Patent Publication Number: US-2006000161-A1

Title: Modular skylight frame and system

Description:
BACKGROUND  
      Skylights are useful and popular features in buildings. Allowing natural lighting to the interior of buildings, skylights are used with residences, schools, shopping malls, office buildings, and the like.  
      A skylight involves an opening through the roof of a building, above which is constructed a perimeter curb for support of the skylight about the opening upon the roof. Construction of the skylight itself, under existing systems, may involve erection and interconnection of various struts, standards, beams, channels, gutters, and the like above the curb. Thereafter, glazing units may be installed and weatherproofed to the constructed frame assembly. Such weatherproofing might involve wet glazing, often undertaken on the job site by professional glaziers. Alternatively, dry glazing may be used, in which a complicated series of gaskets and seals are installed. Dry glazing is considered inferior by some in the market, in that it requires numerous parts that must be fitted together exactly, it is aesthetically complicated, and it requires increased maintenance. On the other hand, wet glazing on the job site may be problematic, in that professionally-trained glaziers must be located and retained, job quality may be irregular, and later responsibility for leaks or failure may be disputed between various tradesmen or material suppliers.  
      Assembly of existing skylight systems is primarily completed on the job site itself. Lacking standardization, various pieces and parts are brought to the site, along with the requisite relatively large number of tools for the assembly. So located, the skylight system is then constructed, piece by piece, over the sometimes large and always dangerous opening in the roof. Moreover, existing gabled skylight systems often produce lateral loading upon the mounting structure, such as the roof curb, which requires more than minimal professional design and engineering considerations. Of course, the tooling costs necessary to produce the various pieces and parts of existing skylight systems is not insignificant, as numerous parts, often of varying configurations, must be manufactured.  
      Once assembled, existing skylight systems often suffer from inferior drainage features. As an outside structure, skylight systems are exposed to rain and must shed that rain in an efficient and effective manner, yet existing systems often provide for inefficient or inelegant, and unattractive, drainage systems.  
      Transportation of the skylight system to the job site is required. Accordingly, the transportability of the various components comprised by the skylight system is an issue to be considered in design. Furthermore, the skylight system must be moved to the roof of the building for installation, which presents another transportability issue. For example, a system so bulky and cumbersome that a crane is required for lifting the system from a truck to a rooftop is less desirable than a system in which components may be handled manually by workers on site.  
      It is also recognized that pre-assembled individual single unit skylight lens assemblies involving a single light aperture, have reached a high level of sophistication, engineering, and reliability. Such units are delivered complete from the factory. Glazing of the light panels has already been completed, under controlled, standardized conditions in a factory by workers with specialized expertise. Installation has been simplified, and performance of these units installed in the field has been superior. Such skylight lens assemblies are available pre-assembled in several standard sizes, such as 2×2 feet, 2×4 feet, 3×3 feet, 4×4 feet, and 4×6 feet. Several models of such skylights include an integrated flashing system, weatherproofing the entire assembly. An example of such a skylight lens assembly is disclosed in application Ser. No. 10/612,386, entitled “Skylight With Sealing Gasket,” owned by the same Assignee as the present invention and incorporated herein by reference.  
      Accessories, such as awnings, shades, blinds, electrochromic mechanisms, and photovoltaic systems, are available for some single unit skylights. Existing skylight systems may not provide for the inclusion of such accessories, either in allowing for attachment of such systems or providing for structural support of the added weight of such systems, or providing for efficient or aesthetic wiring of electrically powered accessories.  
      The present invention relates to improvements upon the known skylight frame systems and provides distinct advantages over the conventional systems and methods.  
     SUMMARY OF THE INVENTION  
      In response to the discussed difficulties and problems, a new skylight frame and system has been discovered.  
      Certain aspects of the present invention provide for a pre-assembled skylight frame module, to be installed upon new construction or in retrofitting a newer skylight to an existing structure.  
      As used herein, “pre-assembled” is understood to mean a construction that is fabricated and assembled distant from the installation site at which the skylight system is to be mounted.  
      According to certain aspects of the present invention, a first skylight mount is provided. The first skylight mount includes opposed first and second rafters and opposed upper and lower purlins, the rafters and purlins interconnected to define a rectangular aperture between them. Likewise, a second skylight mount is provided, it, too, including first and second opposed rafters, and upper and lower opposed purlins, the rafters and purlins interconnected to define a rectangular aperture between them. The first skylight mount is attached to the second skylight mount along the respective upper purlins. Attachment of the first skylight mount to the second skylight mount at the respective upper purlins may define an angle between the first and second skylight mounts ranging from 90 degrees to 180 degrees. Such attachment may be substantially rigid.  
      Each of the two skylight mounts of the pre-assembled skylight frame module may be configured for engagement with a pre-assembled skylight lens assembly, of predetermined size, over each of the rectangular apertures of the skylight mounts.  
      Other aspects of the present invention also provide that the cross-sectional configuration of the upper and lower purlins may be substantially the same. Likewise, the cross-sectional configurations of the first and second rafters may be substantially the same.  
      The lower purlins may include a hinge member adapted for attachment to a roof curb hinge. The roof curb hinge, so used, may attach the pre-assembled skylight frame module to the roof curb or other mounting structure upon the building roof. In one embodiment, the lower purlins of the skylight mounts may include within their structure a hinge member adapted for attachment to a roof curb hinge.  
      The skylight mounts, constructed of the rafters and purlins, may include a top wall configured for abutment with a skylight lens assembly gasket of a pre-assembled skylight lens assembly.  
      Adapted for receipt of a pre-assembled skylight lens assembly, the pre-assembled skylight frame modules of the present invention may include a screw receiver for receipt of screw attachment of the pre-assembled skylight assemblies to the skylight mounts.  
      Channels within the rafters of the skylight mounts may also be provided. Similarly, the purlins of the skylight mounts may include channels.  
      Further, at least one of the skylight frame modules of the present invention may be adapted for attachment of skylight accessories, such as awnings, shades, blinds, electrochromic mechanisms and photovoltaic systems.  
      According to certain other aspects of the present invention, a skylight frame system is provided, comprising at least two pre-assembled skylight frame modules. Such pre-assembled skylight frame modules are configured for side-by-side installation, each such module including a first and second skylight mount. Each of the first and second skylight mounts include opposed rafters, an upper purlin and an opposed lower purlins, the rafters and purlins interconnected to define a rectangular aperture between them. Within such skylight frame system, each first and second skylight mounts are attached together at their respective upper purlins. Such attachment may be at an obtuse angle, thereby forming a gable, or may be at 180 degrees. Further, the rafters between the modules are configured for attachment one to the other, for instance at the job site. The attachment of the first skylight mount and the second skylight mount may be substantially rigid, for instance by welding.  
      Each of the first and second skylight mounts are adapted for engagement with a pre-assembled skylight lens assembly, of predetermined size, over the rectangular apertures.  
      Some of the rafters of the skylight mounts may include within them a secondary gutter, for drainage of water.  
      At least one of the lower purlins of one of the skylight mounts of the skylight frame system herein may include a hinge member adapted for attachment to a roof curb hinge. Alternatively, a hinge may be connected with at least one of the lower purlins for hingeable attachment to a roof curb.  
      The rafters of the skylight mounts of the within skylight frame system may have substantially the same cross-sectional configuration. Likewise, the purlins may have substantially the same cross-sectional configuration.  
      The skylight frame system disclosed herein may include skylight frame modules in which at least one of the rafters is configured to engage with another rafter of an adjacent module upon installation of the module side-by-side, one of the rafters having a male member and the adjacent rafter having a complementary female member configured to engage with the male member.  
      The skylight frame system may also include channels within the rafters, or within the purlins, or within both.  
      The skylight frame system disclosed herein also may include, with at least one of the skylight frame modules, configuration for attachment of skylight accessories.  
      The rafters and purlins of the skylight mounts of the skylight frame modules of the within skylight frame system may include a top wall configured for abutment with a gasket carried by a pre-assembled skylight lens assembly. Similarly, the rafters and purlins may also include a screw receiver for receipt of screw attachment of a pre-assembled skylight system.  
      Structural and operational details of preferred designs of the modular skylight frame and system and components embodying the invention and advantages obtained thereby will become apparent from the appended drawings and the detailed description to follow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The aspects described above, as well as other apparent aspects, advantages, and objectives of the present invention are apparent from the detailed description below in combination with the drawings. It should be noted that the appended drawings are not necessarily to scale in all instances, but may have exaggerated dimensions in some respect to illustrate the principles of the invention.  
       FIG. 1  is a perspective, partially disassembled view of a modular skylight system in accordance with certain aspects of the present invention, with two pre-assembled skylight systems installed thereupon along with two accessories;  
       FIG. 2  is a perspective view of a modular skylight frame suitable for use in the system of  FIG. 1 , or alone;  
       FIG. 3A  is a cross-sectional perspective view taken along line B-B in  FIG. 1 ;  
       FIG. 3B  is a cross-sectional view of one exemplary embodiment of one aspect of the present invention, taken along line B-B in  FIG. 1 ;  
       FIG. 3C  is a cross-sectional view of an alternative exemplary embodiment, taken along line B-B in  FIG. 1 ;  
       FIG. 4A  is a cross-sectional view of one embodiment, taken along line C-C in  FIG. 1 ;  
       FIG. 4B  is a cross-sectional view of an alternative exemplary embodiment, taken along line C-C in  FIG. 1 ;  
       FIG. 5  is a cross-sectional perspective view of an exemplary embodiment, taken along line D-D in  FIG. 1 ;  
       FIG. 6  is a cross-sectional perspective view, taken along line E-E in  FIG. 1 . 
    
    
     DETAILED DESCRIPTION  
      Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and is not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. It is intended that this application includes such modifications and variations as come within the scope and spirit of the invention. Repeat use of reference characters throughout the present specification and appended drawings is intended to represent the same or analogous features or elements of the invention.  
       FIG. 1  shows an exemplary embodiment of a modular skylight frame system in accordance with certain aspects of the present invention. The frame system, generally  10 , is adapted for installation about an opening through a building roof. The frame system  10  may be used with new construction or may be used to retrofit a newer skylight system to an existing building structure. The system depicted in  FIG. 1  illustrates six skylight apertures and, as will be appreciated from the description below, is constructed of three skylight frame modules. For illustration purposes, two lens assemblies  20  are depicted on  FIG. 1 . Likewise, each of the skylight lens assemblies  20  upon system  10  may include an accessory  84 .  
       FIG. 2  illustrates a modular skylight frame  15 . Modular skylight frame  15  includes first skylight mount  18  and second skylight mount  19 . Each of the skylight mounts includes an upper purlin  30  and a lower purlin  40 . Likewise, each of the two skylight mounts includes a left rafter  50  and a right rafter  60 . The rafters and purlins of each skylight mount are interconnected to define rectangular apertures therebetween; aperture  23  is defined within first skylight mount  18  and aperture  24  is defined within second skylight mount  19 .  
      As illustrated in  FIG. 2 , upper purlins  30  of the respective skylight mounts  18  and  19  are attached at purlin juncture  17 . Such attachment may be by weldment or by mechanical connection. In the illustrated embodiment, purlin juncture  17  is configured to define angle A between first skylight mount  18  and second skylight mount  19 , thereby forming a gable.  
      It will be appreciated that system  10  depicted in  FIG. 1  comprises three skylight frame modules  15 , interconnected side-by-side. Within the scope of this invention, combinations of skylight frame modules  15 , of matching rafter lengths and of either equal or varying purlin lengths, may be used to constitute system  10 .  FIG. 3A , taken at line B-B in  FIG. 1 , illustrates the attachment of a left rafter  50  of one such skylight module with a right rafter  60  of an adjacent skylight module. As depicted in  FIG. 3A , left rafter  50  is abutted against right rafter  60 . Left rafter  50  may be attached to right rafter  60  by a variety of means, including bolting, or by male-female interfitting configurations as will be described below with reference to  FIG. 3C . Still with reference to  FIG. 3A , rafters  50 ,  60  are understood to include rafter grooves  51 . Rafter grooves  51  are adapted for receipt of screw attachment of pre-assembled skylight lens assemblies  20  upon the skylight mounts. Such screws may be passed through the flashing or other mounting structures of the pre-assembled skylight assemblies, and received within rafter grooves  51  for secure attachment of such pre-assembled skylight assemblies to the modular skylight frame system  10 .  
      Rafters  50 ,  60  may also be understood to include secondary gutters  52 . Secondary gutters  52 , disposed lower than skylights mounted upon rafters  50 ,  60 , are configured for receipt of water from above and shedding of such water out of the skylight system  10 . Such water is prevented from entering beneath the skylight assembly  10  by gutter cap  53 , which bridges between the two secondary gutters  52  of rafters  50 ,  60 .  
      Also depicted in  FIG. 3A  is rafter cap  56 . Rafter cap  56 , in cooperation with rafters  50 ,  60 , forms channel  57 . Rafter cap  56  may be installed after wiring, insulation, or the like is passed through channel  57 , thereby concealing such material from view and presenting an aesthetically appealing outer surface, and may be removable for later access to channel  57 . Such wiring may be utilized for accessories  84 , such as awnings, shades, blinds, electrochromic mechanisms, and photovoltaic systems.  
      With reference now to  FIG. 3B , greater detail may be understood as to one embodiment of rafters  50 ,  60 . As depicted therein, for example, rafter  50  may include a top wall  581 . Top wall  581  may include a gasket registration notch  32 , adapted for receipt of a skylight gasket  21  of a pre-assembled skylight lens assembly  20 . First wall  581 , in cooperation with such a gasket  21 , allows for a weatherproof seal between rafter  50  and a skylight lens assembly  20 .  
      Rafter  50  may also include interior wall  582 . Interior wall  582  is interior to system  10  and lies within the interior space of building upon which system  10  is installed.  
      Rafter  50  may also include a third wall  583 , in a preferred embodiment generally perpendicular to first wall  581 , and presented for attachment to a skylight lens assembly  20  mounted thereon. Third wall  583  may include rafter groove  51 , for receipt of screw attachment of skylight lens assembly  20  to rafter  50 .  
      Rafter  50  may also include a fourth wall  584 , in a preferred embodiment generally perpendicular to third wall  583 . Fifth wall  585  is connected with fourth wall  584 , in a preferred embodiment generally perpendicularly, and sixth wall  586  is connected to fifth wall  585  generally perpendicularly in a preferred embodiment. Fifth wall  585  and sixth wall  586  form two of the three sides of secondary gutter  52 . Secondary gutter  52  is completed by the upper extension of seventh wall  587 . Eighth wall  588 , in a preferred embodiment, is oriented generally perpendicularly and inwardly from seventh wall  587 . Finally, ninth wall  589  extends from eighth wall  588  to complete the cross-sectional configuration of one embodiment of rafter  50 .  
      As illustrated for example in  FIG. 3B , a rafter cap  56  is depicted attached to rafter  50 . Rafter cap  56  may be configured for snap-fit engagement with rafter cap cleats  590  on interior wall  582  and ninth wall  589 .  
      In one embodiment, rafter  50  is attached to rafter  60  with rafter bolt  54 . Rafters  50 ,  60  may also include screw bosses  55 , for receipt of the head of rafter bolt  54 . So configured, and with the use of washer  58 , rafter  50  may be attached to rafter  60  with use of only a single wrench, as the head of rafter bolt  54  is kept by a screw boss  55 .  
      As illustrated in  FIG. 3B , attachment together of rafters  50 ,  60  define between them a primary gutter  599 . Primary gutter  599  is defined by respective opposing walls  583 , respective fourth walls  584 , and gutter cap  53 .  
      With reference to  FIG. 3B , it will be understood that rainwater falling upon a skylight lens assembly  20  may be shed off of skylight lens frame  22  toward fourth wall  584 , and shed from system  10  by primary gutter  599 . From there, water is prevented from entering between rafters  50 ,  60  by gutter cap  53 . Instead, such water may be allowed to enter secondary gutter  52 , and thereby be shed from the system  10 .  
       FIG. 3C  illustrates an alternative embodiment for attachment of adjacent rafters of modules  15 . As depicted therein, left rafter  50 ′ is attached to right rafter  60 ′. Such attachment is provided by receipt of flange  93  within the gutter defined by alternative fifth wall  585 ′, alternative sixth wall  586 ′, and wall  594 . Alternative seventh wall  587 ′ is configured to attach directly to alternative fourth wall  584 , eliminating walls  585  and  586  from the alternative embodiment depicted in  FIG. 3B , to create a hidden standing seam between rafters  50 ′,  60 ′. Such configuration allows for attachment of left rafter  50 ′ to right rafter  60 ′ without use of nuts or other mechanical fasteners. Rainwater falling upon a skylight lens assembly  20  may be shed from skylight lens frame  22  to fourth wall  584 ′. Such rainwater would either be shed from the system by fourth wall  584 ′, or may enter between walls  585 ′ and  594 , to be shed from the system.  
      Comparison of  FIGS. 3B and 3C  illustrate that, in one embodiment of the present invention depicted in  FIG. 3B , left rafter  50  and right rafter  60  may have cross-sections that are substantially identical. As such, a beam extruded or otherwise fabricated to form a left rafter  50  may be oriented reversely and thus form a right rafter  60 , with the two rafters  50 ,  60  thereby attachable one to the other. Alternatively, in the embodiment depicted in  FIG. 3C , left rafter  50 ′ differs from right rafter  60 ′, requiring a different extrusion or other formative process.  
       FIG. 4A  illustrates a cross-sectional view of a purlin  40  attached to a curb  70 . Purlin  40  may include a top wall  481 , including a gasket registration notch  32  for receipt of a skylight lens assembly gasket  21 . Purlin  40  may also include an interior wall  482 , oriented for presentment to the interior of the skylight system  10  upon completion of installation. Lower purlin  40  may also include third wall  483 , disposed from the opposed end of top wall  481 . Third wall  483  may include purlin groove  31 , for receipt of screw attachment of a skylight lens assembly  20 . Oriented away from third wall  483  is fourth wall  484 , in a preferred embodiment at a right outward angle from third wall  483 . Fifth wall  487  is attached to the end of fourth wall  484 , in a preferred embodiment at approximately right angle. Along the length of fifth wall  487  may be included counterflashing flange  496 , for receipt of and attachment to counterflashing  75 . Attached to fifth wall  487  is a bottom wall  488 , and extending from bottom wall  488  is lower wall  489 . Interior wall  482  and bottom wall  489  may include cleats  490 , for snap-fit engagement with purlin cap  46 . As will be observed, lower purlin  40  and purlin cap  46  cooperate to form channel  491 , adapted for receipt and concealment of electrical wiring, insulation, and the like.  
      Attached to bottom wall  488  may be male hinge piece  42 , which may be attached with hinge bolt  45 . It is to be understood that male hinge-piece  42  may be an elongated member, extending all or part of the length of lower purlin  40 . At installation, male hinge piece  42  is slidably installed within female hinge piece  43 , and female hinge piece  43  may then be bolted or screwed to curb  70 , for example with curb bolt  44 . Disposed between curb  70  and female hinge piece  43  is curb flashing  71 . Curb flashing  71  includes inboard lip  72 , configured to prevent drainage of condensation or water to the interior of a building and instead to prompt drainage of such water outboard of system  10 . Curb flashing  71  may also include outboard flange  73 , for further protection of curb  70  from water draining from curb flashing  71 .  
      Lower purlin  40  may include a plurality of holes  499 , for drainage of condensation from within system  10 .  
       FIG. 4B  illustrates an alternative embodiment of lower purlin  40 , in which male hinge piece  42  is not a separate component to be bolted to lower purlin  40 , but instead male hinge piece  498  is a part of and extends outwardly from alternative bottom wall  488 ′.  
       FIG. 5  is a cross-sectional view taken at line D-D of  FIG. 1 , showing the attachment of upper purlins  30  of two skylight mounts  18 ,  19  in a skylight frame module  15 . As shown therein, two upper purlins  30  are attached at purlin juncture  17 . Purlin juncture  17  is understood to the point of proximity of the respective intersections  390  of walls  387  and bottoms  488  of the upper purlins  30  of skylight mounts  18 ,  19 . Such attachment may be by way of mechanical attachment (not shown) or by weldment. In the case of weldment, such weldment may be along the entirety of the lengths of upper purlins  30 , or only a portion or portions of such length.  
      Also as shown in  FIG. 5 , an alternative purlin cap  46 ′ is depicted, for comparison with purlin cap  46  depicted in  FIG. 4A . Between upper purlin  30  and purlin cap  46 ′ is defined channel  491 .  
      Purlin juncture  17  is provided to attach upper purlins  30  at angle A.  
      Also as depicted in  FIG. 5 , top cap  16  is disposed at top walls  484  of the respective upper purlins  30  to prevent intrusion of water to purlin juncture  17 , and may be weatherproofed thereto with caulking, gasketing, or the like. Top cap  16  may be attached by conventional methods.  
      Comparison of lower purlin  40  in  FIG. 4A  to upper purlins  30  in  FIG. 5  reveals that the same cross-sectional configuration may be used for lower purlins  40  and upper purlins  30 . Alternatively, different cross-sectional configurations may be used, as revealed by comparison of the alternative lower purlin  40 ′ in  FIG. 4B  to the upper purlins  30  in  FIG. 5 .  
       FIG. 6  illustrates the cross-sectional view of an exemplary end glazing panel, to close the ends of the skylight system  10 . As depicted therein, glazing rails  83  may carry glazing panels  85 , and are configured for attachment to right rafter  60  and curb  70 . An alternative end cap seal  81  may be provided for attachment to right rafter  60 , in snap-fit engagement to cleat  591  and glazing rail  83 . Alternatively, solid panels (not shown) may be used to clear the ends of system  10 . Ridge joint end cap  86  may be used in cooperation with top cap  16  to close the end of system  10 .  
      Consideration of the foregoing description illustrates that system  10  may be adapted for a wide variety of skylight applications. For a skylight opening of a given length and width, only three variables need be considered. First, from the available, standardized pre-assembled skylight systems commercially available, which length and width may be chosen for the intended length and width of skylight opening. Once such selection is made, angle A may be calculated. For example, an opening six and a half feet wide and twenty feet long might result in the selection of standardized, pre-assembled 4×4 foot skylight assemblies. Angle A may then be calculated to be approximately 93 degrees, and five pre-assembled skylight frame modules could be constructed accordingly. Thereafter, each such module approximately 4×6½ feet in footprint, could be stacked one atop the other, shipped to the site, carried by hand to the skylight opening, and assembled thereon with simple and few tools. Thereafter, ten such 4×4 foot standardized pre-assembled skylight assemblies could be installed upon the constructed skylight frame system. Male hinge piece  42  ( FIG. 4A ) and female hinge piece  43  allow for a broad range of such gable angles A, such as 90° to 180°, and attachment of upper purlins  30  together result in a rigid frame producing minimal lateral stress upon curb  70 .  
      System  10  provides for superior drainage of rainwater from system  10 . For example, rainwater falling upon top cap  16  would be shed to fourth wall  484  ( FIG. 3B ). Such rainwater may flow from fourth wall  484 , or may flow into secondary gutters  52 . In either event, such rainwater would flow from the rafters  50 ,  60  and be disposed outboard of system  10  upon counter flashing lip  76  ( FIG. 4A ) to the roof.  
      It will also be observed that the skylight mounts  18 ,  19  ( FIG. 2 , for example) also are adapted for receipt of accessories. For example, rafters  50 ,  60  are structurally rigid to support such systems and are capable of accepting interior shade accessories. The pre-assembled skylight frame modules  15  are also capable of accepting exterior awning accessories and the like. Furthermore, upper purlins  30  and lower purlins  40  are structurally rigid to support hinges and electrical ventilation operators, for opening the skylight lens assemblies  20  for example.  
      While the invention shown herein is capable of attaining the objects of the invention, it is to be understood that it is the presently preferred embodiments of the present invention and is thus representative of the subject matter that is broadly contemplated. It is to be further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents, 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.”