US20100139186A1 - Skylight with curb design - Google Patents
Skylight with curb design Download PDFInfo
- Publication number
- US20100139186A1 US20100139186A1 US12/328,394 US32839408A US2010139186A1 US 20100139186 A1 US20100139186 A1 US 20100139186A1 US 32839408 A US32839408 A US 32839408A US 2010139186 A1 US2010139186 A1 US 2010139186A1
- Authority
- US
- United States
- Prior art keywords
- curb
- layer
- fastener
- skylight
- receiving
- 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.)
- Abandoned
Links
- 238000009413 insulation Methods 0.000 claims abstract description 7
- 229920000877 Melamine resin Polymers 0.000 claims abstract description 5
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims abstract description 5
- 239000006260 foam Substances 0.000 claims description 15
- 239000002023 wood Substances 0.000 claims description 11
- 229920000642 polymer Polymers 0.000 claims 2
- 229920006248 expandable polystyrene Polymers 0.000 claims 1
- 229920002457 flexible plastic Polymers 0.000 claims 1
- 239000000758 substrate Substances 0.000 claims 1
- 229920006327 polystyrene foam Polymers 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 9
- 239000012528 membrane Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- AXOXZJJMUVSZQY-BVDKBYOBSA-N sip 20 Chemical compound C([C@@H](C(=O)N[C@H](C(=O)N[C@@H](C)C(=O)N[C@@H](CO)C(=O)NCC(=O)N[C@@H](CCCNC(N)=N)C(=O)N[C@H](C(=O)NCC(=O)N[C@@H](CCCNC(N)=N)C(=O)N[C@@H](CCCNC(N)=N)C(=O)N[C@@H](CC(N)=O)C(=O)N[C@@H](C)C(=O)N[C@@H]([C@@H](C)CC)C(=O)N[C@@H](CC=1NC=NC=1)C(=O)N[C@@H](CC(O)=O)C(O)=O)C(C)O)[C@@H](C)CC)NC(=O)[C@H](CC(O)=O)NC(=O)[C@H](C)NC(=O)[C@H](CC=1C=CC(O)=CC=1)NC(=O)[C@@H](NC(=O)[C@@H](N)C(C)O)C(C)O)C1=CC=CC=C1 AXOXZJJMUVSZQY-BVDKBYOBSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000004591 urethane sealant Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/03—Sky-lights; Domes; Ventilating sky-lights
- E04D13/0305—Supports or connecting means for sky-lights of flat or domed shape
- E04D13/0315—Supports or connecting means for sky-lights of flat or domed shape characterised by a curb frame
Definitions
- Skylights can be applied to a roof deck using several installation methods. Certain skylights are supported on a curb which raises the skylight above the surface of the roof.
- Foam insulated curbs have been utilized, such as those disclosed, for example, in Kiekhaefer U.S. Pat. No. 3,417,522; Jentoft et al. U.S. Pat. No. 4,073,097; and Moench et al. U.S. Pat. No. 4,233,493, as well as several others.
- these foam insulated curb structures are unitary structures formed in a mold. They may have limited structural integrity and, further, require a separate mold for each different size skylight. Further, since they are unitary in structure, they use a large amount of space during shipping and are difficult to transport and use at the construction site.
- curbing such as simply dimensional lumber, such as 2 ⁇ 6's, and the like. These are difficult to assemble on site and, further, lend themselves to irregularities in size and variations in plumb. Further, the wood itself provides less than adequate thermal insulation, making the curb only minimally efficient portion of the skylight.
- a skylight curb can be formed from structural insulated panels (SIP). More particularly, the structural insulated panels take the form of elongated plank components with an outer fastener engaging portion and an inner finish portion and an intermediate foam core. The edge structures of each of these planks are designed to provide for easy assembly.
- An edge of a first SIP plank includes a fastener-receiving insert at the end of the foam core, while the adjacent edge of a second SIP plank includes an elongated fastener-receiving portion, or wood portion, which overlaps the first SIP plank, allowing the two to be screwed together forming a precise 90° angle.
- Four SIP planks are fastened together to form a curb.
- FIG. 2 is a view of the curb shown in FIG. 1 prior to assembly
- FIG. 3 is an exploded view of a skylight incorporating the curb of the present invention.
- FIG. 5 is a cross sectional view taken at lines 5 - 5 of FIG. 4 .
- a skylight assembly 10 located on roof surface 12 includes a rectangular curb 14 surrounded by flashing 16 with a skylight 18 resting above the flashing and the curb.
- the curb 14 is formed from structural insulated panels or SIPs 20 , 22 , 24 and 26 .
- the SIPs each include an outer portion or layer 28 which is designed to receive and hold a fastener, a central foam portion or layer 30 and an inner finished portion or layer 32 .
- the length of the SIPs is determined by the size of the skylight while the height can be about 9 inches or more.
- the outer portion 28 can be formed from any material that will receive and hold a fastener. Typically, it will be a wood based material such as plywood, particle board or OSB or metal. In particular, OSB having a thickness of from about 1 ⁇ 4 inch to about 3 ⁇ 4 inch can be used, and, in particular, OSB having a thickness of about 1 ⁇ 2 inch to 7/16 inch provides adequate structural integrity. To provide fire retardance a layer of dry wall (not shown) can cover the OSB.
- the inner portion 32 provides a finished interior surface. It is not designed to be penetrated by any fastener and it is preferable to utilize a material that provides some structural strength to the SIP.
- a solid, non-foam plastic or polymeric material is suitable.
- melamine coated masonite material having a smooth innermost surface can be used in the present invention.
- Other materials which are suitable for interior portion 32 include, for example, wood having a finished surface, such as stained or painted wood, as well as other polymeric materials. Any material that does not require additional finishing facilitates installation and reduces expenses.
- the SIP itself is formed by simply bonding the three layers together. This is generally done in a factory so that the SIP is structurally sound and dimensionally precise.
- Flashing 16 is then applied over the curb surface.
- the flashing can be either a continuous strip of flexible flashing, generally with a preapplied adhesive, or can be a preformed unitary structure configured to fit directly over the curb 14 .
- the flashing 16 extends from the top surface 62 of curb 14 over the side 28 covering the L-brackets with a bottom edge 64 adhered to the membrane 56 .
- the flashing is simply adhered to the curb and to the roofing structure with a preapplied adhesive.
- the skylight 18 is then applied to the upper edge 62 of the curb utilizing a urethane sealant 66 .
- the skylight incorporates an integral condensate grill 68 around the inner peripheral edge of the curb adhered to the skylight with an adhesive bonding tape 70 .
- the outer rim 72 of the skylight is then fastened to the side walls 28 of the curb, again with screws 74 .
- the skylight structure 10 of the present invention provides several advantages.
- the insulating factor of the SIP is extremely high due to the insulating foam core.
- the SIP also provides significant rigidity.
- the curb assembly can be brought to the roof in sections and assembled at the roof, construction costs are reduced. Due to the structure of the curb assembly, assembling the curb structure on the roof is relatively simple, requiring only tools that would be with the builder at the time.
- the screwed butt-joined panel edges are designed to provide precise 90° angles. Further, the maintenance free interior with the white melamine coated masonite curb liner 32 provides a finished inner surface that requires no additional trim.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
A skylight assembly includes a curb which supports the skylight above the roof surface. The curb is formed from four mechanically connected structural insulated panels. The panels include an outer fastener-receiving member such as OSB with an intermediate polystyrene foam layer and an innermost melamine layer. The curb is assembled on site and fastened to the roof structure with brackets. The melamine surface provides a finished interior surface and the curb itself provides thermal insulation.
Description
- Skylights can be applied to a roof deck using several installation methods. Certain skylights are supported on a curb which raises the skylight above the surface of the roof.
- Foam insulated curbs have been utilized, such as those disclosed, for example, in Kiekhaefer U.S. Pat. No. 3,417,522; Jentoft et al. U.S. Pat. No. 4,073,097; and Moench et al. U.S. Pat. No. 4,233,493, as well as several others. Generally, these foam insulated curb structures are unitary structures formed in a mold. They may have limited structural integrity and, further, require a separate mold for each different size skylight. Further, since they are unitary in structure, they use a large amount of space during shipping and are difficult to transport and use at the construction site.
- Other structures have been used to form curbing, such as simply dimensional lumber, such as 2×6's, and the like. These are difficult to assemble on site and, further, lend themselves to irregularities in size and variations in plumb. Further, the wood itself provides less than adequate thermal insulation, making the curb only minimally efficient portion of the skylight.
- The present invention is premised on the realization that a skylight curb can be formed from structural insulated panels (SIP). More particularly, the structural insulated panels take the form of elongated plank components with an outer fastener engaging portion and an inner finish portion and an intermediate foam core. The edge structures of each of these planks are designed to provide for easy assembly. An edge of a first SIP plank includes a fastener-receiving insert at the end of the foam core, while the adjacent edge of a second SIP plank includes an elongated fastener-receiving portion, or wood portion, which overlaps the first SIP plank, allowing the two to be screwed together forming a precise 90° angle. Four SIP planks are fastened together to form a curb.
- The formed rectangular curb structure can then be fastened to a roof substructure using L-brackets, or other similar brackets. A water tight seal between the curb and roof membrane is formed using flexible flashing. Finally, the skylight is simply placed on top of the curb structure laid on a bead of waterproofing sealant and fastened into place.
- The objects and advantages of the present invention will be further appreciated in light of the following detailed descriptions and drawings in which:
-
FIG. 1 is a perspective view of a skylight curb according to the present invention; -
FIG. 2 is a view of the curb shown inFIG. 1 prior to assembly; -
FIG. 3 is an exploded view of a skylight incorporating the curb of the present invention; -
FIG. 4 is a perspective view of a skylight that incorporates the curb of the present invention; and -
FIG. 5 is a cross sectional view taken at lines 5-5 ofFIG. 4 . - As shown in
FIG. 4 , askylight assembly 10 located onroof surface 12 includes arectangular curb 14 surrounded by flashing 16 with askylight 18 resting above the flashing and the curb. - The
curb 14 is formed from structural insulated panels orSIPs layer 28 which is designed to receive and hold a fastener, a central foam portion orlayer 30 and an inner finished portion orlayer 32. The length of the SIPs is determined by the size of the skylight while the height can be about 9 inches or more. - The
outer portion 28 can be formed from any material that will receive and hold a fastener. Typically, it will be a wood based material such as plywood, particle board or OSB or metal. In particular, OSB having a thickness of from about ¼ inch to about ¾ inch can be used, and, in particular, OSB having a thickness of about ½ inch to 7/16 inch provides adequate structural integrity. To provide fire retardance a layer of dry wall (not shown) can cover the OSB. - The foam core is designed to provide insulation and is preferably a rigid foam such as polystyrene foam. It can have any thickness designed to achieve the requisite insulation. Insulation having a thickness of 1 to 5 inches can be used, with polystyrene insulation of 3 to 4 inches generally being considered as adequate, and, in particular, 3⅝ inch expanded polystyrene foam is suitable for use in the present invention.
- The
inner portion 32 provides a finished interior surface. It is not designed to be penetrated by any fastener and it is preferable to utilize a material that provides some structural strength to the SIP. In particular, a solid, non-foam plastic or polymeric material is suitable. In particular, melamine coated masonite material having a smooth innermost surface can be used in the present invention. Other materials which are suitable forinterior portion 32 include, for example, wood having a finished surface, such as stained or painted wood, as well as other polymeric materials. Any material that does not require additional finishing facilitates installation and reduces expenses. - The SIP itself is formed by simply bonding the three layers together. This is generally done in a factory so that the SIP is structurally sound and dimensionally precise.
- As shown,
SIPs SIPs corners 34. The end structures of the SIPs are designed to facilitate formation of thesecorners 34.SIPs end portion 36 of theouter portion 28, which extends beyond theends SIPs ends wood insert 44 at the distal ends of thefoam portion 30 wherein the wood insert is coextensive with theends portion 28 and the inner finishedportion 32. - The
corners 34 are assembled by simply fixing anend portion 36 ofSIP end 50 ofSIP 26 and insertingscrews 52 through the extendedportion 36 into thewood insert 44. As the wood insert is tightly bound to the SIP, this holds the entire structure together forming a very precise 90° angle. The assembledcurb 14, as shown inFIG. 1 andFIG. 3 , is then placed on a roof surface surrounding anopening 54 in theroof surface 12.Membrane roof material 56 is then applied over theroof surface 12 and the curb is fastened to the roof surface with L-brackets 58 fastened to theside wall 28 ofcurb 14 withscrews 60 extending through the brackets to the fastener-receivingouter surface 28 of theSIPs brackets 58 are then fastened to the roof surface withscrews 60 extending through the L-bracket into theroof surface 12. - Flashing 16 is then applied over the curb surface. The flashing can be either a continuous strip of flexible flashing, generally with a preapplied adhesive, or can be a preformed unitary structure configured to fit directly over the
curb 14. The flashing 16 extends from thetop surface 62 ofcurb 14 over theside 28 covering the L-brackets with abottom edge 64 adhered to themembrane 56. - Preferably, the flashing is simply adhered to the curb and to the roofing structure with a preapplied adhesive. The
skylight 18 is then applied to theupper edge 62 of the curb utilizing aurethane sealant 66. As shown, the skylight incorporates anintegral condensate grill 68 around the inner peripheral edge of the curb adhered to the skylight with anadhesive bonding tape 70. Theouter rim 72 of the skylight is then fastened to theside walls 28 of the curb, again with screws 74. - The
skylight structure 10 of the present invention provides several advantages. The insulating factor of the SIP is extremely high due to the insulating foam core. The SIP also provides significant rigidity. Further, because the curb assembly can be brought to the roof in sections and assembled at the roof, construction costs are reduced. Due to the structure of the curb assembly, assembling the curb structure on the roof is relatively simple, requiring only tools that would be with the builder at the time. The screwed butt-joined panel edges are designed to provide precise 90° angles. Further, the maintenance free interior with the white melamine coatedmasonite curb liner 32 provides a finished inner surface that requires no additional trim. - The risk of cutting the membrane is reduced because no metal flashing is employed, yet the curb and skylight assembly are firmly fixed to the roof using simple L-brackets. Finally, the overall cost of production is significantly reduced. Because the SIPs can be formed without a separate mold, virtually any size skylight can be utilized simply by changing the length of the SIPs.
- This has been a description of the present invention along with the preferred method of practicing the present invention wherein the invention itself should only be defined by the appended claims.
Claims (12)
1. A skylight curb comprising four structural insulated panels connected to each other at four corners;
each panel comprising an outer fastener-receiving layer adhered to an inner rigid foam layer bonded to an innermost layer having a finished surface;
each corner formed from interconnected first ends of one of said SIPs mechanically fastened to second ends of one of said SIPs wherein said first ends include an extended portion of said fastener-receiving layer extended beyond ends of said insulated layer and said finished layer, said second ends including fastener-receiving inserts adjacent an end of said insulated layer;
mechanically fastened fasteners extended through said extended portion into said insert forming corners having 90° angles.
2. The curb claimed in claim 1 wherein said finished surface comprises a polymer.
3. The curb claimed in claim 2 wherein said polymer comprises melamine.
4. the curb claimed in claim 1 wherein said fastener-receiving surface comprises wood.
5. The curb claimed in claim 4 wherein said fastener-receiving surface comprises particleboard.
6. The curb claimed in claim 4 wherein said fastener-receiving surface comprises OSB.
7. The curb claimed in claim 1 wherein said insulation layer comprises foamed polystyrene.
8. The curb claimed in claim 1 wherein said insert comprises wood.
9. The curb claimed in claim 1 wherein the frame is fixed to a roof substrate by brackets.
10. The curb surface claimed in claim 9 wherein flexible flashing is fixed to a top edge of said curb and an outer section of said curb and along said bottom edge of said curb.
11. the structure claimed in claim 10 further comprising a skylight fixed over said flashing.
12. A skylight assembly comprising four separate curb members each curb member comprising an outer fastener-receiving layer adhered to a rigid foam layer, in turn adhered to an inner finished layer;
said panels assembled together at four corners;
each corner formed from interconnected first ends of one of said SIPs mechanically fastened to a second ends of one of said SIPs wherein said first end have an extended portion of said fastener-receiving layer extended beyond ends of said foam layer and said finished layer and wherein said second ends have fastener-receiving inserts adjacent an end of said foam layer wherein said four panels are assembled together at 90° angles;
said curb fastened to a roof surface with a plurality of L-brackets fastened to said fastener-receiving surface of said curb members;
a flexible plastic flashing member surrounding said curb member;
and a skylight assembly fastened to an upper edge of said curb member.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/328,394 US20100139186A1 (en) | 2008-12-04 | 2008-12-04 | Skylight with curb design |
CA2660236A CA2660236A1 (en) | 2008-12-04 | 2009-03-26 | Skylight with curb design |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/328,394 US20100139186A1 (en) | 2008-12-04 | 2008-12-04 | Skylight with curb design |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100139186A1 true US20100139186A1 (en) | 2010-06-10 |
Family
ID=42229342
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/328,394 Abandoned US20100139186A1 (en) | 2008-12-04 | 2008-12-04 | Skylight with curb design |
Country Status (2)
Country | Link |
---|---|
US (1) | US20100139186A1 (en) |
CA (1) | CA2660236A1 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120174506A1 (en) * | 2011-01-11 | 2012-07-12 | US Sunlight Inc. | Method and Apparatus for Skylight Tube |
US20120216464A1 (en) * | 2009-11-12 | 2012-08-30 | Stefano Bonapace | Device for protecting door or window closure elements for roofs or the like against atmospheric precipitation |
US8943767B2 (en) * | 2013-03-11 | 2015-02-03 | David L. Lewis | Cover device and cover device kit |
US9016016B2 (en) | 2013-03-04 | 2015-04-28 | Duane G Den Adel | Insulated perimeter roof curb |
US20150275565A1 (en) * | 2012-10-08 | 2015-10-01 | Rockwool International A/S | Window monitoring system |
US20160153185A1 (en) * | 2013-07-05 | 2016-06-02 | Rockwool International A/S | A corner bracket, a bracket system, use of such a corner bracket, a window mounting collar and a window mounting system |
DE202016101133U1 (en) * | 2016-03-02 | 2017-06-06 | Essmann Gmbh | Curbs |
US9933183B1 (en) | 2017-11-01 | 2018-04-03 | Duane Den Adel | Dynamic insulated roof curbs for use with mechanical units |
US20180340336A1 (en) * | 2017-05-25 | 2018-11-29 | Todd Fischer | Bracket Cover Flashing System and Method fo Use |
USD886327S1 (en) * | 2017-06-09 | 2020-06-02 | Dometic Sweden Ab | Skylight dome |
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- 2008-12-04 US US12/328,394 patent/US20100139186A1/en not_active Abandoned
-
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- 2009-03-26 CA CA2660236A patent/CA2660236A1/en not_active Abandoned
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US6444073B1 (en) * | 1997-04-25 | 2002-09-03 | Brunswick Corporation | Thermoplastic multi-layer composite structure |
US5960596A (en) * | 1998-06-23 | 1999-10-05 | The Bilco Company | Roofing mechanism |
US7296388B2 (en) * | 2003-08-12 | 2007-11-20 | Valentz Arthur J | Skylight having a molded plastic frame |
US20080282632A1 (en) * | 2007-05-15 | 2008-11-20 | Sleeman William R | Composite building panel |
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US20120174506A1 (en) * | 2011-01-11 | 2012-07-12 | US Sunlight Inc. | Method and Apparatus for Skylight Tube |
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US9593524B2 (en) * | 2012-10-08 | 2017-03-14 | Rockwool International A/S | Window mounting system |
US9016016B2 (en) | 2013-03-04 | 2015-04-28 | Duane G Den Adel | Insulated perimeter roof curb |
US8943767B2 (en) * | 2013-03-11 | 2015-02-03 | David L. Lewis | Cover device and cover device kit |
US20160153185A1 (en) * | 2013-07-05 | 2016-06-02 | Rockwool International A/S | A corner bracket, a bracket system, use of such a corner bracket, a window mounting collar and a window mounting system |
US9598854B2 (en) * | 2013-07-05 | 2017-03-21 | Rockwool International A/S | Corner bracket, a bracket system, use of such a corner bracket, a window mounting collar and a window mounting system |
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US20180340336A1 (en) * | 2017-05-25 | 2018-11-29 | Todd Fischer | Bracket Cover Flashing System and Method fo Use |
US10676934B2 (en) * | 2017-05-25 | 2020-06-09 | Todd Fischer | Bracket cover flashing system and method of use |
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US9933183B1 (en) | 2017-11-01 | 2018-04-03 | Duane Den Adel | Dynamic insulated roof curbs for use with mechanical units |
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