GB2275075A - Rooflight - Google Patents

Abstract

A rooflight is readily assembled from an elongate mounting member 20, a frame member, and a top member. The mounting member is secured to a support structure 40 in a roof, and the frame member 1 and top member 54 co-operate with each other to clamp the glazing panels 51, 52 in the rooflight. The mounting members may be mounted on the support structure to form a sub-frame, and the frame members, glazing panels and top members together form an upper glazed structure which is adapted to be secured to the sub-frame. Fig. 3 illustrates a rooflight in which the frame member is hinged to the mounting member. <IMAGE>

Description

TITLE: ROOFLIGHT The present invention relates to a set of components for constructing a roof light, notably a free standing rooflight having a simplified construction, and to a method for assembling the rooflight in situ at the locus of use.

BACKGROUND TO THE INVENTION: Free standing rooflights or ventilators typically comprise a frame, typically a square or rectangular plan shape frame, onto which a top glazed unit is mounted to form the window or closure to the aperture defined by the frame. The frame is fitted into the aperture in the roof which the rooflight or ventilator is to serve. This frame can be made on site from wood by a builder as a modification to an existing roof or whilst the roof structure of a new roof is being built.

However, it is preferable that the frame be manufactured by the manufacturer of the glazed top portion of the rooflight so that the frame and glazed top unit are compatible and manufactured to the same tolerances and standards.

Typically, the frame has been made from aluminium or a structural plastic and the glazed top unit secured to that frame to form a unitary construction. It has also been proposed that the top glazed unit be secured to the frame by snap fasteners and/or sprung toggles or the like carried by the frame or top unit which engage a flange carried by the other member.

Hitherto, such structures have been made from different shapes of metal or plastic extrusion for each type of rooflight, which incurs excessive tooling costs and limits the freedom of a user to repair the rooflight, once installed, since the fastening of the top glazed unit to the frame does not readily permit disassembly of the rooflight, for example to replace a broken glazing panel.

We have now devised a form of construction which can be readily assembled from a set of standard components or by simple modification of one of those standard components to enable different forms of rooflight to be made either on site or under factory conditions with reduced tooling costs and simplified construction. The invention also provides a method for assembling the rooflight on site with reduced risk of damage of the top glazed unit.

SUMMARY OF THE INVENTION: The present invention provides a set of components adapted to inter-engage with one another to form a glazing support assembly adapted to support one or more glazing panels or members, which glazing support assembly is adapted to be secured to a support structure to form part of a rooflight assembly, characterised in that the set of components comprises: a) an axially elongate mounting member, b) an axially elongate frame member, and c) a top member; the frame member being capable of being modified so as to be adapted to be secured to the mounting member, and the mounting member being adapted to be secured to the support structure; wherein the frame member is adapted to form a side member of the glazing support assembly, one of either the mounting member or the frame member including a channel, the other including a first box section member adapted to be received in the channel, the frame member carrying means for engaging and locating the glazing panel(s) or member(s) to be carried by the glazing support assembly, and carrying one or more means by which the top member can be removably secured to the frame member in engagement with the glazing panel(s) or member(s) so as to secure the glazing panel or member between the frame member and the top member.

Preferably the frame member acts as the main structural member of the glazing support assembly.

A plurality of sets of components may be used in the construction of a roof light.

It is preferred that the mounting member is in the form of a channel and the frame member comprises a first box section which is capable of being modified to be adapted to be received in this channel.

A seal may optionally be provided in the bottom wall of the first box section so that a substantially water-tight seal is formed when the frame member is secured to the mounting member.

In a first embodiment the frame member is adapted to be secured to the mounting member by means of inter-engaging snap fit members. Preferably, the snap fit members are in the form of co-operating lug members. Arrow head snap fasteners, or other suitable forms of snap fasteners may, however, also be used.

Alternatively, in a second embodiment the frame member may be secured to the mounting member by means of a hinge member, so that the frame member may be pivoted with respect to the mounting member when it is desired, for example, to open the roof light.

Where the frame member is secured to the mounting member by means of a hinge member, it is preferred that the hinge member carry an axial bead which is a sliding fit into a groove formed in or on a wall of the mounting member. The hinge member may be secured to a wall of the frame member by any suitable means, for example adhesive, rivets, or screws.

In a preferred embodiment, the frame member is provided with a second box section member which extends along the operatively outward facing side of the frame member, part or all of the outward facing wall of the second box section member being adapted to be cut away or otherwise removed, either to expose an engagement member for the snap fit engagement of the frame member with the mounting member as set forth above, or to provide a partially or wholly open bottom to the second box section member to permit the fitting of an axial hinge member adapted to connect the frame member pivotally to the mounting member.

Where the component members are formed by extruding a suitable solid or closed pore resin, the walls of the second box member can readily be cut away by a knife, saw, hot wire, water jet or air blade or other means so that the frame member can be modified to provide a snap fit or hinged mounting of the frame member upon the mounting member.

Preferably, the frame member and the top member engage the periphery of the glazing member(s) or panel(s).

The set of components of the invention thus enables a rooflight manufacturer to construct a fixed glazing roof light merely by cutting away part of the outer side wall of the second box section member, or to construct a hinged glazing roof light by cutting away the outer edges of the second box section member. Alternatively, a sliding version of the rooflight may be contructed by cutting away the appropriate parts of the frame members at the corner of the frame constructed from those members. These variations can be achieved without the need to modify other components of the frame and mounting, thus enabling a wide range of structures to be built from standard components.Since the top member is demountably secured to the frame member, the most frequent need for repair, namely a broken glazing unit or member, can be readily carried out without the need to cut away or otherwise damage other components of the frame, as is necessary with current designs of rooflights.

The set of components is preferably formed so as to be secured to a support structure in the form of a lower frame or upstand which is to be located in the structure of the roof and supports the roof light. Such a support structure is typically formed from an extruded aluminium or structural plastic and is provided with means at or adjacent its upper edge whereby the mounting member of the set of components of the invention can be affixed thereto, for example by means of inter-engagement of a radially extending flange carried by the lower frame with one or more co-operating flanges carried dependent from the mounting member.

The mounting member may also optionally be provided with one or more recesses for the attachment of clips or other means for retaining protective or decorative trim for the support structure. The trim may be of aluminium, plastics material, or any other suitable structural materials.

Typically the support structure has four edges which define a square or rectangular plan shape, and suitable lengths of elongate mounting member are mounted on each edge to form a sub-frame. The mounting members may be joined together by means of mitre joints, adhesive, or other techniques.

A frame of dimensions and shape matched to those of the sub frame is constructed by joining suitable lengths of elongate frame members together by means of mitre joints, adhesive, or other techniques. Similarly a plurality of top members of dimensions and shape matched to those of the sub-frame may be joined together to form a top clamping member.

Alternatively the top members may be separate from one another when in use for clamping the glazing member or members. The frame may be mounted on the sub-frame during construction in situ, and the rooflight then assembled by clamping a glazing panel or panels between the frame and the top member or members. Alternatively an upper glazed unit may be formed separately from the sub-frame, for example under factory conditions, by securing a glazing panel or panels to the assembled frame by means of the top member or members which clamp the glazing panels between the top member and the upper surface of the frame. Typically a spacer will be trapped between the glazing panels to ensure the desired spacing between the panels.Seals may optionally be provided between the glazing panels and the top member, and between the glazing panels and the frame to achieve a weatherproof seal and/or to accommodate variations in the thickness of the panels and variations in the dimensions of the various parts of the rooflight.

The mounting members can be mounted on the support structure to form a sub-frame which is installed on site, and any weatherproofing, flashing, or bitumen work required adjacent the sub-frame can be carried out before the upper glazed unit is snap fitted into place, or otherwise mounted upon the mounting member after the risk of dirt, bitumen or other damage to the glazing unit has passed.

Where the frame is a snap fit upon the sub-frame, part of the mounting members and/or the frame members can be cut away adjacent the corner of the assembly formed therefrom so as to permit the frame to slide upon the sub-frame.

The invention therefore also provides a rooflight comprising a) a sub-frame comprising a support structure having four edges defining a square or rectangular plan shape, and each edge having mounted on it a mounting member as hereinbefore described, b) an upper glazed unit comprising i) a frame of similar plan shape to the sub frame, constructed from elongate frame members as hereinbefore described, ii) one or more glazing panels, and iii) a plurality of top members, each of similar length to a corresponding frame member; wherein the glazing panel or panels are clamped between the frame and the top members, and wherein the upper glazed unit is mounted on the sub-frame.

The invention also provides a method for assembling a rooflight constructed from a set of the components of the invention, which method comprises mounting the mounting members in position upon the support structure to form a sub-frame, and thereafter snap fitting the remainder of the rooflight assembly to the sub-frame. Such a form of assembly is primarily applicable to a fixed glazing rooflight where no other form of fitting of the glazed upper portion to the mounting member is required.

Although it is preferred that the frame member be mounted on the mounting member by engagement of lugs on the mounting member with outwardly extending members carried by the frame member, it will be appreciated that the outwardly extending members and the associated first box section member can be carried by the mounting member and the lugs by the elongate frame member. In this case, it may be desirable to cut away the portions of the second box member required for the specific form of rooflight required once the potentially damaging bitumen or other weatherproofing work adjacent the sub-frame has been completed. In this way the interior of the second box member and the lips of the outwardly extending members are not exposed until immediately before they are required to be used.

DESCRIPTION OF THE DRAWINGS: To aid understanding of the invention, a preferred form thereof will be described by way of illustration with respect to the accompanying drawings in which: Figure 1 is a transverse section through an elongate frame member suitable for use in the invention; Figure 2 is a transverse section through a mounting member suitable for use in the invention; Figure 3 is a transverse section through an assembled rooflight in which the elongate frame member of Figure 1 is modified to be a snap fit into the mounting member of Figure 2; Figure 4 is a transverse section through an assembled rooflight in which the elongate frame member of Figure 1 is pivotally mounted upon the mounting member of Figure 2; Figure 5 is a transverse section through an alternative rooflight assembly similar to Figure 3; and Figure 6 is a transverse section through an alternative design of elongate frame member used in the construction of the rooflight assembly of Figure 5.

DESCRIPTION OF THE PREFERRED EMBODIMENT: The elongate frame member of Figure 1 comprises a first box section 8, a second box section 7, and a main upper box section 1. The main upper box section 1 has a sloping upper face 2 designed to shed any water draining from the glazing panels onto it radially outward. The face 2 carries two upstanding members 3 and 4 extending axially. The members 3 and 4 carry radially inwardly extending lugs 5 and 6 which engage as a snap fit with corresponding lugs carried by the top member as shown in Figures 3 and 4, so that the top member can be removably secured to the elongate frame member.

Below the main box section 1 are located respectively the first and second box sections 7 and 8 located parallel and alongside one another. The main box section 1 extends radially outwardly beyond the second box section 7 to provide an overhang 9 which can be perforated or can carry a perforated mesh 10 as shown in Figure 3. This provides a means for ventilating the volume under the glazing panel through a variable aperture control 11 shown in Figure 3.

Alternatively, the variable control 11 can be replaced by a mesh or series of apertures in the radially inward wall of box section 1 to give fixed ventilation.

The lower wall of the first box section 8 can be provided with a seal 16 which is mounted thereon, for example, by means of the axial lipped groove 12. This bottom wall forms the central portion of the axially extending outwardly extending member and carries along its edges the lugs 13 and 14 which are to secure the elongate frame member of Figure 1 to the mounting member of Figure 2. The lug 14 forms at least part of the bottom wall of the second box section 7 and extends to the axial wall 15 which is dependent from the overlying bottom wall of the main box section 1. The wall 15 and/or the lug 14 are to be removed for the assembly of the rooflight frame as described below and can be provided with lines of weakness or reduced thickness along the intended lines of cutting to facilitate manual cutting away of the wall or lip.

The mounting member comprises a double axial channel member 20 having radially inwardly projecting lugs 21 and 22 at or adjacent the axial walls 23 and 24 of the upper channel 25.

As shown, it is preferred to form the radially outward wall 23 with an axial circular or other recess 26a adapted to receive and retain part of any hinge mechanism which is used to secure the elongate frame member to the mounting member as shown in Figure 4. An additional axial circular recess 26b is provided on the side wall 30. The lower axial channel 27 is preferably also provided with inwardly projecting flanges 28 and 29 carried at or adjacent the lower lips of the side walls 30 and 31 forming the channel 27. These flanges are to engage with the top portion of a support structure as shown in Figures 3 and 4 by which the assembled rooflight is to be secured to the roof structure (not shown).

The elongate frame member and the mounting member can be made from a wide range of suitable materials, notably from a rigid closed pore structural plastic, for example a UPVC, using any suitable technique, preferably by extrusion of the thermoplastic resin.

In use, an mounting member 20 is slid onto each edge of the support structure 40 to form a sub-frame, and the mounting member 20 is held upon the support structure by the inter engagement of the flanges 28 and 29 with flanges and/or grooves 41 and 42 at or adjacent the upper edge of the support structure-40 as shown in Figure 3. Part of the wall 15 and/or the lug 14 forming the walls of the second box section 7 of the elongate frame member are cut away, for example by a saw or knife, depending upon the type of rooflight which is to be assembled. Thus, for a fixed glazing rooflight as shown in Figure 3, the wall 15 is cut away to leave the full radial extent of the lug 14 exposed for engagement with the lug 21 on the mounting member.

Here, the lower axial circular recess 26b has also been cut away. The first box section 8 can be provided with an axial metal or other stiffener 50 as shown to impart rigidity to the frame constructed by joining suitable lengths of the elongate frame member, for example using mitre joints and adhesive or other techniques, to form a square or rectangular plan shaped frame. A top member is mounted on a corresponding length of elongate frame member in the frame. Glazing panels 51 and 52 can be secured to the frame by means of the top member 53 which clamps the glazing panels between the top member and the upper face of the frame, typically with a spacer (not shown) trapped between the glazing panels to ensure the desired spacing between the panels.If desired, seals 60 and 61 can be carried by those portions of the top member and the elongate frame member where they engage the glazing panels to achieve a weatherproof seal and/or to accommodate variations in the thickness of the panels and variations in the dimensions of the various parts of the rooflight.

The top member is preferably provided with an outer portion 54, which is downwardly curved to provide a protective cowl to the outer edge of the rooflight assembly. The lower face of the top member carries downwardly projecting lugs 55 and 56 which are a snap fit engagement with the lugs 5 and 6 carried by the top face of the elongate frame member so that the top member is removable from the elongate frame member to enable a glazing panel to be removed and replaced.

The upper glazed unit comprising the frame formed from the lengths of elongate frame member, the top members and the glazing panels can be manufactured under factory clean conditions and retained wrapped against damage until required to be fitted to the sub-frame in the roof structure which has the mounting member 20 exposed at its upper edge.

The unit is then unwrapped to expose the lugs 13 and 14 and snap fitted into the mounting member.

In the alternative shown in Figure 4, the sub-frame and glazed unit are made in the same manner as just described, except that lugs 14 and 13 are removed from the lower wall of the elongate frame member of Figure 1. Wall 15 of box section 7 can be retained to provide a channel into which a hinge member can be push fitted, the hinge member carrying an axial bead which is a sliding fit into to groove 26 formed in side wall 23 of the mounting member.

Alternatively, the wall 15 can be removed as well and the hinge member secured, for example by adhesive, rivets or screws to the exposed outer face of the first box section 8 as shown in Figure 4.

In an alternative embodiment shown in Figure 5, the side wall 30 of the mounting member is provided with a recess 62 to facilitate attachment of, for example, a clip to retain an aluminium trim or protective strip for the side upstand member 40. The second axial circular recess 26b is retained to allow, for example, for an alternative hinge location.

In this embodiment, the interconnecting lugs 5, 6 on the upper box section 1 and the lugs 55, 56 on the the cowl 54 are replaced respectively by recesses 70, 72 on the box 1 and by arrow head snap fastners 66, 68 on the cowl 54, which may facilitate location and attachment of the cowl to the frame member. The seal 16 between the first box section 8 and the mounting member 20 is provided with lateral fins 64 which help to reduce displacement of the seal 16 during assembly of the rooflight. Although this embodiment is illustrated with reference to a seal 16 which is provided with fins 64, the fins are not essential to the operation of the rooflight, and a seal 16 without fins 64, as illustrated in Figures 3 and 4, may also be employed.

Thus, from a single set of extrusions providing the elongate frame member, the mounting member and the top member, it is possible to construct a number of different types of rooflight merely by cutting away part of all of the wall 15 and lug 14 of the box section 7. This simplifies the instructions required for the manufacture of the rooflight and requires the manufacture of only three types of extrusion, thus reducing tooling costs.

Figure 6 shows an alternative design of elongate frame member, which is used in the construction of the rooflight assembly shown in Figure 5. The upper box section 1 is provided with recesses 70, 72 for receiving arrow head snap fasteners, and the lug 14 is ready formed, removing the need to cut away part of the wall of a second box section.

It will be understood that the members shown in the drawings are for illustrative purposes only, and the invention is not limited to these embodiments. Many minor variants on the basic design may readily be devised within the scope of the invention.

Claims (13)

1 A set of components adapted to inter-engage with one another to form a glazing support assembly adapted to support one or more glazing panels or members, which glazing support assembly is adapted to be secured to a support structure to form a rooflight assembly, characterised in that the set of components comprises: a) an axially elongate mounting member, b) an axially elongate frame member, and c) a top member; the frame member being capable of being modified so as to be adapted to be secured to the mounting member, and the mounting member being adapted to be secured to the support structure; wherein the frame member is adapted to form a side member of the glazing support assembly, one of either the mounting member or the frame member including a channel, the other including a first box section member adapted to be received in the channel, the frame member carrying means for engaging and locating the glazing panel(s) or member(s) to be carried by the glazing support assembly, and carrying one or more means by which the top member can be removably secured to the frame member in engagement with the glazing panel(s) or member(s) so as to secure the glazing panel or member between the frame member and the top member.

2 A set of components as claimed in claim 1, wherein the mounting member is in the form of a channel and the frame member comprises a first box section which is adaptable to be received in this channel.

3 A set of components as claimed in claim 1 or claim 2, wherein the frame member is provided with a second box section member which extends along the operatively outward facing side of the frame member, part or all of the outward facing wall of the second box section member being adapted to be cut away either to expose an engagement member for snap fit engagement with the mounting member, or to provide a partially or wholly open bottom to the second box section member to permit the fitting of an axial hinge member adapted to connect the frame member pivotally to the mounting member.

4 A set of components as claimed in any one of the preceding claims, wherein the frame member is adapted to be secured to the mounting member by means of inter-engaging snap fit members.

5 A set of components as claimed in claim 4, wherein the snap fit members are in the form of co-operating lug members.

6 A set of components as claimed in any one of claims 1 to 3 wherein the frame member is adapted to be secured to the mounting member by means of a hinge member, so that the frame member may be pivoted with respect to the mounting member.

7 A set of components as claimed in claim 6, wherein the hinge member carries an axial bead which is a sliding fit into a groove formed in or on a wall of the mounting member.

8 A set of components as claimed in any one of the preceding claims, wherein the frame member and the top member are adapted to engage the periphery of the glazing member(s) or panel(s).

9 A set of components as claimed in any one of the preceding claims, wherein the mounting member is provided with one or more recesses for the attachment of clips or other means for retaining protective or decorative trim for the support structure.

10 A rooflight comprising a) a sub-frame comprising a support structure having four edges defining a square or rectangular plan shape, and each edge having mounted on it a mounting member as hereinbefore described, b) an upper glazed unit comprising i) a top member as hereinbefore described, of similar plan shape to the sub-frame, ii) one or more glazing panels, and iii) a frame of similar plan shape to the sub frame, constructed from elongate frame members as hereinbefore described, wherein the glazing panel or panels are clamped between the frame and the top member, and wherein the upper glazed unit is mounted on the sub-frame.

11 A roof light as claimed in claim 10, wherein part of the mounting members and/or the frame members are cut away so as to permit the frame to slide upon the sub-frame.

12 A method of assembling a rooflight from sets of components as claimed in claim 1, comprising the steps of mounting the mounting members to form on the support structure to form a sub-frame, and thereafter snap fitting the remainder of the rooflight assembly to the mounting members.

13 A set of components substantially as hereinbefore described with reference to and as shown in any one embodiment of the drawings.