Supporting A Load On A Roof

Abstract

The invention provides a system for installing a rail and closure assembly on a metal roof. The rail and closure assembly includes a supporting rail and closure structure adapted to be supported by adjacent rib elevations of the roof, and an overlying load adapted to be supported by the rail and closure structure. The rail and closure structure diverts water around the rail and closure assembly. The entire heights of the side rails, including the rail bottoms, are above the closest portions of the panel flats. At least one panel of each of the side rails faces the respective rib along the full length of the respective side rail. The rail and closure assembly also includes a lower closure. Opposing ends of the lower closure extend upwardly and interface with the ribs. The lower closure further comprises a lower flange which interfaces with a respective panel flat.

Claims

1-20. (canceled)

21. A load system for installing a load on a metal panel roof, such metal panel roof comprising elongate metal roof panels, each having a length and a width, such roof panels defining elevated roof panel ribs, panel flats being disposed between such roof panel ribs, said load system comprising: (a) a rail and closure structure comprising (i) a first side rail, having first and second ends, a first length between the first and second ends, a first top, and a first bottom, a first downwardly-facing surface of said first side rail being mounted directly to a first upwardly-facing surface of a first such rib along an entirety of the first length of said first side rail, and (ii) a second side rail, having third and fourth ends, a second length between the third and fourth ends, a second top, and a second bottom, a second downwardly-facing surface of said second side rail being mounted directly to a second upwardly-facing surface of a second such rib along an entirety of the second length of said second side rail, the bottom of at least one of said first and second side rails, at a given point along the length of the respective said side rail, being spaced above an elevation of a portion of the respective panel flat which most closely underlies the respective said side rail at such point along the length of the respective said side rail; and (b) a load adapted to be supported by said rail and closure structure.

22. A load system as in claim 21 wherein a portion of only a single such roof panel rib is cut away, leaving first and second cut rib edges, respectively up slope and down slope on such roof, and an empty space between the up-slope and down-slope cut rib edges, at least one of the cut rib edges being spaced from the respective said side rail.

23. A load system as in claim 22 wherein said load comprises first and second adjacent skylights supported end to end over a single aperture in the roof.

24. A load system as in claim 22 wherein said cut away portion of the respective roof panel rib is made at only one of the respective roof panel ribs to which said side rails are directly mounted.

25. A load system as in claim 21 wherein said system comprises first and second adjacent skylights supported end to end over a single aperture in the roof.

26. A load system as in claim 21 wherein said first and second side rails overlie said ones of such roof panel ribs along full lengths of said first and second rails.

27. A load system as in claim 21 wherein the downwardly-facing surfaces of said first and second side rails are fastened directly to the upwardly-facing surfaces of such first and second ribs by screws or rivets spaced from each other along the lengths of said first and second side rails.

28. A load system as in claim 21, installed on a roof and overlying a roof penetration.

29. A load system as in claim 21 wherein said load extends upwardly above the tops of said first and second side rails.

30. A load system for installing a load on a metal panel roof, such metal panel roof comprising elongate metal roof panels, each having a length and a width, such roof panels defining elevated roof panel ribs, panel flats being disposed between such roof panel ribs, said load system comprising: (a) a rail and closure structure suitable for being supported by ones of the elevated roof panel ribs, said rail and closure structure comprising a first side rail, for mounting directly to a first such rib wherein a first bottom panel of said first side rail faces a panel of such first rib, along a full length of said first side rail, and a second side rail, for mounting directly to a second such rib, wherein a second bottom panel of said second side rail faces a panel of such second rib, along a full length of said second side rail; and (b) a load adapted to be supported on said rail and closure structure.

31. A load system as in claim 30 wherein, when said load system is installed on such roof, a portion of a such rib is cut away, leaving first and second cut rib edges, and a space between the cut rib edges, one of the cut rib edges being spaced from a respective said rail.

32. A load system as in claim 31 wherein only one of the respective roof panel ribs, to which said rails are mounted, is cut away to define such space between the cut rib edges.

33. A load system as in claim 30 wherein said load system, when installed on such roof, comprises first and second adjacent skylights supported end to end over a single aperture in such roof.

34. A load system as in claim 30 wherein, when said load system is installed on such roof, said rail and closure structure overlies adjacent ones of the roof panel ribs along the full lengths of said first and second rails.

35. A load system as in claim 30, installed on a roof, said load overlying a hole in the roof.

36. A load system for installing a load on a metal panel roof, such metal panel roof comprising elongate metal roof panels, each having a length and a width, such roof panels having upstanding rib elevations, defining elevated roof panel ribs, at opposing sides of the respective roof panels, panel flats being disposed between such roof panel rib elevations, said load system comprising: (a) a rail and closure structure comprising (i) a first side rail, having first and second ends, a first upstanding web, a first mounting flange at a top of said first upstanding web, and a first lower shoulder extending from a first bottom of said first upstanding web, said first lower shoulder being mounted to a first such rib, and (ii) a second side rail, having third and fourth ends, a second upstanding web, a second mounting flange at a top of said second upstanding web, and a second lower shoulder extending from a second bottom of said second upstanding web, said second lower shoulder being mounted to a second such rib, roof panel profiles being defined by cross-sections extending across the widths of such roof panels, further comprising (c) a lower closure structure having opposing upwardly-extending ends thereof, configured to interface with the metal roof panel profiles at the ribs to which said side rails are mounted, and a lower flange configured to interface with an intervening panel flat between such ribs, said lower closure further having an upstanding panel, extending upwardly from said lower flange and extending between such first and second ribs, thereby to prevent flow of water from an up-slope side of said lower closure structure to a down-slope side of said lower closure structure.

37. A load system for installing a load on a metal panel roof, such metal panel roof comprising a plurality of elongate metal roof panels, each having a length and a width, such roof panels defining elevated roof panel ribs, panel flats being disposed between such roof panel ribs, said load system comprising: (a) a rail and closure structure comprising (i) a first side rail having first and second ends, a first length between the first and second ends, a first top, and a first bottom, said first side rail being mounted to a first such rib along an entirety of the first length of said first side rail, (ii) a second side rail, having third and fourth ends, a second length between the third and fourth ends, a second top, and a second bottom, said second side rail being mounted to a second such rib along an entirety of the second length of said second side rail, at a given point along the length of each said side rail, an entirety of a height of the respective said side rail, from the bottom of said side rail to the top of said side rail, being spaced above an elevation of a portion of the respective panel flat which most closely underlies the respective said side rail at such point along the length of the respective said side rail; and (b) a load supported by said rail and closure structure.

38. A load system as in claim 37, further comprising an upper diverter extending between the first and third ends of said first and second side rails, and a lower closure extending between the second and fourth ends of said first and second side rails.

39. A load system as in claim 37 wherein said load extends upwardly above the first and second tops of said first and second side rails.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] 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 combination with the accompanying drawings.

[0037] FIG. 1 is a view showing the roof profile of metal roof panels of the type known as standing seam roof panels.

[0038] FIG. 2 is a view showing the roof profile of metal roof panels of the type known as architectural standing seam roof panels.

[0039] FIG. 3 is a view showing the roof profile of metal roof panels of the type commonly referred to as snap seam roof panels.

[0040] FIG. 4 is a view showing the roof profile of metal roof panels of the type commonly referred to as exposed fastener roof panels.

[0041] FIG. 5 is a view showing the roof profile of metal roof panels of the type commonly known as foam core panels.

[0042] FIG. 6 is a side view showing the major components of the system as installed on a metal panel roof.

[0043] FIG. 7 is a top plan view of the installed system, showing placement of skylights and the direction of water flow over the roof.

[0044] FIG. 8 is a cross sectional view showing connections of the skylight frame to the rail and closures structure, and the latter affixed over the outer surfaces of respective rib elevations of the metal panel roof.

[0045] FIG. 9 is a perspective view, partially cut away, showing internal structure of the system as installed on the rib elevations of a metal panel roof.

[0046] FIG. 10 is a perspective view of the upper diverter of the rail and closure structure.

[0047] FIG. 11 is a top view of the upper diverter of the rail and closure structure.

[0048] FIG. 12 is a front elevation view of the upper diverter of the rail and closure structure.

[0049] FIG. 13 is a perspective view of the lower closure of the rail and closure structure.

[0050] FIG. 14 is a top view of the lower closure of the rail and closure structure.

[0051] FIG. 15 is a front elevation view of the lower closure of the rail and closure structure.

[0052] FIG. 16 is a perspective and partially cut away view showing a connection of adjacent skylights of the system.

[0053] FIG. 17 shows detail of how the batten connects adjacent skylights and prevents water ingress between them.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0054] The products and methods of the present invention provide a rail and closure structure for use in installing various roof penetrating structures in metal panel 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.

[0055] The number of skylights can vary from one to many structures connecting end to end, limited only by the amount of support provided by the roof structure, which roof structure is left largely intact during the skylight installation process.

[0056] The system utilizes the major rib structure in the roof as the primary structure supporting the skylight assembly. Typical conventional skylight installations do not allow for continuous runs, but rather use a curb construction that is typically 2-3 times wider than the present system.

[0057] The present rail and closure structure does not require a complex structure underneath the roof panels, nor does it require a separate curb construction to support or attach the skylight. The rail and closure structure is overlaid onto the roof system and allows for thermal expansion and contraction of the rail and closure structure by utilizing the major profiles of the metal panel roof for support. This is accomplished through direct attachment of the rail and closure structure to the major roof panel ribs.

[0058] 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.

[0059] The rail and closure structure can be applied to various types of ribbed roof profiles. FIG. 1 shows the roof profile of a metal panel roof of the type known as the standing seam roof 10. The standing seam roof 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.

[0060] 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.

[0061] 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, and panel flat 34. Adjacent R panels are secured to the roof through structural fasteners 35 in the panel flat, adjacent shoulder 36. The rib is formed from overlapping regions, or side laps 38, with the adjacent panels secured to each other by stitch fasteners 39. The trapezoidal major ribs of the R panel roof are most typically formed at 8 to 12 on center.

[0062] 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 roof 40. A snap seam panel roof 40 has panel flats 44 and standing seams or snap seams 48 at adjacent panels.

[0063] FIG. 5 is a view showing the roof profile of a metal panel 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.

[0064] The system of the invention includes a rail and closure structure adapted to be supported on the major elevations, seams, rib structures, or other structural elements of such roof profiles, where the standing structure provides the support, and the skylight or other load is secured over an opening formed in the intervening, non-structural roof flat region.

[0065] 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.

[0066] 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 cutaway regions, or gaps 122 formed to accommodate the structure, as described more fully as follows.

[0067] 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 ventilating structures, which can all be adapted to be supported on the rail and closure structure system.

[0068] Again in reference to FIGS. 6 and 7, the system includes rail and closure structure 140, generally comprised of side rails 142 and 144, an upper diverter 146 disposed at the rib cutaway section or gap 122, and a lower closure 150. At gap 122, a plate 148 is located under the gap 122 to prevent water leakage into the underlying building. In assembling the rail and closure structure to a roof, plate 148 is sealed and fastened securely to the roof panel supports.

[0069] FIG. 7 shows 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.

[0070] Lower closure 150 seals the lower end of the system from the elements.

[0071] In reference now to FIG. 8, there is shown a cross section through the skylight 130 region of the rail and closure assembly 100, showing the securement of the assembly 100 to the standing seam panel roof 110. In particular, FIG. 8 depicts the use of the ribs 112 to support the side rails 142 and 144. Each rail 142 or 144, has a rail upper flange or bearing surface 240 and a rail shoulder 242. The rail 142 or 144 is secured to the skylight frame 132 by a plurality of fasteners 300.

[0072] The rail shoulder 242 is shaped to fit closely over the outside of the roof rib 112, and is secured to roof rib 112 by a plurality of rivets 310. Upper flanges 240 of the rails support the skylight frame 132. A sealant 330 can be applied to the upper flange to seal against the passage of water or air.

[0073] 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 used to seal any open areas of the roof panels.

[0074] In FIG. 9 a partially cut away perspective view of the rail and closure 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. FIG. 9 shows how the rail and closure structure incorporates the structural profile of the metal roof panels, including the elevations and ribs used in sealing adjacent panels, to provide the support of skylights. In this fashion, the system adopts various advantages of a standing seam roof.

[0075] 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 the cave and allowed to expand and contract toward and away from the ridge. Very wide roofs can be fixed at midspan and expand and contract toward and away from both the cave and the ridge. The design of the rail and closure assembly 100 takes full advantage of the floating features of contemporary roofing structures, and when a skylight is so secured to the roof panel elevations, the skylight assemblies themselves are able to draw strength from the structural load bearing capacity of the standing seam roof profile.

[0076] Shown in FIG. 9 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 122 in a rib at the up-slope end of the rail and closure assembly.

[0077] The skylight 130 is supported on the rail and closure structure 140, as previously described.

[0078] 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.

[0079] Adjacent the up-slope end of the rail and closure structure 140, a single rib 112 is typically cut away to create gap 122, thereby to accommodate drainage at the up-slope 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 can be cut for roofs having an R panel profile.

[0080] The retained portions of rib 112 function similar to e.g. flange and web portions of an I-beam, thus 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 can be removed to allow additional light from the skylight 130.

[0081] 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.

[0082] 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 other fasteners such as screws and the like.

[0083] Looking now to FIGS. 10 through 12, an upper diverter 146 provides closure and diversion of water around the up-slope end of the assembly to an adjacent panel flat. Diverter 146 also provides a weather tight seal at the up-slope end of the assembly, with the plate 148. In reference to the side rails 142 and 144 on 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 flange 400 of the diverter 146 acts with upper flanges 240 of the side rails 142 and 144 to form the bearing surface of the skylight frame.

[0084] Lower flange 410 of diverter 146 runs along the panel flat 114. The diverter 146 also has a diversion surface 420 and fastener holes 430 along the lower flange.

[0085] At one end of diverter 146 is a rib mating surface 440 and at the other end is a rib sealing plate 450.

[0086] FIGS. 13 through 15 show the lower closure 150 that is used to maintain a weather tight seal at the lower end of the assembly. Shown in reference to the side rails 142 and 144 in FIG. 13, lower closure 150 is adapted to fit the profile of the rib 112. The side rails 142 and 144 abut lower closure 150 and the height of the lower closure 150 matches the heights of the side rails.

[0087] Lower closure 150 has an upper flange 500 and a lower flange 510, as well as an upstanding closure web 520. The lower flange 510 includes fastener holes 530.

[0088] The lower closure 150 also includes rib mating surfaces 540 and 550 to provide a tight fit along the ribs 112.

[0089] Looking now to FIGS. 16 and 17, 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. This small number of openings can be maintained along a single rib, with one continuous opening, rather than multiple openings, permitting an equal or greater amount of ambient light into the building.

[0090] In the case of standing seam roofs, the system provides the ability to remove roof panel material only in the panel flat portion 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.

[0091] 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.

[0092] The rail and closure assembly 100 is particularly useful for continuous runs of skylights end to end. FIG. 16 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 closure 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.

[0093] FIG. 17 is a side elevation view of the batten 620, showing how the batten fits over the adjacent upper and lower standing rib frames 600 and 610.

[0094] As one example, skylights can be produced in units of up to 10 feet long, and connected end to end for as long a distance as necessary, as each skylight unit is supported by the ribs of the roof profile. The standing rib elevation (the major corrugation) runs longitudinally along the length of the assembly and mates with the respective rails 142, 144 along the entire length of assembly 100, regardless of the number of adjacent structures 140. No water can enter over the top of the rail and closure assembly.

[0095] Where it is desired that the skylight starts at the ridge of the roof, a simple flashing can be inserted under the ridge cap.

[0096] 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 onto the next adjacent roof panel.

[0097] If desired, a simple rail enclosure extension could be used to increase the height or distance between the top of the skylight frame and the roof panel, and can be adapted to simply lay over or attach to the top of the rail and closure structure. Such an extension can be produced to extend along the upper flange of the rail and closure structure, 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 upward extensions optionally being used to elevate the overall height of the structure for such varied purposes. Various forms for such an extension are suitable, and the skilled artisan will understand various ways and means of designing and manufacturing such extension to accomplish the goal of added height to the skylight.

[0098] 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.