Supporting a load on a roof

Abstract

The invention provides a system for installing a load on a metal panel roof, the system comprising a rail and closure structure adapted to be supported by ribs defined by the roof panels, and a load adapted to be supported on the rail and closure structure. In some embodiments, standing seams on ribs, and side rails on the rail and closure structure, extend parallel to each other, and optionally parallel to opposing sides of a hole in the roof. In some embodiments, substantially all of a downwardly-directed force of the load passes downwardly through the rail and closure structure to the ribs, and from the ribs to underlying structural members of the building.

Claims

1. A rail mounting system for mounting a skylight or other load on a metal panel roof in which elongate metal roof panels are arranged side by side, with edges of adjacent ones of the roof panels being joined to each other to define elevated roof panel ribs, and panel flats of the roof panels disposed between adjacent ones of the elevated ribs, the rail mounting system comprising: a first side rail and a second side rail for supporting opposing sides of the skylight or other load, the first and second side rails each having a profile configured to attach to the elevated ribs and to provide structural support for the skylight or other load along substantially an entire length of the skylight or other load, the first and second side rails each including: an upstanding riser, and a bottom shoulder structure extending from the upstanding riser, the bottom shoulder structure including a first shoulder element attached directly to the upstanding riser and extending along the length of the side rail, and laterally away from the upstanding riser, the first shoulder element having a first surface facing in a first direction having a downwardly-directed component, the bottom shoulder structure further including a second shoulder element attached directly to the first shoulder element, the second shoulder element extending in a second single direction, different from the first direction; the rail mounting system further comprising: an upper end element and a lower end element opposite the upper end element, the upper and lower end elements each extending across a panel flat of the metal panel roof and attached directly to the first side rail and to the second side rail.

2. The rail mounting system of claim 1, wherein the upper end element includes an upper flange adapted to support a portion of the skylight or other load.

3. The rail mounting system of claim 2, wherein the upper end element also includes a lower flange, and a plate that connects the lower flange to the upper flange.

4. The rail mounting system of claim 1, wherein the upper end element includes a lower flange, an upper flange, and a plate that connects the lower flange to the upper flange.

5. The rail mounting system of claim 1, wherein the upper end element includes a profiled portion that generally fits a profile of a given one of the elevated ribs.

6. The rail mounting system of claim 1, wherein the lower end element includes an upper flange adapted to support a portion of the skylight or other load.

7. The rail mounting system of claim 6, wherein the lower end element also includes a lower flange, and a web that connects the lower flange to the upper flange.

8. The rail mounting system of claim 1, wherein the lower end element includes a lower flange, an upper flange, and a web that connects the lower flange to the upper flange.

9. The rail mounting system of claim 1, wherein the lower end element includes a profiled portion corresponding to a profile of a given one of the elevated ribs.

10. A metal panel roof, comprising: a metal panel roof in which elongate metal roof panels are arranged side by side, with edges of adjacent ones of the roof panels being joined to each other to define elevated roof panel ribs, and panel flats of the roof panels disposed between adjacent ones of the elevated ribs; and the rail mounting system of claim 1 mounted atop the metal panel roof.

11. A rail mounting system for mounting a skylight or other load on a metal panel roof in which elongate metal roof panels are arranged side by side, with edges of adjacent ones of the roof panels being joined to each other to define elevated roof panel ribs, and panel flats of the roof panels disposed between adjacent ones of the elevated ribs, the rail mounting system comprising: a first side rail, a second side rail, a first transverse support member, and a second transverse support member; wherein the first and second side rails are disposed opposite each other and spaced apart such that the first side rail extends along a first elevated rib of the metal panel roof and the second side rail extends along a different second elevated rib of the metal panel roof; wherein the first side rail includes a first upstanding riser and a first bottom shoulder structure, the first bottom shoulder structure including a first shoulder element and a second shoulder element, the second shoulder element connected to the first upstanding riser through the first shoulder element, the first and second shoulder elements being angled relative to each other to fit closely over an angled profile of the first elevated rib; wherein the second side rail includes a second upstanding riser and a second bottom shoulder structure, the second bottom shoulder structure including a third shoulder element and a fourth shoulder element, the fourth shoulder element connected to the second upstanding riser through the third shoulder element, the third and fourth shoulder elements being angled relative to each other to fit closely over an angled profile of the second elevated rib; wherein the first and second transverse support members are disposed opposite each other, each such support member extending between and attached directly to the first and second side rails; wherein the first side rail extends a first length from the first transverse support member to the second transverse support member, and the first bottom shoulder structure is configured to contact the first elevated rib entirely along the first length so that a first downward force from the skylight or other load is transmitted through the first side rail entirely along the first length; and wherein the second side rail extends a second length from the first transverse support member to the second transverse support member, and the second bottom shoulder structure is configured to contact the second elevated rib entirely along the second length so that a second downward force from the skylight or other load is transmitted through the second side rail entirely along the second length.

12. The rail mounting system of claim 11, wherein the first transverse support member includes an upper flange adapted to support a portion of the skylight or other load.

13. The rail mounting system of claim 12, wherein the first transverse support member also includes a lower flange, and a plate that connects the lower flange to the upper flange.

14. The rail mounting system of claim 11, wherein the first transverse support member includes a lower flange, an upper flange, and a plate that connects the lower flange to the upper flange.

15. The rail mounting system of claim 11, wherein the first transverse support member includes a profiled portion that generally fits a profile of a given one of the elevated ribs.

16. The rail mounting system of claim 11, wherein the second transverse support member includes an upper flange adapted to support a portion of the skylight or other load.

17. The rail mounting system of claim 16, wherein the second transverse support member also includes a lower flange, and a web that connects the lower flange to the upper flange.

18. The rail mounting system of claim 11, wherein the second transverse support member includes a lower flange, an upper flange, and a web that connects the lower flange to the upper flange.

19. The rail mounting system of claim 11, wherein the second transverse support member includes a profiled portion corresponding to a profile of a given one of the elevated ribs.

20. A metal panel roof, comprising: a metal panel roof in which elongate metal roof panels are arranged side by side, with edges of adjacent ones of the roof panels being joined to each other to define elevated roof panel ribs, and panel flats of the roof panels disposed between adjacent ones of the elevated ribs; and the rail mounting system of claim 11 mounted atop the metal panel roof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A more complete understanding of the present invention and the attendant features and advantages thereof may be had by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein various figures depict the components and composition of the multiple skylight system.

(2) FIG. 1 is a view showing the roof profile of a metal roof of the type known as the standing seam roof panel.

(3) FIG. 2 is a view showing the roof profile of a metal roof of the type known as an architectural standing seam roof.

(4) FIG. 3 is a view showing the roof profile of a metal roof of the type commonly referred to as a snap seam roof.

(5) FIG. 4 is a view showing the roof profile of a metal roof of the type commonly referred to as an exposed fastener roof panel.

(6) FIG. 5 is a view showing the roof profile of a metal roof of the type commonly known as foam core panel.

(7) FIG. 6 is a side view showing the major components of the system as installed on a metal roof.

(8) FIG. 7 is a top plan view of the installed system, showing the placement of skylights and the direction of water flow over the roof.

(9) FIG. 8 is a cross sectional view showing the connections of the skylight frame to the rail and closures structure, and the latter affixed over the outer surfaces of adjacent rib elevations of the metal roof.

(10) FIG. 9 is a cross sectional view showing an alternative arrangement for the elements shown in FIG. 8, only with the rail and closure structure connecting along the inner faces of adjacent rib elevations.

(11) FIG. 10 is a perspective view partially cut away showing internal structure of the system as installed on the rib elevations of a metal roof.

(12) FIG. 11 is a perspective view of the upper rain pan or diverter of the rail and closure structure.

(13) FIG. 12 is a top view of the upper rain pan or diverter of the rail and closure structure.

(14) FIG. 13 is a front plan view of the upper rain pan or diverter of the rail and closure structure.

(15) FIG. 14 is a perspective view of the lower rain pan or lower closure of the rail and closure structure.

(16) FIG. 15 is a top view of the lower rain pan or lower closure of the rail and closure structure.

(17) FIG. 16 is a front plan view of the lower rain pan or lower closure of the rail and closure structure.

(18) FIG. 17 is a perspective and partially cut away view showing a connection of adjacent skylights of the system.

(19) FIG. 18 shows detail of how the batten connects adjacent skylights and prevents water egress between them.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(20) The products and methods of the present invention provide a skylight rail and closure system for use in installing various roof penetrating structures in metal roofs. For purposes of simplicity, roof penetrating structures and skylights will be used interchangeably to mean various forms of roof structures installed for passage of light and/or ventilation to the interior of the building. In the case of roof ventilation, examples include simple ventilation openings, such as for roof fans, and smoke vents, which are used to allow the escape of smoke through the roof during fires.

(21) The number of skylights can vary from one to many structures connecting end to end be from one to as many as the building roof structure will support, limited only by the amount of support provided by the roof surface structure, which is left largely intact during the installation process.

(22) The system utilizes the major rib structure in the roof as the primary support structure and water barrier to fasten the skylight assembly. Typical skylight installations do not allow for continuous runs, but use a curb construction that is typically 2-3 times wider than the present system.

(23) The present skylight system does not require a complex structure underneath the panels or a separate curb construction to support or attach the skylight. The rail and closure assembly is overlaid onto the roof system and allows for thermal expansion and contraction by utilizing the major profiles of the metal roof panel for support. This is accomplished through direct attachment of the rail assembly and a combination of the panel flat and major ribs for support and attachment of the closure assembly.

(24) In reference now to the figures, the system allows the installation of two or more adjacent skylights in an end to end fashion along the major rib structure of a building's metal roof panel profile.

(25) The skylight system may be applied to various types of ribbed roof profiles. FIG. 1 is a view showing the roof profile of a metal roof of the type known as the standing seam roof panel 10. These include the standing seam roof, which has trapezoidal major ribs 12 typically 24 to 30 on center. Each panel 10 will also include the panel flat 14, having a shoulder 16 and seamed at adjacent panels forming a standing seam 18, which is folded over and seamed to prevent water from penetrating the roof.

(26) FIG. 2 is a view showing the roof profile of a metal roof of the type known as an architectural standing seam roof, produced of a series of overlapping architectural standing seam panels 20. Each panel 20 comprises a panel flat 24, with an architectural standing seam 28 formed at the interconnecting panels.

(27) FIG. 3 is a view showing the roof profile of a metal roof of the type commonly referred to as an R panel or exposed fastener panel 30, with each panel having a rib 32, panel flat 34. Adjacent R panels are secured to the roof through a structural fastener 35, and at the shoulder 36 which is formed from overlapping regions, or side lap 38, the adjacent panels are secured through a stitch fastener 39. The trapezoidal major ribs of the R panel roof are most typically formed at 8 to 12 on center.

(28) FIG. 4 is a view showing the roof profile of a metal roof of the type commonly referred to as a snap rib seam panel 40. Snap seam panels 40 have a panel flat 44 and a standing seam or snap seam 48 at adjacent panels.

(29) FIG. 5 is a view showing the roof profile of a metal roof of the type commonly known as foam core panel 50, which has a rib 52, a liner panel 53, a panel flat 54 and a foam core 57. Side laps 58 are secured by a stitch fastener 59. This panel is typically installed from the interior of the building.

(30) The system includes a rail and closure assembly adapted to be supported onto the major elevations, seams, rib structures, or other structural elements of such roof profiles, where the standing structure provides the support, and the skylight is secured through an opening formed in the intervening, non-structural roof flat region.

(31) Turning now to FIG. 6, there is shown an exemplified rail and closure assembly 100 adapted for attachment to a standing seam panel roof 110. While the following figures depict such an assembly, it will be understood that the components could easily be adapted, by shaping of the elements, for attachments to any roof system that has a profile with elevations providing a place for structural support.

(32) Looking again to the figures, particularly FIGS. 6 and 7, there is shown such a standing seam panel roof 110 having structural and other elements including a raised rib 112, a panel flat 114, shoulder 116 and standing seam 118. Also depicted are the ridge cap 120 of the roof structure, and a series of cutaway regions, or gaps 122 formed to accommodate the structure, as described more fully as follows.

(33) Shown as part of the system, and exemplified in this case, is a skylight 130, generally comprising a skylight frame 132 and skylight lens 134. While the figures depict a skylight, it will be understood that the system could also be adapted for use with any number of roof penetrating structures, from various types of skylights to smoke vents or other loads or other ventilating structures, which can all be adapted to be supported on the rail and closure assembly system.

(34) Again in reference to FIGS. 6 and 7, the system includes a rail and closure structure 140, generally comprised of side rails 142 and 144, and upper diverter 146 disposed at the rib cutaway section, or gap 122. FIGS. 6 and 7, collectively, show the rail 142 being mounted to the rib by rivets 310 at leading, intermediate, and trailing portions of the length of the rail. At this gap 122, a plate 148 may be located under the gap 122 to prevent water leakage from roof. In assembling the rail and closure structure to a roof, the plate 148 may be sealed and fastened securely to the roof panel supports.

(35) Looking more particularly to FIG. 7 it is shown how the gap 122 in the roof rib 112 allows water flow 200 along the roof surface, over plate 148, and down and away from the roof ridge cap 120.

(36) The rail and closure assembly structure 140 may also include a lower closure 150 to seal the system from the elements.

(37) In reference now to FIG. 8, there is shown a cross section through the skylight 130 region of the rail and closure structures 100, showing the securement of the assembly 100 to the standing seam panel roof 110.

(38) FIGS. 6 and 7 illustrate the skylight load length extending in the same direction as the roof ribs 112. FIG. 8 illustrates the skylight load width. FIGS. 6-8 show the skylight load being separate and distinct from the rail and closure structure 140. FIGS. 6 and 7 also show the rails extending substantially the full length of the skylight load. FIG. 8 shows rails 142, 144 contacting respective underlying ones of the ribs and extending upwardly from the underlying ribs, and supporting the skylight load; and the underlying ribs supporting the rails along substantially the full length of the skylight load.

(39) In particular, FIG. 8 depicts the use of the ribs 112 to support the side rails 142 and 144 on opposing sides of panel flat 14. It is seen that each of rail 142, rail 144, and upper diverter 146 has an upper support flange defining an upper bearing surface 240 at a common elevation above the panel flat of a next adjacent roof panel, supported by a generally vertically upstanding web. Rails 142, 144 have lower shoulders 242 supporting the upstanding webs. FIG. 11 shows the upper bearing surfaces of the diverter and the rails at a common elevation.

(40) FIG. 6, in combination with FIG. 8, shows that rails 142 and 144 extend substantially the full length of the overlying skylight load, and that the skylight load is secured to the underlying rails by fasteners 300 spaced along the lengths of the rails. The rails 142 and 144 extend upwardly from and above the ribs in contacting and supporting the load, whereby substantially all of the downwardly-directed force of the load passes downwardly through the rails at the vertically upstanding webs, as elements of the rails, and from the rails downwardly to the underlying ones of the ribs, and from the ribs downwardly to structural support members of the building. Particularly as illustrated in FIG. 7, as supported by FIGS. 6, 8, and 10, all of the downwardly-directed force of the skylight load passes downwardly through respective ones of the roof panels, ultimately through the respective roof panel ribs, along substantially the full length of the load, to underlying elements of the building support structure. As illustrated in FIG. 7, the load extends between the first and second rails across the entire width of the respective panel flat.

(41) The rail shoulder 242 is shaped to fit closely over the outside of the roof rib 112, and FIG. 8, in combination with FIG. 6, shows the rail secured directly to roof rib 112 by a rivet 310. A rail support flange supports the skylight frame 132, where a sealant 330 can be applied to seal against the passage of water or air.

(42) FIG. 9 depicts a variation of the rail and closure assembly 100 shown in FIG. 8, only where the rail shoulder 242 is shaped to fit closely along the inside of the roof rib 112, and is secured to roof rib 112 by rivet 310. As for FIG. 8, the rail bearing surface 240 similarly supports the skylight frame 132, where a sealant 330 can be applied.

(43) It can be seen that the rail and closure structure 140 of the assembly 100 can be produced to fit closely along the contour of the roof 110, and can be so configured to have end portions that match the contour of the ribs 112. The various mating surfaces of the structure 140 and the roof 110 can be sealed in various ways known to the roofing art, including caulking or tape mastic, or various rubber fittings or inserts can be provided be used to seal the open area of the panel roof.

(44) In FIG. 10 a partially cut away perspective view of the rail and closure structure assembly 100 is used to show the support of the rail and closure system by the standing seam panel roof 110, particularly the elevated rib 112 providing the structural support. In FIG. 10, it is seen how the rail and closure system incorporates the structural profile of the upper panels of metal roof structure, the elevations and ribs used in sealing adjacent panels, to provide the support of adjacent skylights. In this fashion, the system adopts various advantages of a standing seam roof.

(45) Most standing seam roofs are seamed using various clip assemblies that allow the roof to float, along the major elevation. Typically, the roof is fixed at cave and allowed to expand and contract over at ridge. Very wide roofs can be fixed at midspan and expand towards both the eave and ridge. The design of the skylight system takes full advantage of the floating features of contemporary roofing structures, and when a skylight is so secured to the elevations, the skylight assemblies themselves are able to draw strength from the structural load bearing capacity of the roof profile.

(46) Shown in FIG. 10 is the panel flat 114, rib 112 and shoulder 116, as well as the standing seam 118. The ridge cap 120 is also shown, as well as the gap in the roof 122.

(47) The skylight 130 is supported on the rail and closure structure 140, as previously described.

(48) The rail and closure structure 140 is secured by its side rails 142 and 144 by a series of fasteners 300 to the skylight frame 132 and to the ribs 112 by a series of rivets 310.

(49) In application, from each structure 140 a single rib 112 is typically cut away to accommodate drainage at the high end of the system (toward ridge cap 120). This is an important feature for standing seam, architectural standing seam and snap seam roofs. Two ribs may be cut for roofs having an R panel profile.

(50) The retained portions of rib 112 serve as a beam to support the side rails 142 and 144 and maintain a watertight seal along the length of the assembly. Internal portions of the ribs 112 may be removed to allow additional light from the skylight 130.

(51) A single bearing plate structure 148 is used for sealing the cut away rib. The bearing plate 148 also provides some support to link adjacent rib elevations 112, and is typically produced of steel or other material sufficient to provide a rigid substructure to the skylight rail and closure structure.

(52) The rail and closure structure 140 is shaped in such a manner that the skylight can be easily fastened directly to the rail portion, with rivets or fasteners such as screws and the like. The rail and closure structure 140 may also be designed to accept a safety security guard before the skylight is installed.

(53) Looking now to FIGS. 11 through 13, an upper or high end diverter 146 provides closure and diversion of water around the top of the assembly to an adjacent panel flat. Diverter 146 also provides a weather tight seal at the upper end of the assembly, with the plate 148 (not shown). In reference to the side rails 142 and 144 of a standing seam panel roof 110, the diverter 146 generally fits the profile of the rib 112 at the region of the cut away gap 122. The side rails 142 and 144 abut the diverter 146 and the height of the diverter 146 closely matches them in height. The upper support flange 400 of the diverter 146 actually acts with upper support flanges 240 of the side rails 142 and 144 to form the bearing surface of the skylight frame.

(54) The diverter 146 lower flange 410 runs along the panel flat 114. The diverter 146 also has a diversion surface 420 and fastener holes 430 along the lower flange.

(55) At one end is a rib mating surface 440 and at the other a rib sealing plate 450 is formed.

(56) FIGS. 14 through 16 show the low end closure 150 that is used to maintain a weather tight seal at the lower end of the assembly. Shown again in reference to the side rails 142 and 144 of a standing seam panel roof 110, the closure 150 is adapted to fit the profile of the rib 112. The side rails 142 and 144 abut the closure 150 and the height of the closure flange matches the height of flanges 240 of the side rails and the diverter, whereby the rail and support structure defines a plurality of support flanges having bearing surfaces all interfacing with said load at a common elevation above the panel flat of a respective next adjacent roof panel.

(57) Looking to the closure 150, it is seen to have an upper support flange 500 and a lower flange 510, as well as a closure web 520. The lower flange 510 includes fastener holes 530.

(58) The closure 150 also includes rib mating surfaces 540 and 550 to provide a tight fit along the ribs 112.

(59) Looking now to FIGS. 17 and 18, the adaptation of the system for the application of multiple roof penetrating structures is described. A chief aspect of the assembly 100 is the reduction in the number of roof penetrations required to provide daylight to the interior of a structure, as fewer, longer cuts can be made along the roof elevations. These minimized openings can be maintained along a single rib, if desired, with one continuous opening versus many smaller ones permitting an equal or greater amount of ambient light into the building.

(60) In the case of standing seam roofs the system provides the ability to remove only a portion of the bottom flat of the panel. This maintains the structural integrity of the roof in that multiple sections of major panel elevations are not removed, as is done to accommodate a typical curb assembly. Thus, the roof's structural integrity is not compromised to that extent and there are fewer potential areas for water infiltration, in that the skylight panels can be attached very near the ridge of the building and run to the eave requiring water to be diverted only once near the ridge of the roof plane and only across one panel flat.

(61) To the limited extent that cutaways are made to the elevations, these are made small, on the order of a few inches or less, solely for the purpose of allowing drainage past the skylights.

(62) The rail system is designed to install to either the inside or outside of the major rib elevation for any of the aforementioned roof panel profiles.

(63) The rail and closure assembly 100 is particularly useful for continuous runs of skylights end to end. FIG. 17 shows how two adjacent skylights of the rail and closure assembly 100 can be affixed along a standing seam panel roof 110. Instead of producing the lights with diverters and lower closures, where adjacent lights abut, the rail and curb structures 140 are provided with upper and lower standing rib frames 600 and 610 at adjacent ends of the adjacent structures 140. A batten 620 is provided to secure the system 100 against the elements.

(64) FIG. 18 is a side elevational view of the batten 620, showing how it fits over the adjacent upper and lower standing rib frames 600 and 610.

(65) As only one example, skylights can be produced in units of up to 10 feet long, and connected in this fashion for as long as necessary, as each skylight unit is supported by the primary rib of the profile. The standing rib elevation (the major corrugation) runs longitudinally along the length of the assembly and mates along the entire assembly 100, regardless of the number of adjacent structures 140. No water can enter over the top of the rail and closure assembly.

(66) Where it is desired that the skylight starts at the ridge of the roof, a simple flashing can be inserted under the ridge cap.

(67) Where the ridge cap has a configuration to fit the rib elevations (major corrugations) in the roofing panels, a portion of the one rib may be cut out (approximately 2), allowing the water from the roof panel above to be diverted on to the next panel.

(68) If desired, a simple rail enclosure extension could be used to increase the height or distance between top skylight frame and the roof panel, and can be adapted to simply lay over or attach to the top of the rail and closure assembly. Such an extension could be produced to rest along the upper flange of the rail and closure assembly, to effectively raise the height of the skylight or smoke vent to accommodate different skylight depths or other design features, or to accommodate snow conditions and the like. In this fashion, the rail and closure structure can be produced to a standard height, with varying extensions used to elevate the overall height of the structure for such varied purposes. Various forms for such an extension would be suitable, and the skilled artisan will understand various ways and means of designing and manufacturing these to accomplish the goal of added height to the skylight.

(69) While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of this invention.