weather seal of the roof scuttle. In one embodiment, pivotal corner brackets are secured to the capflashing of a roof scuttle with the vertical members of the safety railing being inserted in openings in the brackets. In another embodiment, an elongated bracket is used along two opposed sides of the roof scuttle which brackets are firmly held against the outside walls of the roof scuttle by tie rods, a strap or a cable. The elongated bracket has vertical openings at its distal ends for securing the vertical members of the safety railing and horizontal openings or slots for the tie rods, straps or cables. A hinged gate is also provided which preferably has a self-closing hinge.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to horizontal hinged door assemblies such as roof scuttles and, in particular, to a safety railing which may easily be installed on new and existing roof scuttles by unskilled labor without compromising the integrity of the weather seal of the roof scuttle. 
   2. Description of Related Art 
   Horizontal hinged (covers) doors are commonly used for roof scuttles, automatic fire vents, ceiling access doors, basement doors and other access doors. The present invention will be directed for convenience to single door roof scuttles which are used to provide access to a roof but it will be appreciated to those skilled in the art that the invention is applicable to other horizontal hinged doors such as double leaf roof scuttles for which a safety railing around the door is desired. 
   Roof scuttles are ruggedly built for long, dependable service and generally comprise a rectangular frame extending above the roofline and which surrounds the opening to be covered. A door is hinged to the frame for motion of the door between an open and closed position The conventional roof scuttle has a vertical sheet metal inner wall with an outwardly extending 90° horizontal anchoring flange at the bottom of the wall, which flange is nailed or otherwise secured to the roof deck through holes provided in the flange. Rigid fiberboard insulation extends around the inner wall and forms the outer wall of the frame. A capflashing is connected to the top of the inner wall usually by welding and extends downward over the top portion of the outer wall. Roofing materials are then used to waterproof the outer wall of the frame typically by rolling the roofing along the roof surface and then up the vertical outer walls (curb) of the frame and securing the roofing material to the curb. When the roofing material is secured a weather resistant installation is complete. 
   Securing the roofing material to the roof scuttle frame requires experienced and skilled labor to properly waterproof the scuttle. A number of patents have issued in this area relating to forming a waterproof seal between a waterproof roofing material and the scuttle frame surrounding a roof opening. In U.S. Pat. No. 5,960,596, a roofing device is shown for sealing the roofing material to a roof scuttle having a curb wherein the roofing material is wrapped over an elongated resilient filler piece which is snuggly inserted into a filler channel between the wall and a top flange of the capflashing of the scuttle. A conventional roof scuttle of the prior art is shown schematically herein in  FIG. 1  wherein the inner wall  19  of the roof scuttle is bent 90° to form a base flange  23  which may be adhesively sealed and nailed or screwed in a conventional manner to the roof through openings  23   a . The roof surface and outer wall curb  18   a  of the roof scuttle are covered with a roofing material which is then secured in place against the outer wall  18   a . Another similar sealing system for a conventional roof scuttle is shown in U.S. Pat. No. 4,941,300. In U.S. Pat. No. 4,781,008 a frame assembly is shown for surrounding an opening in a building surface and for securing a waterproof roofing material to the frame assembly. All the above patents are hereby incorporated by reference. 
   Use of a roof scuttle necessarily leaves an opening in the roof when the door of the roof scuttle is open as shown in FIG.  1 . 
   Bearing in mind the problems and deficiencies of the prior art, it is one object of the present invention to provide a roof scuttle for enclosing a roof opening which roof scuttle has a safety railing attached thereto which is easily installed by unskilled labor on any size new or existing roof scuttle without compromising the integrity of the weather seal of the roof scuttle. 
   It is another object of the present invention to provide methods for installing a safety railing on a new or existing roof scuttle without compromising the integrity of the weather seal, which methods are easily performed by unskilled labor. 
   Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification. 
   SUMMARY OF THE INVENTION 
   The above and other objects, which will be apparent to those skilled in art, are achieved in the present invention which relates in one aspect to a roof scuttle and safety railing system for enclosing a roof opening comprising:
         a rectangular roof scuttle having a vertical curb extending upward from the roof surface and extending around the periphery of an opening in the roof, the vertical curb having front, rear and opposed sides, a door hinged to the scuttle for moving to an open or closed position and a capflashing on the top of the curb which has a horizontal member extending outward from the curb and at least one vertical member extending downward toward the roof surface with a space between the outside wall of the curb and the inside wall of the vertical member, the capflashing extending around the periphery of the curb;   two pairs of brackets secured to the vertical member of the capflashing with each bracket proximate each corner of the scuttle, each pair of brackets having at least one bracket which is pivotable laterally about a vertical axis and preferably having a vertically disposed pivot pin plug spaced away from the vertical member and one or more arms pivotally mounted thereto, each arm having at least one vertically spaced opening for holding and securing a vertical member of a safety railing and the other bracket of each pair also being pivotable or fixed extending outward from the vertical member and having at least one vertically spaced opening therein for holding and securing the other vertical member of the safety railing;   one or more safety railings, each railing having two vertical members and one or more horizontal connected cross members running between the two vertical members with each vertical member being held and secured in a bracket opening; and   optionally a gate hingedly connected at the front side of the roof scuttle to one of the safety railing vertical members for movement to and away from the roof opening.       

   Another aspect of the invention is a roof scuttle and a safety railing system for enclosing a roof opening comprising:
         a roof scuttle having a vertical curb extending upward from the roof surface and extending around the periphery of an opening in the roof having front, rear and opposed sides and a door hinged to the scuttle for moving the door to an open or closed position;   opposed elongated brackets, preferably channel shaped, running either along the front and rear sides or the opposed sides and having their distal ends extending outward from each edge of the curb, each end of the brackets having at least one vertically spaced through opening to hold and secure a vertical member of a safety railing and one or more horizontal through openings away from the edge of the curb; and   one or more elongated tie rods running along each side of the curb not having a bracket, the ends of each rod passing through the horizontal through openings and being fastened to the brackets holding the brackets firmly against the vertical curb; and   one or more safety railings each railing having two vertical members and one or more horizontal connected cross members running between the two vertical members with each vertical member being held and secured in a bracket vertical opening; and   optionally a gate hingedly connected at the front side of the roof scuttle to one of the safety railing vertical members for movement to and away from the roof opening.       

   In another aspect of the invention a roof scuttle and safety railing system for enclosing a roof opening is provided comprising:
         a roof scuttle having a vertical curb extending upward from the roof surface and extending around the periphery of an opening in the roof having front, rear and opposed sides and a door hinged to the scuttle for moving the door to an open or closed position;   opposed elongated brackets, preferably channel shaped, running either along the front and rear curb or the opposed sides and having their distal ends extending outward from the edge of the curb each edge of the bracket having at least one vertically spaced through opening to hold and secure a vertical member of a safety railing and one or more horizontal through openings away from the edge of the curb; and   a flexible strap or cable running around the periphery of the curb and passing through the horizontal openings in the brackets, which strap or cable is fastened to hold the brackets firmly against the side of the curb; and   one or more safety railings each railing having two vertical members and one or more horizontal connected cross members running between the two vertical members with each vertical member being held and secured in a bracket vertical opening; and   optionally a gate hingedly connected at the front side of the roof scuttle to one of the safety railing vertical members for movement to and away from the roof opening.       

   In another aspect of the invention, a method is provided for installing a safety railing on a new or existing roof scuttle used to cover a roof opening comprising the steps of:
         providing a roof scuttle surrounding a roof opening, which scuttle has a vertical curb extending upward from the roof surface and extending around the periphery of the opening in the roof, the vertical curb having front, rear and opposed sides and the scuttle is weather proofed and installed on the roof, the roof scuttle having a capflashing on the top of the curb having a horizontal member extending outward form the curb and at least one vertical member extending downward toward the roof surface with a space between the outside wall of the curb and the inside wall of the vertical member, the capflashing extending around the periphery of the curb;   securing two pairs of brackets to the vertical member of the capflashing with each bracket proximate each corner of the scuttle, each pair of brackets having at least one bracket which is pivotable laterally about a vertical axis and preferably having a vertically disposed pivot pin plug away from the vertical member and one or more arms pivotally mounted thereto, each arm having at least one vertically spaced opening for holding and securing a vertical member of a safety railing and the other bracket of each pair also being pivotable or fixed extending outward from the vertical member and having at least one vertically spaced opening therein for holding and securing the other vertical member of the safety railing;   providing one or more safety railings each railing comprising two spaced apart vertical members and connecting cross members;   inserting the vertical members of each safety railing into the vertical bracket openings on the opposed sides of the scuttle; and   optionally providing a gate hingedly connected to at the front side of the roof scuttle to one of the vertical members of the safety railing for movement to and away from the roof opening;   securing each vertical member in each vertical bracket opening.       

   In a further aspect of the invention a method is provided for installing a safety railing on a new or existing roof scuttle used to cover a roof opening comprising the steps of:
         providing a roof scuttle having a vertical curb extending upward from the roof surface and extending around the periphery of an opening in the roof having front, rear and opposed sides and a door hinged to the scuttle for moving the door to an open or closed position;   positioning opposed elongated brackets, preferably channel shaped, running either along the front and rear sides of the curb or the opposed sides of the curb, which brackets have their distal ends extending outward from the edge of the curb, each end of the brackets having at least one vertically spaced opening to hold and secure a vertical member of a safety railing and having one or more horizontal through openings away from the edge of the curb; and   securing one or more tie rods running along the sides of the curb not having the brackets, the ends of each rod passing through the horizontal openings and fastened to the brackets holding the brackets firmly against the vertical curb;   one or more safety railings each railing having two vertical members and one or more horizontal connected cross members running between the two vertical members with each vertical member being held and secured in a vertical bracket opening; and   optionally a gate hingedly connected at the front side of the roof scuttle to one of the safety railing vertical members for movement to and away from the roof opening.       

   In another aspect of the invention a method is provided for installing a safety railing on a new or existing roof scuttle comprising the steps of:
         providing a roof scuttle having a vertical curb extending upward from the roof surface and extending around the periphery of an opening in the roof having front, rear and opposed sides and a door hinged to the scuttle for moving the door to an open or closed position;   positioning opposed elongated brackets, preferably channel shaped, running either along the front and rear sides of the curb or the opposed sides of the curb, which brackets have their distal ends extending outward from the edge of the curb, each end of the brackets having at least one vertically spaced openings to hold and secure a vertical member of a safety railing and having one or more horizontal through openings away from the edge of the curb; and   running a flexible strap or cable around the periphery of the curb through each of the horizontal bracket openings and then fastening the strap or cable together to hold the brackets firmly against the sides of the curb;   one or more safety railings each railing having two vertical members and one or more horizontal connected cross members running between the two vertical members with each vertical member being held and secured in a bracket opening; and   optionally a gate hingedly connected at the front side of the roof scuttle to one of the safety railing vertical members for movement to and away from the roof opening.       

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
       FIG. 1  is a perspective view of a roof scuttle of the prior art. 
       FIG. 2  is a perspective view of a roof scuttle and safety railing system of one aspect of the invention using pivotal brackets. 
       FIG. 3  is a schematic elevational view of a curb and a door of a roof scuttle having a vertically pivotal bracket secured to the capflashing of the roof scuttle. 
       FIG. 4  is a perspective view of a roof scuttle and safety railing system of another aspect of the invention using a flexible strap to secure safety railing mounting brackets to the scuttle curb. 
       FIG. 5  is a perspective view of a roof scuttle and safety railing system of another aspect of the invention using tie rods to secure safety railing mounting brackets to the scuttle curb. 
       FIG. 6  is a perspective view of a safety railing mounting bracket used in the invention as shown in  FIGS. 4 and 5 . 
       FIG. 7A  is a perspective view of part of a pivotal bracket used in the invention. 
       FIG. 7B  is a plan view of the bracket of FIG.  7 A. 
       FIG. 7C  is a perspective view of a flange member used in conjunction with the bracket of FIG.  7 A. 
       FIG. 7D  is a perspective view of the assembled bracket using the components of  FIGS. 7A and 7C . 
       FIG. 8  is a perspective view of a fixed bracket which can be used in the invention. 
       FIG. 9  is a schematic elevational view of a clamp used to secure a pivotable bracket to the capflashing. 
       FIG. 10A  is a plan view of a capflashing showing brackets on the capflashing used to secure a pivotable bracket to the capflashing. 
       FIG. 10B  is an elevational view of a pivotable bracket of the invention for use with the capflashing of FIG.  10 A. 
       FIG. 11  is a perspective view of a capflashing containing brackets to hold and secure a pivotable bracket of the invention to the capflashing. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   In describing the preferred embodiment of the present invention, reference will be made herein to  FIGS. 1-8  of the drawings in which like numerals refer to like features of the invention. 
   Referring to  FIG. 1 , a roof scuttle of the prior art without a safety railing is shown generally as  10 . The scuttle has a cover or door  11  which is hinged by hinge  13  to the roof scuttle frame shown generally as  12 . The roof scuttle frame  12  comprises a vertical outer wall  18   a , and a vertical inner wall  19 . The frame has a top capflashing shown generally as  16  having a top horizontal curb  17 . The scuttle also has a spring lift mechanism  14  rotably held by a bracket  14   a  to the inner frame wall  19  and by bracket  14   b  to the door  11  to facilitate opening and closing of the roof door. A rotatable support strut shown as  15  engages L-slot  27  during opening and closing of the door and maintains the roof door of the scuttle in an open position until it is desired to close the roof scuttle door. A door handle is shown as  28 . Also shown is a lock  24  and gasket  25  which travels around the door and sits on top curb  17  to seal the door when closed. 
   The capflashing  16  is an integral structure comprising a horizontal top curb  17  having an inner lip  17   a  (not shown), vertical upper outer wall  18 , an angular flange  20  which is connected to a vertical flange  21  and which ends in a downwardly outwardly extending drip edge flange  22 . The roof scuttle has an outside curb  18   a  ending at nailing flange  23  (with nail openings  23   a ) which nailing flange is formed by bending the inner wall  19  90° at the lower end. The curb  18   a  is typically rigid fiberboard insulation and the inner wall  19  sheet metal generally about ⅛ inch thick. The lip  17   a  of the capflashing is typically welded to the inner frame wall  19  to secure the capflashing to the door assembly. The capflashing is made from sheet metal and is generally about ⅛ inch thick. 
   Referring now to  FIG. 2 , the roof scuttle of  FIG. 1  is shown having a safety railing system of the invention. Pivotable brackets  37  are shown at the corners of the roof scuttle and comprise transverse arms  41   a  and  41   b  which are attached to vertical member  21  of the capflashing by appropriate fasteners such as bolts. The bracket  37  has a pivot plug  43  disposed vertically. Two swivel brackets  45   a  and  45   b  are pivotally attached to the plug  43  and have openings in which the vertical members of the safety railing are inserted and secured. It can be seen that left railing vertical members  34   a  and  34   b  are inserted into their respective bracket openings and right railing vertical members  29   a  and  29   b  are inserted into their respective bracket openings. The right safety railing has cross members  30   a  and  30   b  and a central support  31 . The left safety railing has cross members  35   a  and  35   b  and a central support  36 . A gate  48  is shown hingedly connected to left safety railing vertical member  34   a . The gate comprises a vertical member  49  which is hingedly connected to vertical member  34   a  by hinges  69   a  and  69   b . As shown in  FIG. 2 , a torsion bar  59  is used to form a self-closing force for the gate. When the gate is swung outward from the roof scuttle opening, the torsion bar is rotated (twisted) creating a force which will return the gate to its original position after the opening force is released. The gate  48  comprises cross members  50   a  and  50   b  and connected vertical member  51 . 
   Any self-closing hinge may be used for the gate of the roof scuttle of the invention. A helix hinge can be used whereby the offset hinge mechanism elevates the center of gravity of the gate during opening and likewise provides for the automatic return of the gate to the closed position. 
   Referring now to  FIG. 3 , the roof scuttle comprises an inner wall  19  with an upper inward lip  19   a . Inner wall  19  has a 90° bend at the lower end thereof to form an anchoring flange  23 . The upper portion of the roof scuttle has a capflashing  16  comprising horizontal curb  17  and downward lip  17   a , an upper vertical outer wall  18 , angled flange wall  20 , vertical wall  21  and drip edge flange  22 . A curb  18   a  completes the frame. A hinge  13  connects the frame to the door  11  and a spring lift mechanism  14  is shown rotably connected to inner wall  19   a  by bracket  14   a . The roof scuttle is shown installed on a roof wherein the anchoring flange  23  is secured to roof  26 . Three sheets of roofing material shown in composite as  32  are laid on the roof and the outer wall  18   a  of the frame to seal the frame. Ballast  33  is shown as part of the roofing material. An elongated filler piece (not shown) may be used to hold the roofing material as described in U.S. Pat. No. 5,960,596, supra. It should be appreciated that the installation of this type roof scuttle requires a skilled worker to properly apply the roofing material to waterproof the scuttle. 
   Referring now to  FIGS. 4 and 6 , a roof scuttle safety railing system is shown generally as  90 . An elongated bracket  60   a  and an opposing elongated bracket  60   b  are positioned at the front and rear sides of the curb. The brackets have a channel shape and have an elongated body portion  61  which is slightly longer than the side of the curb and transverse arm portions  62   a  and  62   b . The base has one or more horizontal openings  63  to accommodate connecting tie rods and horizontal openings  64  for straps to be passed through. The arms  62   a  and  62   b  have vertical spaced openings  65   a  and  65   b  to hold and secure the vertical members of the safety railing. 
   Right safety railing vertical members  29   a  and  29   b  and left safety rail vertical members  34   a  and  34   b  are positioned in their respective bracket openings  65   a  and  65   b . The right safety railing has cross members  30   a  and  30   b  and a central vertical support  31 . The left safety railing has cross members  35   a  and  35   b  and central support  36 . The gate  48  of  FIG. 2  is not shown for clarity but would be connected to the railing as described above. A strap  80  is passed through the horizontal openings  64  in the elongated brackets  60   a  and  60   b  and extends around the periphery of the roof scuttle curb. The strap is tightened and locked and holds the two elongated brackets  60   a  and  60   b  against the front and rear sides of the roof scuttle and secures the vertical members of the railing system. 
   Referring now to  FIG. 5 , a roof scuttle railing system (shown generally as  100 ) similar to that in  FIG. 4  is shown except that tie rods  70  are used to hold the front and rear elongated brackets  60   a  and  60   b  firmly against the side of the curb. The ends of the tie rod are preferably threaded and a nut  73  is used to secure the tie rod to the bracket. As in  FIG. 4 , the gate is not shown for clarity. 
   Referring now to  FIG. 6 , the elongated bracket  60  is shown in detail. The bracket is a channel shape and has an elongated flat base  61  and transverse arms  62   a  and  62   b . The base  61  has horizontal tie rod openings  63  at each end thereof and one or more horizontal strap hole openings (shown as slots)  64  proximate the tie rods openings. The elongated bracket also has vertically axially spaced through openings in the arms  62   a  and  62   b  shown as  65   a  and  65   b . As noted above the vertical support members of the safety railing are inserted into openings  65   a  and  65   b  to secure the railing to the brackets. All the openings in the bracket are away from the edge of the curb so that the tie rods and straps can pass through and the vertical members of the safety railing have clearance for opening and closing the door. A stop  74  is disposed under opening  65   b  to support the vertical railing member. 
   Referring now to  FIG. 7A , one part of a preferred pivotal bracket used in the invention is shown generally as  37 . The bracket comprises transverse arms  41   a  and  41   b  which are bent angularly outward ( 42   a  and  42   b ) to accommodate a pivot pin plug  43  which is welded or otherwise secured at the ends of  42   a  and  42   b . A through opening  43   a  is provided in the plug  43  to accommodate a pivot pin. Openings  75  are provided for receiving the bracket to the capflashing. A plan view of the bracket is shown in FIG.  7 B. 
   A swivel bracket member shown in  FIG. 7C  generally as  44  comprises a flat oval shaped bracket body  45  having a through opening  47   a  therein to accommodate a vertical safety rail member. The bracket body  45  also has an opening  91  and has a through opening  46  to accommodate a pivot pin. A set screw  81  is used to secure the safety railing member in the opening. 
   In use, as shown in  FIG. 7D , the opening  46  in the swivel bracket member  44  is mated with the opening  43   a  of the bracket. A pivot pin  76  would then be inserted through both openings so that the swivel portion  44  can swing laterally about a vertical axis as shown by the arrows. This lateral movement allows for the use of different length safety railings and/or the ease of installing the safety railing since dimensional variations of the curb can be accommodated by swiveling the bracket. Two swivel bracket members  45   a  and  45   b  are preferably used to provide additional stability to the railing vertical members. A locking screw  81  is also preferably used to secure the railing in the opening. When the railing is inserted and secured in the bracket openings the swivel bracket members  45   a  and  45   b  are secured by tightening the pivot pin. 
   Referring now to  FIG. 8 , another bracket that may be used in the invention is a fixed bracket shown generally as  38 . The bracket has transverse arms  53   a  and  53   b , an outward extending shoulder  54  having an elongated vertically spaced member  54   a  connected to bracket railing holding members  55   a  and  55   b  which have axially aligned openings  56   a  and  56   b  therein to accommodate the vertical member of the safety railing. Openings  75  are provided to secure the bracket to the capflashing. A set screw  81  is used to secure the railing in the opening. 
   Referring to  FIG. 9 , a schematic elevational view of a capflashing connected to inner wall  19  is shown. The capflashing has a horizontal curb  17  and downward lip  17   a , an upper vertical outer wall  18 , angled flange wall  20 , vertical wall  21  and drip edge flashing  22 . Referring to  FIG. 7D  a swivel bracket member  37  may be secured to vertical member  21  of the capflashing by a clamp  101  which extends from the surface of arm  41   b  of the swivel bracket to the inner wall of vertical wall  21  and is secured to wall  21  by a thumb screw  102 . The thumb screw  102  may also be at the other end of clamp  101 . This provides a method for securing the swivel bracket to the capflashing without any penetration of the roof scuttle structure. 
   Referring now to  FIGS. 10A and 10B , a plan view of a capflashing which has been modified by welding or otherwise securing flanges to the capflashing is shown. Thus, in  FIG. 10A , flanges  103   a ,  103   b  and  103   c  are welded to vertical member  21  and have respective openings  106   a ,  106   b  and  106   c . The swivel bracket of  FIG. 7D  is shown modified by having legs  104   a ,  104   b  and  104   c  extending downward from the lower surface of arm  41   b . Legs  104   a ,  104   b , and  104   c  are shown having outward nubs  107  and openings  108  which when the legs are inserted into their respective openings  106   a ,  106   b  and  106   c , will snap into the openings and be held securely in the openings, thus securing the swivel bracket to the capflashing. 
   Referring now to  FIG. 11 , a perspective view is shown of a capflashing which has been modified by securing flanges  105   a  and  105   b  to vertical member  21  of the capflashing by welding or other means. Flange  105   a  comprises a body portion  110  and an extending leg  111  at its base and is open at its upper end. Flange  105   b  comprises body portion  112  and extending leg  113  and is open at its lower end. The swivel bracket of  FIG. 7A  is shown secured in flange members  105   a  and  105   b  and is secured to vertical member  21  of the capflashing. Thus, arms  41   a  and  41   b  of the swivel brackets extend through the openings in the flanges  105   a  and  105   b  and are held securely to the vertical member  21  of the capflashing. This likewise avoids penetration of the roof scuttle structure. 
   While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.