Abstract:
Various skylight connectors are disclosed. A sheet is integrally formed with tabs along opposed axial edges of the sheet, and the sheet can be bent into a tubular configuration with the tabs along one edge engaging tab holes along the other edge and vice-versa to hold the sheet in the tubular configuration. Also, a skylight dome fastener adaptor includes a hollow body, and ribs are formed on the outer surface to engage a hole in a skylight dome to impede rotation of the body in the hole when a fastener is disposed in the adaptor and threadably engaged with a dome flashing. Additionally, various quick connect zip ties and clips are disclosed for quickly and easily engaging components of a skylight assembly.

Description:
This application is a division of application Ser. No. 09/414,175, filed Oct. 7, 1999, now U.S. Pat. No. 6,321,493. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to connectors for tubular skylights. 
     BACKGROUND 
     Tubular skylights have been provided for illuminating the interiors of buildings in an aesthetically pleasing and energy efficient way with natural sunlight. An example of a commercially successful skylight is disclosed in the present assignee&#39;s U.S. Pat. No. 5,099,622, and further examples of effective tubular skylights are disclosed in the present assignee&#39;s U.S. Pat. No. 5,896,713 and in allowed U.S. patent application Ser. No. 09/126,331, all of which are incorporated herein by reference. 
     In tubular skylights such as the those mentioned above, a transparent plastic dome is mounted on a roof of a building by means of a metal flashing that is attached to the roof. Extending down from the dome is a metal tube that has a highly reflective inner surface. The tube extends down to the ceiling of the interior room sought to be illuminated, where it terminates at a disk-shaped light diffuser mounted on the ceiling by means of one or more support rings that engage the lower end of the tube. 
     It will be appreciated that with the above general description of tubular skylights in mind, many components must be connected together. As but one example, the tube itself is ordinarily made from a flat sheet of metal that is bent into a cylindrical shape to form the tube, with the opposite ends of the sheet of metal slightly overlapping each other in the cylindrical configuration and being held in the cylindrical configuration by manually taping the length of the joint between the ends of the bent sheet. As understood by the present invention, while effective, the above-mentioned manual means for forming the tube can result in tubes having diameters that might exhibit deviations slightly from design. Moreover, it is sometimes desirable that the tube slightly taper, i.e., assume a slightly frusto-conical shape, and it is difficult to precisely configure a tube to have such a shape using the manual taping method described above. Fortunately, the present invention recognizes that it is possible to easily and with a high degree of repeatability effect a precisely-configured skylight tube. 
     As another example, consider the connection between the plastic dome and metal flashing. A metal screw is advanced through an ABS washer that is positioned in a hole in the dome, and the screw engages the metal flashing. As recognized herein, the washer can sometimes undesirably rotate in the hole of the dome, thereby rendering it less than optimally effective as a connection interface with the screw and, hence, the flashing to which the dome is mounted. 
     As yet other examples, connecting the diffuser and the various support rings to the lower end of the tube and to the ceiling must be accomplished in relatively confined areas, and accordingly can be a cumbersome and time-consuming task. The present invention understands that such connections can be effected quickly and securely by the novel connecting systems and methods disclosed herein. 
     SUMMARY OF THE INVENTION 
     A light transmitting member for a skylight includes a sheet defining opposed axial edges. The sheet can be bent into a light transmitting configuration, wherein the axial edges are juxtaposed with each other and a light transmitting channel is established by the sheet. First and second sets of axially spaced tab elements are formed along respective axial edges of the sheet. A first tab element in the first set includes a tab while a second tab element in the second set defines a tab opening. As disclosed in detail below, the tab is movable between an engage configuration, wherein the tab can be received through the tab opening, and a lock configuration, wherein the tab cannot be removed from the tab opening to thereby hold the sheet in the light transmitting configuration. Indeed, at least upper and lower tab elements include respective tabs and respective tab openings, and the tab of each tab element in a pair is receivable through the tab opening of the other tab element in the pair. 
     In a preferred embodiment, each set of tab elements includes at least two tab elements. The tab elements in the first set are juxtaposed with respective tab elements in the second set when the member is in the light transmitting configuration to establish plural tab element pairs. Each tab element is integral to the sheet, i.e., the sheet is cut to form the tabs, with the tabs being retained on the sheet by an uncut living hinge. 
     Furthermore, the sheet is formed with at least two upper tab elements in each set of tab elements. The upper tab elements of one set are axially and radially spaced from each other to facilitate selectively establishing one of: a frusto-conical shape, and a cylindrical shape, of the sheet in the light transmitting configuration. 
     In another aspect, a method for forming a skylight tube includes providing a sheet defining first and second opposed edges, and forming plural tabs along at least the first edge and forming plural tab openings along at least the second edge. The method further includes advancing the tabs through respective tab openings with the sheet in a light transmitting configuration. Then, the tabs are bent to hold the sheet in the light transmitting configuration. 
     In yet another aspect, a skylight tube includes a sheet having a reflective surface. Fasteners are formed integrally on the sheet. The fasteners can be moved to hold the sheet in a light transmitting configuration, wherein the reflective surface is an inside surface. 
     In another aspect, a skylight dome fastener adaptor includes a hollow body defining an outer surface. Plural ribs are formed on the outer surface and are configured for engaging a hole in a skylight dome in an interference fit to impede rotation of the body in the hole. 
     In still another aspect, a lower skylight assembly includes a skylight dress ring that has a vertical flange formed with at least one clip hole. A skylight support ring has a vertical flange closely spaced from the vertical flange of the dress ring and terminating in a horizontal flange defining a ratchet aperture. Per present principles, a zip clip has an elongated body defining opposed first and second elongated surfaces, and a clip protrudes from one of the surfaces and is received in the clip hole of the dress ring. Also, at least one of the surfaces of the zip clip is formed with ratchet structure that engages the ratchet aperture of the support ring to thereby hold the dress ring onto the support ring. 
     In yet another embodiment, a zip tie has an elongated body defining first and second ends. A ratchet structure is formed on the body. Moreover, a clip arm is attached to and extends perpendicularly away from the first end of the body. Still further, the clip arm defines a channel. The channel is configured to receive a threaded fastener in self-tapping threadable engagement. 
     The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which: 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a skylight tube sheet prior to fastening the sheet in the light transmitting configuration; 
     FIG. 2 is a perspective view of a skylight tube sheet in the light transmitting configuration, in an exploded relationship with a skylight dome and a diffuser plate; 
     FIG. 3 is a perspective view of the skylight dome fastener adaptor, in exploded relationship with a skylight dome, fastener, and flashing, with portions of the dome and flashing cut away for clarity; 
     FIG. 4 is a partial cross-sectional view of the lower end of a skylight, showing a zip clip engaging the dress ring with the support ring, with the zip clip illustrated as being displaced into the support ring to better illustrate the ratchet opening; 
     FIG. 5 is a cross-sectional view of the present zip tie with dry wall screw receiving channel, in operable engagement with a ceiling ring and dress ring. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring initially to FIGS. 1 and 2, a light transmitting member is shown, generally designated  10 , for transmitting light from a roof-mounted plastic transparent dome  12  to a ceiling-mounted diffuser plate  14 . As disclosed in detail below, the member  10  can be formed in a cylindrical configuration or in a slightly tapered, i.e., frusto-conical, configuration to establish a skylight tube. 
     As shown in FIG. 1, the member  10  includes a metal sheet  16  that defines opposed axial edges  18 ,  20 . When the sheet  16  is bent in the light transmitting configuration shown in FIG. 2, the axial edges  18 ,  20  are closely juxtaposed with each other and indeed overlap each other. In the light transmitting configuration, the sheet  16  defines a light transmitting channel  21  that is bounded by an inside surface on which is disposed a reflective coating  22 , to render the inside surface highly reflective. 
     In accordance with the present invention, to provide a means for holding the sheet  16  in the light transmitting configuration shown in FIG. 2, fasteners are formed on the sheet  16 . More specifically, first and second sets  24 ,  26  of tab elements, generally designated  28 , are formed integrally in the sheet  16  along respective axial edges  18 ,  20 , as best shown in FIG.  1 . The tab elements  28  in a set accordingly are axially spaced from each other. More specifically, each set  24 ,  26  of tab elements includes two upper elements  28  as shown, two lower elements  28 , and a single middle element  28 , although other element patterns can be established in accordance with present principles. In any case, as can be appreciated in reference to FIGS. 1 and 2, the tab elements  28  in the first set  24  are juxtaposed with respective tab elements  28  in the second set  26  when the sheet  16  is in the light transmitting configuration, to establish plural tab element pairs for purposes to be shortly disclosed. 
     In the second set  26  of tab elements, the elements  28  are colinear with each other as shown in FIG.  1 . Also, in the second set  26 , the two upper and two lower tab elements  28  each include a respective tab  30  formed by a cut in the sheet  16  around three sides of the tab  30 , with a fourth side of the tab  30  being uncut and consequently establishing a living hinge  32  about which the tab  30  can be pivoted. The free end  34  of each tab  30 , i.e., the end opposite the respective living hinge  32 , can be rounded as shown for safety. When the tab  30  is pivoted away from the sheet  16 , a tab opening  36  is established as shown best in FIG.  1 . If desired, the tab of the middle tab element  28 M in the second set  26  can be removed, such that the middle element  28 M consists of a permanent aperture as shown in FIG.  1 . 
     The tab elements  28  in the first set  24  are essentially identical in construction and operation to the tab elements  28  in the second set  26  shown in FIG.  1  and described above, with the following exceptions. The top-most element  28 T, middle element  28 N, and bottom-most element  28 B are axially aligned with each other as shown. On the other hand, a second top element  28 TS that is closely spaced from the top-most element  28 T and second bottom element  28 BS that is closely spaced from the bottom-most element  28 B are axially aligned with other and are slightly axially and radially spaced from the top-most and bottom-most elements  28 T,  28 B, respectively. The middle element  28 N of the first set  24  of elements includes both a tab and a tab opening as shown. 
     With the above disclosure in mind, it may now be appreciated that the tab  30  of the top-most element  28 T in the first set  24  can be moved about its respective living hinge  32  to an engage configuration, wherein the tab  30  extends radially outwardly from the sheet  16  and the tab  30  can be received through the tab opening  36  of the corresponding tab element  28  in the opposite set  26 . Also, the tab  30  can be moved to a lock configuration, wherein the tab  30  is folded back away from the opening  36  in which it is received to overlap the sheet  16 , such that the tab  30  cannot be easily removed from the tab opening  36  (without bending the tab) to thereby hold the sheet  16  in the light transmitting configuration. Likewise, the tab  30  of the middle element  28 N in the first set  24  can be engaged with the middle element  28 M of the second set  26 , and the bottom-most element  28 B of the first set  24  can engage the corresponding element in the second set  26  of tab elements. It is to be understood that the tabs  30  in the second set  26  can be likewise interlocked with tab openings  36  in the first set  24  of tab elements. In the example above, the second top element  28 TS and second bottom element  28 BS are not used, and a skylight tube is provided that has a cylindrical configuration and a maximum diameter. 
     It is to be further appreciated that instead of using the top-most and bottom-most elements  28 T,  28 B, the second top element  28 TS and second bottom element  28 BS can be used in conjunction with the middle element  28 N of the first set  24 , thus providing a skylight tube with a cylindrical configuration and a minimum diameter. Still further, a skylight tube can be provided that has a slightly frusto-conical shape by using the top-most element  28 T, middle element  28 N, and second bottom element  28 BS of the first set  24 . Or, a skylight tube can be provided that has a slightly frusto-conical shape by using the second top element  28 TS, middle element  28 N, and bottom-mosf element  28 B of the first set  24 . 
     FIG. 3 shows a skylight dome fastener adaptor  40  that can be disposed in a hole  42  of a plastic transparent skylight dome  44 . The top lip portion of a metal flashing  46  can be juxtaposed with the dome  44 . The flashing  46  is formed with a hole  48  that is juxtaposed with the hole  42  of the dome  44  and that indeed is coaxial therewith. With this structure, the threaded shank  50  of a fastener  52  is advanced through the adaptor  40  and can be threadably engaged with the hole  48  of the flashing  46  (or with a nut opposite the hole  48 ) to hold the dome  44  against the flashing  46 . 
     As shown in FIG. 3, the adaptor  40  includes a hollow hard plastic rigid body  54  that defines an outer surface  56 , and plural, preferably three, ribs  58  are formed on the outer surface  56 . The ribs  58  engage the hole  42  in the skylight dome  44  in an interference fit to impede rotation of the body  54  in the hole  42  when torque is applied to the fastener  52 . 
     In the preferred embodiment shown, each rib  58  includes an axially aligned outer edge  60  and opposed ramped sides  62 ,  64  that extend from the edge  60  to the outer surface  56  of the body  54 . Thus, the ribs  58  have triangular cross-sections. As intended by the present invention, the ribs  58  are formed integrally with the body  54 . 
     In one preferred embodiment, the body  54  is formed with opposed chamfered ends  66 ,  68  as shown. If desired, each rib  54  can include respective rib extensions  70 ,  72  that are formed on respective ends  66 ,  68  of the body  54 . 
     Now referring to FIG. 4, a lower portion of a skylight assembly is shown, generally designated  80 . The assembly  80  includes a ring-shaped plastic skylight dress ring  82  that supports a disk-shaped diffuser plate  84 . In the preferred embodiment shown, the dress ring  82  is formed with a ring-shaped vertical flange  86  that in turn is formed with one or more clip holes  88 . Moreover, a metal or plastic ring-shaped skylight support ring  90  has a vertical flange  92  that is closely spaced from and parallel to the vertical flange  86  of the dress ring  82 . As shown in FIG. 4, the vertical flange  92  of the support ring  90  terminates at its upper edge in a ring-shaped horizontal flange  94  that defines at least one ratchet aperture  96  therethrough. A ratchet tooth  97  extends into the ratchet aperture  96 . If desired, a resilient ring-shaped rubber or plastic seal  98  can be disposed between the vertical flange  86  of the dress ring  82  and a lower metal skylight tube segment . 100 . 
     In accordance with present principles, a flexible plastic zip clip  102  holds the dress ring  82  and support ring  90  together. To facilitate this, the zip clip  102  has an elongated body as shown that defines opposed inner and outer elongated surfaces  104 ,  106 . A small parallelepiped-shaped clip  108  protrudes from the inner surface  104 , and the clip  108  is closely received in the clip hole  88  of the dress ring  82 . Furthermore, the outer surface  106  of the zip clip  102  is formed with zip tie-like ratchet structure  110  that is configured to engage the ratchet tooth  97  of the support ring  90  and thereby hold the dress ring  82  onto the support ring  90 . Both the clip  108  and ratchet structure  110  are made integrally with the body of the zip clip  102 . 
     In a particularly preferred embodiment, the dress ring  82  is formed with a ramp  110  that terminates in an abutment  112 . As shown in FIG. 4, the lower end of the zip clip  102  is sandwiched between the abutment  112  and the vertical flange  86  of the dress ring  82 , to support the zip clip  102 . If desired, a small piece of felt  114  can be glued into the ratchet aperture  96 , with the zip clip  102  being biased against the felt  114  as indicated by the arrow  116  in FIG.  4 . 
     FIG. 5 shows a flexible plastic zip tie  120  that includes an elongated body defining first and second ends  122 ,  124 . A zip tie-like ratchet structure  125  is integrally formed on the zip tie  120  as shown. Furthermore, a rigid clip arm  126  is formed integrally with and extends perpendicularly away from the end  124  of the tie. In accordance with present principles, the clip arm  126  defines a channel  128  generally parallel to the body of the zip tie  120  and thus perpendicular to the clip arm  126 . It is to be appreciated in reference to 
     FIG. 5 that the channel  128  receives a threaded fastener  130 , such as a dry wall screw, with the fastener  130  self-tapping in the channel  128  as it is engaged therewith. 
     With this structure, the zip tie  120  can be used to interconnect skylight assembly components such as a ceiling ring  132  and dress ring  134  holding a diffuser plate  136  with a portion of dry wall. More specifically, the zip tie  120  ratchetably engages the ceiling ring  132  and dress ring  134  in respective ratchet slots  138 ,  140 , and then a structure such as a beam or ceiling or wall can be clamped between the arm  126  and ceiling ring  132 . Moreover, the fastener  130  can be manipulated to engage further wall or ceiling structure above the zip tie  120 . Completing the description of FIG. 5, the ceiling ring  132  engages a lower portion  142  of a skylight tube, and a resilient seal ring  144  can be sandwiched between the dress ring  134  and lower portion  142 . 
     While the particular SYSTEMS AND METHODS FOR CONNECTING SKYLIGHT COMPONENTS as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more”. All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for”.