CA1074974A - Energy efficient skylight construction - Google Patents

Energy efficient skylight construction

Info

Publication number
CA1074974A
CA1074974A CA331,800A CA331800A CA1074974A CA 1074974 A CA1074974 A CA 1074974A CA 331800 A CA331800 A CA 331800A CA 1074974 A CA1074974 A CA 1074974A
Authority
CA
Canada
Prior art keywords
skylight
frame
flange
cover
curbing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA331,800A
Other languages
French (fr)
Inventor
Arthur P. Jentoft
Paul A. Couture
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wasco Products Inc
Original Assignee
Wasco Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CA287,750A external-priority patent/CA1074973A/en
Application filed by Wasco Products Inc filed Critical Wasco Products Inc
Priority to CA331,800A priority Critical patent/CA1074974A/en
Application granted granted Critical
Publication of CA1074974A publication Critical patent/CA1074974A/en
Expired legal-status Critical Current

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  • Building Environments (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

ENERGY EFFICIENT SKYLIGHT CONSTRUCTION

Abstract of the Disclosure An energy efficient skylight construction. A skylight cover is secured by a frame to a curbing comprised of an insulat-ing core, the interior and exterior surfaces of which are covered by non-combustible shields separated along the upper and lower surfaces of the curbing by a gap which serves as a "thermal break"
between the highly conductive inner and outer shields. The frame is pierced by drain openings the exterior of which are covered by a filter type material such as foam or glass fibers that is both absorbtive of moisture and resistant to the passage of air.
The frame is secured to the outward portion of the curbing and includes a flange extending inward across the gap between the shields, which serves as a gutter to collect condensation which drips off the glazing. The inward portion of the flange is covered with an insulating gasket which prevents condensation from forming on the flange and which prevents the warmer, more moisture laden, inside air from reaching the cold underside of the gutter flange or the edge of the outer skin. The core insulation is inserted, without adhesives, into the assembled inside skin, and then the exposed surface of the insulation is bonded to the in-side surface of the outer skin.

1.

Description

11~3/766-~
L`M~/a~s ~79~974 ck~rol~n~ Or tllc Invelltioll The invention in general relates to skylight construc--tions used in buildings to provide daylight and more particularly concerns a skylight construction that is highly energy efficient while at the samc time meets saEety and quality requirements o~
both local and federal regulations.
Basically a skylight permits one to substitute daylight for electric light in a building. This obviously can provide a savings in lighting costs, however with conventional skylight designs this savings can be more than offset by increased heating costs due to thermal energy losses through the skylight. The ~: current high cost of encrgy makes it vcry important to consider the overall energy balance of skylights. A recent study by the University of New ~lampshire has indicated that in order for a skylight to consume less energy than the roof deck it replaces it must include ~1) insulation in the curbing on which the sky-light rests which approaches the effectiveness of the insulation of the roof, and (2) air infiltration approaching zero. Meetlng such objectives in the design of skylights is not easy because 0 skylights must also meet criteria for fire-resistance, shape, - I
strength etc. imposed by federal and local regulations and functional requirements. For example, urethane foam is an effective insulating material which because of low cost and rigidity lends itself to the construction of the curbing to which the skylight cover and frame is secured. However, urethane foam also is a fire hazard, and therefore regulations require that it must be covered with a material such as aluminum;
aluminum, however, is thermally very conductive. Further, molded structural foams which are "self skinning" (i.e., no metal skin is required) have such high densities that they offer very poor risistance to heat loss and they present a fire hazard. Other design materials that might theoretically solve the heating loss
2.

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lly,~/766- C
9,,~/77 ~07 4~7 4 1 problem within thc limitations set by the building codes are prohibitively expensive. I`hus, although energy efficiency has been a goal of skyligllt design for many years, until now competitive skylight constructions have not successfully solved the problem.
Accordingly, it is an object of this invention to achieve one or more of the preceding objects in a skylight construction in whic}l thc curb insulation is nearly as effective as the insulation of the roof.
It is a further object of this invention to achieve one or more of the preceding objects in a skylight construction which reduces air infiltration nearly to zero.
It is another object of this invention to achieve one or more of the preceding objects witll a skylight construction that meets code requirements for fire resistance.
It is a further object of this invention to achieve one or more of the preceding objects with a skyli~ht construction that meets code requirements of shape, strength and like qualities.
It is a further object of this invention to achieve one or more of the preceding objects with a skylight construction that meets functional quality requirements.
It is a further object of this invention to achieve one or more of the preceding objects with a skylight construction that has a pleasing appearance.
It is a further object of this invention to achieve one or more of the preceding objects with a skylight construction that can be produced at a competitive price.

Summary of the Invention According to the invention there is a skylight construc-tion for enclosing a building opening, of the type having a .

107497~

skylight cover secured to a curbing by means of a frame. The frame includes a flange means resting upon the curb assembly, support means at one end of the frame means for receiving and securing an edge of the skylight cover, and means disposed intermediate the ends of the frame means forming a trough for the collection and drainage of condensation from the coverO
Means are provided for securing the flange means of the frame means to the curb assembly, and means cooperating with the support means for retaining the cover in place.
A gasket covers the flange of the frame and extends downward to the interior shield of the curbing thereby closing the gap which exposes the cold underside of the flange and the outside shield to the warm, relatively moist, inside air. Preferably, the flange widens abruptly at its termina-ting edge to form a rim and the gasket comprises a C-shaped body which fits over the rim and which pxovides better insula-tion than a closely fitting gasket, and a downward and rearward projecting tail which closes the gap between the flange and the curb. The frame is pierced by drain openings which are covered by a filter material that is both absorptive of moisture and resistant to the passage of air. Preferably the filter material has a relatively large exposed external area and is located on the exterior of the frame. Preferably a "weld through sealant"
is used in the joint formed by the frame and curbing thereby sealing it when the preferred joining technique of spot welding is used.
~ umerous other features, objects and advantages of the invention will now become apparent from the following detailed description when read in connection with the accom-- 30 panying drawings, in which:

, lw3/?66-c I)M~/ads 9/ ~/77 107497~
1 FIC. 1 is a diagrammatic cross scctional illustration of a portion of the preferre~ em~o~imcnt of the inventio~
FIG. 2 is a cross sectional illustration of a portion f of the preferred embodiment of the frame;
FIG. 3 is an enlarged cross sectional illustration of the preferred embodiment oE the gasket; and FIG. 4 is a cross sectional view of the in~ention taken along line 4-4 of FIG. 1.

With reference now to the drawings and more particularly FIG. 1 thereof, there is shown a diagrammatic cross sectional illustration of a portion of the exemplary embodiment of the invention. Skylight cover 1 is secured by frame 2 to curbing 3.
In the embodiment shown the skylight cover is a double set of acrylic domes 6,7 separated by a layer of pre-molded butyl tape 9, and insulated from frame 2 by pre-molded butyl tape layers 10 and 11. In other embodiments of the invention the cover might be glass or other thermo-plastic domes, thermosetting flat reinforced plastic (commonly called fiberglass panels), extruded plastic shapes, etc. In a cross sectional illustration of the complete invention domes 6,7 would extend some distance to the right of FIG. 1 and the diagram shown in FIG. 1 would be repli-cated in reverse order at the far end of the domes. Domes 6, 7 are secured to frome 2 by retainer 12 held by screw 13. Curbing
3 comprises a highly energy efficient low density foam core 15 coYered by interior aluminum shield 16 and exterior aluminum shield 17 which are separated along the upper and lower surfaces of curbing 3 by gaps 18 and 19. Foam core 15 typically would have a density of from 1.5 to 2 lbs per cubic foot and the 30 aluminum is of a thickness of, for example, .025 inches to .032 inches. The edges of the interior shield may be break-formed oYer the foam to hold it in place. FIG. 1 shows one such securing 5.

' lW3/76~-C
l)M~/ads 9'-~3/77 107497~ i 1 tccniquc whercin edge rid~cs 21 and 22 hold the shield 16 to the core 15. This eliminates the cost of the welds usually required to engage the interior shield to the exterior shield at thc bottom. ~lso, this eliminates the cost and adverse appearance of the welds or fasteners usually required to join the interior shield to the frame. It should be noted that shields 16 and 17 could be replaced by a non-combustible foam surface or by rectangular, flat shects of metal mercly glued to the foam '~
without departing from the concept of the invention.
Referring now to FIG. 2, there is shown a cross sectional illustration of a portion of the preferred embodiment of the frame. The frame comprises a flange 25, downward ~.
protecting legs 28 and 29, screw channels 30, and cover support 31. The frame is composed of extruded aluminum in the preferred embodiment but may also be composed of extruded polyvinyl chloride plastic, extruded foam polyvinyl chloride plastic, etc.
Returning now to FIG. 1, frame 2 is shown secured to the exterior shield 17 which covers the outer portion of curbing 3. In the preferred embodiment, the frame is secured by a spot O weld approximately at point 33 although alternatively it may be secured by pop rivets or other Ineans. In the preferred embodi-ment a weld through sealant 34 is placed between the rame 2 and curbing 3 prior to spot welding. The pressure exerted by the spot welder compresses the sealant thus ensuring that air filtration will not occur at the joint formed by the frame and the curbing. Condensation gutter flange 25 extends inward across gap 19 and its inward portion is covered by gasket 38.
Referring now to FIG. 3 there is shown an enlarged cross sectional illustration of the preferred embodiment of the gasket 38 which comprises a C-shaped body 40 and a downward and rearward projecting tail 41. Gasket 38 is preferably composed of poly-vinyl chloride weather strip molding.
6.

lW3~766-C
~MD/ads 9l13/77 1074~7~

1 Returning to ~IG. 1, gasket 38 is shown to fit over flange rim 26. Gasket 38 and particularly gasket tail 41 close the gap between the flange 25 alld the interior shield 16 thereby preventing condensation from occurring on the underside of the flange or on thc inner edge of the outside shield. The frame is first welded to the outside shield 17 at point 33 and then gasket 38 is engaged with the rim 26 of the frame. The frame is formed with a step near the rim end for permitting clearance of the gasket 38 and the tail 41 is sufficiently long to form a tight fit against the top surface of the shield 16. The insulating core is then placed in tlle inside shield. The inside surface of the outside shield 17 is then coated with adhesive, and the inside shield 16, with insulating core, is pushed in place until the top of the inside shield touches projecting tail 41 of gasket 38.
Drain openings 50 (see FIGS. 1 and 4) are regularly spaced along the frame 2 in order to discharge condensation water collected in frame gutter 51 to the outside. In accordance with the invention,filter material 52, that is both absorbtive of moisture and resistive to the passage of air, is placed over the ~0 end of drain opening 50. In the preferred embodimen~ of the invention the filter material covers drain holes 50 and is held in place by rigid metal screen 54 attached to frame legs 28 and 29. Filter material 52 is preferably a fibrous material consisting of glass or plastic fibers which are designed to accomodate water passage such as polyvinyl chlorids, urethane, etc. can also be used when protected with a coating to permit continued exposure to water. An important feature of the invention is that this filter material absorbs the moisture from the condensation gutter 51 by capillary action, but provides a positive resistance to air filtration (out or in). Filter material 52 has a relatively large exposed external area to facilitate evaporation. FIG. 4 7.

11~3/7~G-C

~M~/ads 107497~

l shows a view of the filtcr matcrial takcn through scction 4-4 of ~IG. 1 showing that in thc l-rercrrcd embodiment of the invention the filter matcrial is exposcd to the outer atmosphere on three sides and is retaincd by means of a screening.
The unique method of co1~struction of the curbing described above is also an important fcature of the invention.
It eliminates conductiorl oÇ hc.lt throug}l the mctal from the inside to the outside o the curb. T}lis enormously reduces heat losses and moreover, virtually eliminates the condensation which occurs on the interior walls of skylight units of conventional design.
~i The unique flange and gasketing arrangement is another important feature of the invention which contributes to the elimination of through metal conductivity, and also serves to improve the durability of the skylight consturction. The gasket shields from condensation and heat pickup, not only the inside edge of the flange 25 but also the metal underside of the frame and the top edge of the exterior shield 17 which otherwise would be exposed to the interior air. The invention urethane foam O core 15 is glued to the shielding 17 ~ or alternative wall materials of the unit) as in conventional designs but need not be bonded to shield 16. The unique flange and gasketing arrange-ment permits the collection of condensation water off thc glasing while protecting the flange edge and underside from condensation.
All of the features of the invention described above work together to provide a thermally efficient skylight construc-tion that can be produced at a competitive price.
There has been described a novel skylight consturction that is energy efficient, meets code requirements for fire resistance, shape, strength, etc, and can be economically manufactured. It is evident that those skilled in the art may now make numerous uses and modifications of and departures from 8.

1~3/766-C
DMD/ads 9/14/77 1074~7~

1 the specific cml)o~ llcl-t dcsclil)c~ hcrcin without dcparting from the ;nventivc collcepts. ~onscqllcntly, thc invcntion is to be construed as embracin~ cach an~ cvcry novel feature and novel combination of featurcs prescnt in or possessed by the apparatus herein di,sclosed.
This application is a division of application Serial No. 287,750 filed September 29, 1977.

''~ c :
, ~

' ' '

Claims (5)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. In a skylight construction having a skylight cover secured to an annular curb assembly, a frame means for supporting the skylight cover over the curb assembly including flange means resting upon the curb assembly, support means at one end of the frame means for receiving and securing an edge of the skylight cover, and means disposed intermediate the ends of the frame means forming a trough for the collection and drainage of condensation from the cover, means for securing the flange means of the frame means to the curb assembly, and means cooperating with the support means for retaining the cover in place.
2. A skylight construction in accordance with claim 1, wherein said frame means has a step at least in part defining the trough and terminating in a free end, and gasket means having one side interlocked with the free end and another end bearing against the curb assembly.
3. A skylight construction in accordance with claim 2, wherein the gasket means is heat insulating and moist air isolating.
4. A skylight construction in accordance with claim 1, wherein said support means includes a platform extending over the trough, said trough having openings therein to permit water drainage.
5. A skylight construction in accordance with claim 3, wherein said retaining means comprises a retainer with the edge of the cover sandwiched between the retainer and platform.
CA331,800A 1977-09-29 1979-07-13 Energy efficient skylight construction Expired CA1074974A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA331,800A CA1074974A (en) 1977-09-29 1979-07-13 Energy efficient skylight construction

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA287,750A CA1074973A (en) 1977-09-29 1977-09-29 Energy efficient skylight construction
CA331,800A CA1074974A (en) 1977-09-29 1979-07-13 Energy efficient skylight construction

Publications (1)

Publication Number Publication Date
CA1074974A true CA1074974A (en) 1980-04-08

Family

ID=25668575

Family Applications (1)

Application Number Title Priority Date Filing Date
CA331,800A Expired CA1074974A (en) 1977-09-29 1979-07-13 Energy efficient skylight construction

Country Status (1)

Country Link
CA (1) CA1074974A (en)

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