Patent Publication Number: US-2017356186-A1

Title: Pre-fabricating a metal dormer

Description:
FIELD 
     The present application relates generally to fabrication of dormers and, more specifically, to a method for pre-fabricating a metal dormer. 
     BACKGROUND 
     A dormer is a structural element of a building that protrudes from the plane of a sloping roof surface. Dormers are used to create usable space in the roof of a building by adding headroom and usually also by enabling addition of windows. Dormers are also used as a secondary source of ventilation in attics when louver vents are installed therein, as opposed to windows. 
     Standard practice for Architectural Dormer fabrication involves constructing a dormer on-site from wood framing materials. Such construction is carried out to defined specifications and geometries within architectural drawings. Wood dormers can also be pre-fabricated, in a manner similar to the manner in which trusses are pre-fabricated, and lifted into place with a crane or extendable job boom fork lift. 
     Dormers for the home building industry are generally designed to meet various criteria. Dormers are designed to be weather tight to minimize ingress of wind, snow and rain. Dormers are also designed to withstand wind, water, snow and ice loads. Dormers are further designed to be aesthetically pleasing and to pass building code regulations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made, by way of example, to the accompanying drawings which show example implementations; and in which: 
         FIG. 1  illustrates an example pre-fabricated dormer in an upper-front-left perspective view; 
         FIG. 2  illustrates the example pre-fabricated dormer of  FIG. 1  in a lower-front-right perspective view; 
         FIG. 3  illustrates the example pre-fabricated dormer of  FIG. 1  in a front plan view; 
         FIG. 4  illustrates the example pre-fabricated dormer of  FIG. 1  in a left side view; 
         FIG. 5  illustrates example steps in a method of pre-fabricating a dormer such as the dormer of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The present application relates to the pre-fabrication of an aluminum dormer with, for example, a sealed, ten-inch flange around the perimeter of the unit, thereby providing for a one-step and relatively easy installation by a home owner, a roofing contractor or a carpenter. 
     According to an aspect of the present disclosure, there is provided a method of pre-fabricating a dormer. The method includes forming, by press-brake and according to a planned geometry, a plurality of dormer components from a metal material, the forming creating creases, cutting the dormer components to fit a roof on which the dormer is to be installed, spot-welding to form welds between the dormer components, sealing between the welds and filling the creases with filling material. 
     Other aspects and features of the present disclosure will become apparent to those of ordinary skill in the art upon review of the following description of specific implementations of the disclosure in conjunction with the accompanying figures. 
       FIG. 1  illustrates an example pre-fabricated dormer  100  in an upper-front-left perspective view. The dormer  100  includes a base plate  102  to which a dormer structure  104  is attached. 
     The dormer structure  104  includes several components, named herein as a dormer roof  104 A, a dormer left wall  104 BL and a dormer right wall  104 BR. At a seam between the dormer left wall  104 BL and the dormer roof  104 A, the dormer structure  104  includes a left cap  104 CL. At a seam between the dormer right wall  104 BL and the dormer roof  104 A, the dormer structure  104  includes a right cap  104 CR. The dormer structure  104  further includes a primary internal frame  106 A and secondary internal frame  106 B. The primary internal frame  106 A and the secondary internal frame  106 B are shaped to match an internal shape of the combination of the dormer right wall  104 BR, the dormer left wall  104 BL and the dormer roof  104 A. 
     The person of ordinary skill in the art will understand that many ornamental shapes are available for the dormer walls  104 BR,  104 BL and the dormer roof  104 A. The dormer roof  104 A, as illustrated in  FIG. 1  has a semi-circular (arcuate) cross-section. 
       FIG. 2  illustrates the example pre-fabricated dormer  100  of  FIG. 1  in a lower-front-right perspective view. 
       FIG. 3  illustrates the example pre-fabricated dormer  100  of  FIG. 1  in a front plan view. 
       FIG. 4  illustrates the example pre-fabricated dormer  100  of  FIG. 1  in a left side view. 
     The applicant has found that, for certain dimensions, forming the dormer roof  104 A and the dormer walls  104 BR,  104 BL of 16 Ga (0.0571 inches thick) 5083 Aluminum alloy presented difficulties when such forming was attempted using common methods. 
     The known 5083 Aluminum alloy was selected for reduced weight, relative to wood, and to provide a predictable degree of corrosion resistance. It has also been contemplated that an alternative material, the known 6061-T6 Aluminum alloy, may be used. 
     Conveniently, the Applicant has developed a method of pre-fabricating metal dormers that overcome various difficulties associated with geometry and metal materials. 
       FIG. 5  illustrates example steps in a method of pre-fabricating a metal dormer, such as the dormer  100  of  FIG. 1 . 
     Initially, the aluminum is etched (step  502 ) to show the lines along which cuts will be made following the forming step. In the case of the dormer  100  of  FIG. 1 , eight components are to be cut and five of these components are to be formed. The five components include: the dormer roof  104 A, the dormer left wall  104 BL; the dormer right wall  104 BR, the left cap  104 CL, and the right cap  104 CR. 
     The five components are then formed (step  504 ) to match a desired geometry. For example, a press-brake process may be used in the forming (step  504 ). The Applicant has noted spaces between press-brake creases and these creases are dealt with in a later step. 
     Each of the components are then cut (step  506 ), according to desired geometry, to fit the slope of the roof on which the dormer  100  will be installed. The cutting (step  506 ) may, for example, be accomplished using plasma technologies. The cutting (step  506 ) may, for example, be carried out in a manner that allows the dormer  100  to fit a 38-degree angle for a roof with 9.25:12 pitch. The cutting (step  506 ) may, for another example, be carried out in a manner that allows the dormer  100  to fit a 45-degree angle for a roof with a 12:12 pitch. 
     The components are then welded (step  508 ) together to arrive at the desired design for the dormer  100 . The Applicant has found spot-welding suitable for step  508 . However, the Applicant has also found that spot-welding results in a dormer that is not particularly water-tight. The non-water-tight welds are dealt with in the next step. 
     It is known that spot-welding leaves gaps between spot-weld locations. Each of these gaps between the spot-weld locations created in step  508  are then sealed (step  510 ) to comply with parameters that set out the degree to which the dormer  100  is to be weather-tight. In one example, the gaps between spot-weld locations may be sealed (step  510 ) with caulking. Additionally, voids and cavities between the press-brake creases are filled (step  510 ) with filler material. One material deemed suitable for use as the filler material in step  510  is Titanium Putty from ITW Devcon, which is a division of Illinois Tool Works of Glenview, Ill. As is conventional, once the filling material has cured, the filling material may be sanded to result in a relatively smooth surface. That is, a surface with minimal evidence of creases, dimples or blemishes. 
     In aesthetic-related processing, the dormer  100  may be anodized, etched and/or sandblasted. Furthermore, the dormer  100  may be powder coated to a desired colour. For example, the desired color may match to siding, windows, soffit and/or fascia. The process in general is called “Pre-Treatment Wash”. The aesthetic-related processing may, for example, begin with a light sandblasting with virgin material (new sand product) followed by an acid wash. The dormer may then be left to dry. Powder coating is the final stage of the aesthetic-related processing. 
     The completed dormer  100  is installed by screwing the base plate  102  onto the roof. The installation may be accomplished with, for example, zinc-plated screws every linear 12″ distance about 10″ in from the outer perimeter of the base plate  102 . As will be understood, the dormer  100  may also be installed by securing the dormer  100  to wood framing with nails or other mechanical fastening means. 
     Conveniently, a pre-fabricated dormer  100  constructed from aluminum materials may be noted for being relatively light compared to heavier wood. In one example, the total weight of the aluminum dormer  100  is 45 lbs. Furthermore, a pre-fabricated dormer  100  constructed from aluminum materials may be noted for being relatively low-cost relative to specialty metal dormers. 
     The above-described implementations of the present application are intended to be examples only. Alterations, modifications and variations may be effected to the particular implementations by those skilled in the art without departing from the scope of the application, which is defined by the claims appended hereto.