Abstract:
A curb assembly is provided for mounting on a sloped, standing seam metallic roof, in order to provide support for a roof fixture, such as an exhaust fan or skylight. The curb assembly includes a box-like structure mounted atop the roof in surrounding relationship to a roof opening. The curb assembly further includes an underlying, below-roof frame assembly. Specialized upper and lower end connection structure serves to securely mount the curb assembly to the metal roof.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. application Ser. No. 14/072,289, filed Nov. 5, 2013, entitled ROOF CURB, which is hereby incorporated in its entirety by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is broadly concerned with improved, prefabricated curb assemblies designed to be mounted on standing seam roofs (which are traditionally formed of metal). More particularly, the invention pertains to the curb assemblies and overall roof constructions with curb assemblies mounted thereon. The curb assemblies are specially designed for rapid and easy field installation, while providing a rigid, water-tight, peripherally sealed construction. 
     2. Description of the Prior Art 
     Roof curb assemblies have been in use for many years for the purpose of mounting roof fixtures, such as exhaust fans, skylights, or air conditioning components. Generally speaking, these curb assemblies include upstanding box walls, which are secured to the underlying roof and in surrounding relationship to an opening formed in the roof and associated with the mounted fixture. In some instances, roof curb assemblies are of modular design and are constructed on site, see, e.g., U.S. Pat. No. 7,065,928. In other instances, prefabricated roof curb assemblies have been provided, which require no field assembly. 
     In many industrial applications, standing seam sloped metal roofs are deemed optimum. These roofs are made up of a series of elongated, side-by-side, interconnected panels and present a higher end and a lower end for water drainage. In the construction of these roofs, the panels are first placed in adjacency with the elongated side marginal standing seam components in close proximity. Thereupon, a seaming device is used to form laps or other types of joints by appropriate joining of the seam components. These joints can take a number of forms, e.g., simple overlaps, single or double locks, tees, snap locks, battens, or trapezoidal laps, see, e.g., http://www.nrca.net/roofing/Metal-roof-systems-for-steep-slope-applications-901. 
     Curb assemblies for standing seam metal roofs must be specially configured in order to accommodate the standing seams, because in many instances, the necessary roof openings have a lateral dimension which crosses one or more of the seams. Moreover, the curb assemblies must be easily installed in the field and designed eliminate or minimize leakage around the assemblies. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the problems outlined above and provides a greatly simplified and easily installed curb assembly. 
     According to one aspect of the present invention a roof construction includes a sloped roof comprising a series of side-by-side panels interconnected along substantially parallel standing seams. The roof presents a higher end and a lower end whereby water will drain from the roof and off the lower end thereof. An opening is formed in the roof and has a lateral dimension transverse to the standing seams so as to cross at least one of the standing seams. The roof construction further includes an integrally formed, prefabricated curb assembly located in surrounding relationship to the opening and operable to support a roof fixture. The curb assembly includes upright, interconnected walls including a pair of opposed sidewalls, a higher end lateral wall, and a lower end lateral wall. The curb assembly also includes higher end connection structure extending at least in part from the bottom margin of the higher end lateral wall and including a plate having an upstanding cap in substantial mating, covering relationship to the at least one standing seam. An end plate covers the lower end of the cap. The curb assembly further includes a water diverter extending between the plate and the outer surface of the higher end lateral wall and being configured to divert water laterally away from the curb assembly. Finally, the curb assembly includes lower end connection structure comprising a cap section in mating, covering relationship to the at least one standing seam at the lower end of the curb assembly. The cap section is located adjacent the bottom margin of said lower end lateral wall, there being an opening formed in said lower end lateral wall in registry with the cap section in order to receive the at least one standing seam. 
     According to another aspect of the present invention, an integrally formed, prefabricated curb assembly is provided. The curb assembly is operable to surround an opening formed in a sloped roof, wherein the roof comprises a series of side-by-side panels interconnected along substantially parallel standing seams. The roof presents a higher end and a lower end whereby water will drain from the roof and off the lower end thereof. The roof opening has a lateral dimension transverse to the standing seams and crosses at least one of the standing seams. The curb assembly includes upright, interconnected walls including a pair of opposed sidewalls, a higher end lateral wall, and a lower end lateral wall. The curb assembly further includes higher end connection structure extending at least in part from the bottom margin of the higher end lateral wall and including a plate having an upstanding cap configured for substantial mating, covering relationship with the at least one standing seam. An end plate covers the lower end of the cap. The curb assembly also includes a water diverter extending between the plate and the outer surface of the higher end lateral wall and being configured to divert water laterally away from the curb assembly. Finally, the curb assembly includes lower end connection structure comprising a cap section configured for mating, covering relationship with the at least one standing seam at the lower end of the curb assembly. The cap section is located adjacent the bottom margin of the lower end lateral wall. There is an opening formed in the lower end lateral wall in registry with the cap section in order to receive the at least one standing seam. 
     In preferred forms, the roof standing seams are generally trapezoidal in cross-section, and the caps and cap sections are configured to overlie and mate with the standing seam ends. Each of the seam caps includes a pair of opposed, upwardly extending, converging bottom sections and an upper cover section spanning the bottom sections and welded thereto. The overall curb assembly also preferably includes a generally quadrate metallic frame adjacent the underside of the metal roof and in general alignment with components of the curb assembly. Threaded connectors are preferably used to securely mount the curb assembly to the roof. 
     This summary is provided to introduce a selection of concepts in a simplified form. These concepts are further described below in the detailed description of the preferred embodiments. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
     Various other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein: 
         FIG. 1  is a perspective view with parts broken away of an installed roof curb assembly constructed in accordance with a preferred embodiment of the present invention, illustrating the higher end of the curb; 
         FIG. 2  is a perspective view similar to that of  FIG. 1 , but illustrating the lower end of the curb; 
         FIG. 3  is a perspective view with parts broken away of the curb, illustrating the higher end and lower end connection structure; 
         FIG. 4  is an enlarged, fragmentary view illustrating the higher end connection structure of the curb, and illustrating the details of the preferred seam cap; 
         FIG. 5  is an enlarged, fragmentary, perspective view of the preferred seam cap, with the roof seam illustrated in phantom; 
         FIG. 6  is a fragmentary, perspective view illustrating the inner surface of the higher end lateral wall and the higher end connection structure; 
         FIG. 7  is a fragmentary, perspective view illustrating the inner surface of the lower end lateral wall, particularly depicting the lower end connection structure of the curb, with the associated roof seam illustrated in phantom; and 
         FIG. 8  is an exploded perspective view of the curb assembly of  FIGS. 1-7 . 
     
    
    
     The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the preferred embodiments. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is susceptible of embodiment in many different forms. While the drawings illustrate, and the specification describes, certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments. 
     Turning now to the drawings, and particularly  FIGS. 1-3 , roof construction  10  is illustrated, broadly made up of a sloped, standing seam metal roof  12 , and an integrally formed, prefabricated metallic curb assembly  14  mounted on the roof  12  and in surrounding relation to a quadrate roof opening  16 . The assembly  14  is designed to support a roof fixture, such as an exhaust fan or skylight (not shown). Although the roof is preferably formed at least substantially of metal, it is within the ambit of the present invention for the roof to be formed of other suitable materials (such as composites, synthetic resin, etc.) 
     The roof  12  is itself conventional, and is made up of a plurality of elongated roof panels  18  each having a central web  20  and upstanding, side marginal, seam-defining walls  22 . The panels  18  are in a sloped orientation, presenting a relatively higher upper end (not shown) and a relatively lower end (also not shown), with the panels  18  running lengthwise between the roof ends. This assures that rain water will be drained from the roof, such water traveling in the direction marked by arrow  24  ( FIG. 1 ). During the construction of roof  12 , the panels  18  are placed in side-by-side adjacency, with the walls  22  being in close proximity. Thereupon, a conventional seaming device is used to form substantially water-tight standing seams  26  along the lengths of the now-interconnected panels  18 . In the illustrated embodiment, the standing seams  26  are generally trapezoidal in cross-sectional configuration, with each wall  22  having a lower, angularly oriented segment  22   a , an upper segment  22   b  extending from the segment  22   a , a flat top segment  22   c , and an uppermost, upstanding seam-defining wall  22   d . It will be appreciated that the illustrated seams  26  are intended to be generic, and thus do not illustrate any specific type of lapped configuration; in practice, of course, the configuration of any particular seam is dependent upon the type of seaming device employed. 
     The roof opening  16  is dimensioned to accommodate the desired roof fixture. In the illustrated embodiment, the opening  16  is generally quadrate (e.g., square or rectangular), with a fore-and-aft length  28  and a lateral length  30 . Those of ordinary skill in the art will appreciate, however, that any suitable opening shape and size is within the ambit of the present invention. The lateral length  30  crosses at least one of the standing seams  26  and, in the particular embodiment shown, the length  30  crosses a pair of adjacent seams  26   a ,  26   b  ( FIG. 8 ). 
     The curb assembly  14  is designed to be placed about the opening  16  and broadly includes upstanding, opposed sidewalls  32  and  34 , a higher end lateral wall  36 , and a lower end lateral wall  38  (the designations “higher” and “lower” being relative to the slope of the roof  12 ). In the illustrated embodiment, the walls  32 - 38  are welded or otherwise interconnected to form a box-like structure. It is noted that the walls  32 - 38  are arranged into a shape and size that corresponds to that of the roof opening  16 , and this shape and size may be similarly varied without departing from the scope of the present invention. The sidewalls  32 ,  34  are preferably identical, and each has upper and lower, inwardly extending, generally U-shaped flanges  40 ,  42 . 
     The higher end lateral wall  36  is preferably fabricated from two welded-together mirror-image wall segments  44  and  46 . Each such segment has a vertical segment  44   a ,  46   a , as well as a triangularly shaped, outwardly extending segment  44   b ,  46   b  defining a hollow interior space below the segments  44   a ,  46   a  (not shown). Internally, the higher end lateral wall includes an upper, inwardly extending, U-shaped flange  48  and a trapezoidal gusset or liner  50  secured to the inner faces of the segments  44  and  46 , thereby closing the hollow interior space ( FIG. 6 ). The segments  44   b ,  46   b  cooperatively define a diverter for rain water (sometimes referred to in the art as a “cricket”). The cricket is configured to divert rain water laterally away from the curb assembly  14 . 
     The lower end lateral wall  38  is equipped with an upper, inwardly extending, generally U-shaped flange  52 , and a lower, opposed, inwardly extending U-shaped flange  54 . However, it will be observed that the flange  54  has a pair of laterally spaced apart, upstanding, integral cap sections  56 , which are important for purposes to be described. Moreover, the wall  38  has a pair of through-openings  58  which are identically configured and in registry with the respective cap sections  56 . 
     Each of the walls  32 - 38  is provided with thermal insulation  60  throughout the lengths thereof, which may be fiberglass or some other suitable insulative material. In the case of the sidewalls  32 ,  34  and lower end lateral wall  38 , the insulation extends between the opposed upper and lower flanges thereof. The insulation for higher end lateral wall  36  extends from the upper flange  48  downwardly to the bottom margin of the liner  50 . In some instances, the insulation associated with the higher end lateral wall  36  is provided by the roof insulation, with such insulation being wrapped up into the curb assembly  14  against the liner  50 . 
     The overall curb assembly  14  also includes higher end connection structure  62  secured to and extending from the lower margin of lateral wall  36 . The structure  62  includes a flat plate  64  equipped with a pair of spaced apart caps  66 , which are configured to mate with and cover the ends of the standing seams  26  crossed by the opening  16 . Also, the lower edges of the segments  44   b ,  46   b  are welded to the plate  64 . 
     In detail, each cap  66  has a pair of opposed, converging sidewall sections  68  and a surmounting top cover  70  secured to the sections  68 . As illustrated in  FIG. 4 , the sidewall sections  68  include a lower, inwardly extending, inclined wall  72  and an upper wall  74 . The walls  72 ,  74  are designed to overlie and mate with the segments  22   a ,  22   b  described previously. The cover  70  has an upper section  76  configured to overlie and mate with the interconnected seam-defining walls  22   d , lateral walls  78  designed to overlie and mate with the walls  22   c , and downwardly extending walls  80  which overlie the walls  74 . In practice, the walls  80  are spot- or tack-welded to the walls  74  in order to maintain the cover  70  in place. The lower ends of the caps  66  are provided with sealing plates  81 , which are welded in place and designed to prevent passage of water into the interiors of the covered standing seams  26  (see  FIGS. 5-6 ). 
     Assembly  14  is also equipped with lower end connection structure in the form of the internal cap sections  56  and openings  58 . As best seen in  FIG. 7 , the cap sections  56  are welded to wall  38  and have wall sections configured to overlie and mate with the ends of the associated standing seams  26   a  and  26   b . The cap sections  56  are integral and have lower wall segments  82  intermediate wall segments  84 , lateral wall segments  86 , and a top cover segment  88 . The cap sections  56  are preferably integral with and form part of the bottom flange  54 . 
     A lower, below-roof frame assembly  90  preferably also forms a part of curb assembly  14 . As will be described, the frame assembly  90  is provided to facilitate connection of the curb assembly  14  to the roof  12 . The frame assembly  90  is preferably designed to have a complemental shape and size to the roof opening  16 . Therefore, in the illustrated embodiment, the frame assembly  90  presents a generally quadrate shape that is slightly larger than the roof opening  16 . The preferred frame assembly  90  comprises four overlapped metallic channels  92  sized and oriented to lie beneath sidewalls  32 ,  34 ; the side margins of plate  64 ; and the lateral width of plate  64 . The frame assembly  90  may be preassembled, or the bars  92  thereof can be individually mounted and attached, as described below. 
     The installation of curb assembly  14  is accomplished by initially applying sealant in the form of caulking tape  94  just inside the perimeter of the assembly  14 . A relatively wide tape section  96  (e.g., formed by a pair of side-by-side tape strips) is applied across the undersides of the caps  66  and the adjacent stretches of the plate  64 . Side marginal tape sections  98  are applied to the undersides of the lower sidewall flanges  42 , and a tape section  100  is applied to the underside of the lower flange  54  (including the cap sections  56  thereof). Next, the upper box-like structure of curb assembly  14  is positioned on roof  12  so that the caps  66  overlie and mate with the ends of the seams  26   a  and  26   b  crossed by opening  16 , and the cap sections  56  similarly overlie and mate with the opposed ends of these seams  26   a ,  26   b . The frame assembly  90  is then supported beneath the roof  12  in alignment with the assembly  14 . Threaded metal screws  102  are used to secure the assembly  14  in place, as illustrated in  FIGS. 1-4 and 6 , with the screws passing through the plate  64 , lower flanges  42  and  54 , roof  12 , and the frame channels  92 . Preferably, a continuous sealant bead (not shown), such as gun grade sealant, is applied about the entire perimeter of the curb assembly  14  between the roof  12  and the plate  64 , between the roof  12  and each of the sidewalls  32  and  34 , and between the roof  12  and the lower end lateral wall  38 . The desired roof fixture can then be installed on the curb assembly  14  in the usual manner. 
     The curb assembly  14  is preferably metallic (except the sealing material), with the various components thereof preferably being welded to one another to provide a unitary, integrally formed structure. Those of ordinary skill in the art will appreciate that the curb assembly may be formed of other suitable materials (such as composites, synthetic resins, etc.), without departing from the spirit of the present invention. 
     The curb assembly  14  provides a number of significant advantages. First, the assembly  14  can be used with a variety of standing seam configurations. In the case of trapezoidal standing seams, it is only necessary to provide appropriately configured cap covers  70  which mate with the selected lap pattern of the seams. Moreover, where other types of standing seams are employed, it is only necessary to stamp the higher and lower end connection structure to provide a mating configuration. 
     The curb assemblies are also easy to install in the field, which reduces labor costs. Provision of prefabricated components, specifically designed for a given standing seam roof, eliminates the need to field-assemble and modify the curbs. The ease of installation also helps assure that the curbs are installed in a safe, water-tight fashion. 
     Although the above description presents features of preferred embodiments of the present invention, other preferred embodiments may also be created in keeping with the principles of the invention. Furthermore, these other preferred embodiments may in some instances be realized through a combination of features compatible for use together despite having been presented independently as part of separate embodiments in the above description. 
     The preferred forms of the invention described above are to be used as illustration only and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention. 
     The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention set forth in the following claims.