A ROOF WINDOW, A KIT WITH A COVERING ASSEMBLY, AND A METHOD FOR MOUNTING A ROOF WINDOW

Abstract

A roof window (1) comprising a frame (2), a sash (3) carrying a pane (4), where the frame (2) comprises an interface unit (8) extending in the length direction (L) of at least one frame member (21, 22, 23, 24). At least one flashing member (1011, 1012, 1013, 1014) comprises a flange (1017) inserted in a flashing reception groove (85) in the interface unit (8) in a direction parallel to the frame plane (F), said flashing reception groove (85) extending in the length direction (L) of the frame member (21, 22, 23, 24). One or more protrusions (85a) are provided in the flashing reception groove for engagement with the flange(s) (1017) and extend(s) in the length direction (L) and is/are made by co-extrusion with one or more parts (80, 86, 88) of the interface unit (8) delimiting the flashing reception groove. A method for mounting a roof window is also disclosed.

Claims

1. A kit comprising a roof window, which is configured for being mounted in a roof structure comprising a roofing material and a covering assembly, said roof window comprising a frame and a sash carrying a pane, where the frame comprises a plurality of frame members together defining a frame opening and a frame plane and each frame member extends in a length direction, where the frame comprises an interface unit extending in the length direction of at least one frame member, where said covering assembly comprises a plurality of flashing members configured for covering a joint between the frame and the roof structure, and where the interface unit comprises a flashing reception groove configured for receiving a flange of at least one flashing member via a groove opening by insertion in a direction parallel to the frame plane, said flashing reception groove extending in the length direction of the frame member, and where one or more protrusions are provided in the flashing reception groove for engagement with the flange(s) (1017), characterised in that the protrusion(s) is/are made by co-extrusion with one or more parts of the interface unit delimiting the flashing reception groove and that the flange of at least one flashing member comprises a marking indicating an intended insertion depth of the flange into the flashing reception groove.

2. The kit according to claim 1, where the interface unit including the protrusion(s) constitutes a monolithic structure.

3. The kit according to claim 1, where the protrusion(s) extend(s) in the length direction.

4. The kit according to claim 1, where the protrusion(s) is/are made from a material having a Shore A hardness of 20 A-95 A.

5. The kit according to claim 1, where the protrusion(s) is/are made from one or more thermoplastic elastomers.

6. The kit according to claim 1, where at least the one or more parts of the interface unit delimiting the flashing reception groove are made of polypropylene mixed with glass fibres.

7. The kit according to claim 1, where the/each protrusion extends over more than half of the height of the flashing reception groove measured perpendicular to the frame plane.

8. The kit according to claim 1 comprising at least three protrusions, and where one or more protrusion(s) extend(s) from each of two opposite sides of the flashing reception groove.

9. The kit according to claim 1, where at least one protrusion has a tapered cross-sectional shape with a minor dimension at a free edge.

10. The kit according to claim 1, where at least one protrusion is inclined in a direction away from the groove opening of the flashing reception groove.

11. The kit according to claim 1, where the total thickness of the flange(s) inserted into the flashing reception groove constitutes less than 50% of the height of the flashing reception groove measured perpendicular to the frame plane.

12. (canceled)

13. (canceled)

14. The kit according to claim 1, wherein the at least one flashing member is a top flashing member, the flange of which extends into the flashing reception groove of a top element of the interface unit, and wherein the top flashing member comprises a corner section at one or both ends seen in the length direction, said corner section extending along a side frame member of the frame in the mounted state.

15. The kit according to claim 14, wherein the corner section comprises a corner flange extending into the flashing reception groove of a side element of the interface unit.

16. The A kit according to claim 1, further comprising a plurality of cladding members covering a part of the sash.

17. A method for mounting a roof window in a roof structure comprising a roofing material, said roof window comprising a frame and a sash carrying a pane, and said frame comprising a plurality of frame members together defining a frame opening and a frame plane and each extending in a length direction, wherein said method comprises the steps of A) arranging the roof window in an opening in the roof structure, B) arranging a plurality of flashing members so that they cover a joint between the frame of the roof window and the roof structure by displacing the flashing member in a direction parallel to the frame plane thereby inserting a flange of at least one flashing member in a flashing reception groove in an interface unit on the frame via a groove opening of the flashing reception groove, said interface unit and said flashing reception groove both extending in the length direction of the frame member, characterised in that during step B) the flange(s) comes into engagement with one or more protrusions in the flashing reception groove, said protrusion(s) being made by co-extrusion with parts of the interface unit delimiting the flashing reception groove, and that the flange of at least one flashing member comprises a marking, and that the displacing of the flashing member is continued until the flange is inserted so deep in the flashing reception groove that the marking reaches or is hidden by the interface unit.

18. The A method according to claim 17, wherein, for the insertion of the flange in the flashing reception groove, the flashing member is displaced in a direction substantially perpendicular to the length direction.

19. (canceled)

20. The method according to claim 18, wherein the at least one flashing member is a top flashing member comprising a corner section at one or both ends seen in the length direction, said corner section extending along a side frame member of the frame in the mounted state and comprising a corner flange extending perpendicular to the length direction of the top flashing member, and wherein the corner flange is inserted into the flashing reception groove of a side element of the interface unit by displacement perpendicular to the length direction of the top flashing member.

21. The kit according to claim 1, where the protrusion(s) is/are made from a material having a Shore A hardness of 35 A-87 A.

22. The kit according to claim 1, where at least the one or more parts of the interface unit delimiting the flashing reception groove are made of polypropylene (PP) mixed with glass fibres, said glass fibres constituting 15% by weight.

23. The kit according to claim 1, where the total thickness of the flange(s) inserted into the flashing reception groove constitutes less than 25% of the height of the flashing reception groove measured perpendicular to the frame plane.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0036] In the following description, embodiments of the invention will be described with reference to the schematic drawings, in which

[0037] FIG. 1 is a perspective view of a roof window with a covering assembly,

[0038] FIG. 2 is a perspective view of a roof window mounted in a roof structure and showing the mounting of a bottom flashing member,

[0039] FIG. 3 corresponds to FIG. 2 but showing the subsequent mounting of side flashing members,

[0040] FIG. 4 is a perspective view showing a further stage of the mounting of the side flashing members,

[0041] FIG. 5 is a cross-sectional view showing the right-hand side flashing member in the mounted state,

[0042] FIG. 6 corresponds to FIG. 3 but showing the subsequent mounting of a top flashing member,

[0043] FIG. 7 is a perspective view showing a further stage of the mounting of the top flashing member,

[0044] FIG. 8 is a cross-sectional view along the line VIII-VIII in FIG. 1,

[0045] FIG. 9 is a cross-sectional view along the line IX-IX in FIG. 1,

[0046] FIG. 10 corresponds to FIG. 8, but showing a different embodiment in a perspective view,

[0047] FIG. 11 is perspective view of an interface unit, and

[0048] FIG. 12 is an end view of an interface unit.

DESCRIPTION OF EMBODIMENTS

[0049] Referring initially to FIG. 1, a roof window 1 is shown with a covering assembly 10, wherein the right-hand side of the top flashing member 1011 is shown in a state of delivery, before adaptation to the shape of a roofing material 112 used alongside the roof window 1 as will be explained later. The roof window 1 is shown in an inclined position as it is intended for being mounted in an inclined roof structure 11.

[0050] In addition to the top flashing member 1011, the covering assembly comprises a plurality of side flashing members 1012, 1013, a bottom flashing member 1014 and a plurality of cladding members 1021, 1022, 1023, 1024 each covering a part of the sash 3 carrying the pane 4.

[0051] The roof window 1 comprises a frame (not visible in FIG. 1), and the top flashing member 1011, the side flashing members 1012, 1013, and the bottom flashing member 1014 extend in a respective length direction L along top, side, and frame members, respectively. The frame members 21, 22, 23, 24 together defining a frame opening covered by the pane 4 and a frame plane F.

[0052] In the embodiment in FIG. 1, the top flashing member 1011 comprises a corner section 1011a at each end, said corner section extending along a side of the roof window 1 and overlapping with a flashing member 1012, 1013. The top flashing member 1011 may thus be said to have the shape of an inverted U embracing the upper part of the roof window 1 when mounted in an inclined roof structure, i.e. the part being arranged uppermost when seen in the direction of inclination of the roof structure (cf. also FIGS. 2, 3 and 6).

[0053] The cladding members 1021, 1022, 1023, 1024 of the covering assembly 10 may be pre-mounted on the roof window 1 or be mounted after the mounting of the flashing members 1011, 1012, 1013, 1014. This is not essential to the present invention and will therefore not be described in further detail here.

[0054] The mounting of the flashing members 1011, 1012, 1013, 1014 starts with the mounting of the bottom flashing member 1014 and as shown in FIG. 2 it is displaced in a direction parallel to the frame plane F and perpendicular to the length direction L of the bottom frame member 24.

[0055] Hereafter, the side flashing members 1012, 1013 are mounted by being displaced in a similar manner as shown in FIG. 3. In the embodiment shown, several side flashing members 1012, 1013 are used at each side of the roof window 1, but it is to be understood that the invention also applies to roof windows wherein the covering assembly 10 only comprises two side flashing members, one at each side of the roof window 1.

[0056] The side flashing members 1012, 1013 shown in FIG. 3 are initially mounted in a state in which an outer section 10120, 10130 configured for resting on the roof structure 11 is in an upright position, and the outer section 10120, 10130 is then folded down onto the roofing material 112 as shown in FIG. 4, ending up with having the shape shown in FIG. 5. This embodiment is particularly well suited for use with flat roofing materials, such as slate, whereas flashing members used with undulating roofing materials, such as tiles, will typically project underneath the roofing material and will therefore typically be mounted without such a folding down step. The folding down may, however, also be used for adapting the shape of the side flashing member to the shape of a roof structure supporting an undulating roofing material.

[0057] As may be seen in FIG. 5, a flange 1017 on the side flashing member 1012 has been inserted in a flashing reception groove 85 in an interface unit 8 of the frame 2, and it is to be understood that both the interface unit 8 and the flashing reception groove 85 therein extend in the length direction L of the side frame member 22. Inside the flashing reception groove 85, elastic protrusions 85a engage with sides of the flange 1017, thereby contributing to keeping it in place in the flashing reception groove 85. In addition to providing friction against the flange 1017, the protrusions 85a may also serve a sealing function. An interface unit of this type is shown in more detail in FIG. 11.

[0058] Turning now to FIG. 6, the mounting of the top flashing member 1011 is shown. As may be seen, it is mounted in the same way as described with reference to the bottom flashing member 1014 in the description of FIG. 2, only displacing it downwards instead of upwards as seen in the direction of inclination I of the roof structure 11.

[0059] As shown in FIG. 7 the corner sections 1011a are subsequently folded down onto the roofing material 112 as described with reference to the outer sections of the side flashing members in FIG. 3. In FIG. 7, the folding is shown as being done by hand, but it could also be done using a tool as shown in FIG. 3.

[0060] As is best seen in FIG. 5, the side flashing members 1012, 1013 comprises a gutter 1012g extending in the length direction L and similar gutters 1011g, see FIGS. 6 and 7, are found in the top flashing member 1011 delimiting each of the corner sections 1011a. In the mounted state, these gutters 1011g, 1012g extend in continuation of each other and allow water to be drained down along the sides of the roof window 1.

[0061] Referring now also to FIG. 8, the displacement of the top flashing member 1011 results in a flange 1017 being inserted in a top element 81 of the interface unit 8 also shown in FIG. 5. As may be seen by comparison to FIG. 9 showing the side of the same roof window 1, the top element 81 of the interface unit 8 is slightly different from the side element 82 of the interface unit 8, but both have the same overall structure with a flashing reception groove 85 receiving the flange 1017.

[0062] The flashing reception groove 85 in the side element 82 of the interface unit 8 is slightly higher than the flashing reception groove 85 in the top element 81. This allows side flashing members 1012, 1013 to overlap as shown in FIG. 1 and further allows corner flanges 1017a on the corner sections 1011a to extend into the flashing reception groove 85 of the side elements 82 of the interface unit 8 overlapping with the flange of a side flashing member as indicated by the broken line 1011 in FIG. 9.

[0063] While not shown it is to be understood that the bottom flashing member 1014 may also comprise a flange, which is inserted in a flashing reception groove 85 in an interface unit 8 as described with reference to the top and side flashing members 1012, 1013 above, and that the bottom flashing member 1014 may also have corner flanges 1017a as described for the top flashing member 1011.

[0064] It is further to be understood that while the drawing shows only embodiments, wherein the flashing reception groove 85 is formed in an interface unit 8 of the frame 2, it is also possible to insert the flange 1017 and corner flange 1017a in flashing reception grooves in for example a wooden frame member or in a frame member made by extrusion. If the flashing reception groove is made in a wooden frame, it may be advantageous for the protrusions to have a sealing function thus preventing moisture from entering into the flashing reception groove.

[0065] FIG. 10 is a cross-sectional view corresponding to that in FIG. 8, but showing a more complex top flashing member 1011 with a diverter rail 103 attached to it and showing only the top frame member 21 and the interface unit 8 of the roof window. As may be seen, the diverter rail has a bent edge 1036 fitting over the flange 1017 on the top flashing member, but it might also be a flange of the diverter rail fitting into a bent edge of the top flashing member. This results in that the thickness of the material inserted in the interface unit is bigger than in FIG. 9, where only two single layer flanges were overlapping. Here three layers of aluminium, each having a thickness of 0.47 mm are used, resulting in a total thickness of 1.4 mm and the total height of the flashing reception groove in the height direction H is 7 mm.

[0066] As is seen in FIG. 10, the insertion of the flange 1017 and the diverter rail 103 in the flashing reception groove 85 results in that the protrusions 85 are forced inwards and bends towards the end wall 86 of the flashing reception groove. If the protrusions were longer, sides of the protrusions would come into contact with the flange. This will of course also be the case in the other embodiments, even though the protrusions are shown in their undeformed state in FIGS. 5, 8 and 9, and will apply also where there is no diverter rail or where the flashing member is embodied differently than what is shown in the drawing.

[0067] In addition to depending on the size of the protrusions, the degree of deformation of the protrusions will depend on the thickness of the inserted material, and the protrusions are therefore deformed more in FIG. 10 than they would be if only a single layer was inserted as shown in FIGS. 5 and 8 or if two layers were inserted as in FIG. 9. In the embodiment in FIG. 10, the total thickness of the inserted material constitutes 20% of the total height of the flashing reception groove 85, and each protrusion 85a extends over 63% of the total height of the flashing reception groove in the undeformed state.

[0068] An interface unit 8 as in FIG. 5 is shown in more detail in FIG. 11 and a cross-sectional of the interface unit in FIG. 10 is shown in FIG. 12. In both cases four protrusions 85a1, 85a2, 85a3, 85a4 are shown in their undeformed state and extend over more than half of the distance between the lower wall 80 and the upper wall 88, i.e. over more than half of the height of the flashing reception groove 85 measured perpendicular to the frame plane.

[0069] Two protrusion 85a1 and 85a3 are provided on the lower wall 80 and the two protrusions 85a2 and 85a4 are provided on the upper wall 88, thus providing substantially the same pressure from both sides, when the flange of the flashing member is inserted. In FIG. 12 a further protrusion 85a5 is provided on the upper wall. This 85a5 protrusion may also come into contact with the flashing member, but in the embodiment shown in FIG. 10 this protrusion serves to deflect water away from the flashing reception groove 85 and into a drainage gutter 1038 of the diverter rail 103.

[0070] The two innermost protrusions 85a1 and 85a2 of the interface units 8 in FIG. 11 and FIG. 12 extend in the height direction H, substantially parallel to each other and perpendicular to the upper and lower walls, whereas the outermost protrusion 85a3-85a5 are inclined with substantially the same inclination away from the groove opening 85b. This may facilitate insertion of the flange by the resistance to insertion increasing gradually. It is also envisaged that the inclination of the protrusions may decrease gradually with the distance from the groove opening 85b so that the outermost protrusion has the largest inclination, and/or that all protrusions may be inclined. The considerations regarding inclination of the protrusions apply to all embodiments of the interface unit.

[0071] In FIG. 11 the protrusions 85a are shown as lips extending over the entire length of the interface unit, but it is to be understood that they could be shorter, possibly even having a cone-shape, such that each of the protrusions shown in FIG. 12 presents a row of cone-shaped protrusions. A brush- or comb-like structure with a continuous attachment to the upper and lower walls 80, 88 from which a series of bristle- or rod-like structures project would also be possible.

[0072] The protrusions 85a are preferably made from a material allowing them to yield when coming into engagement with the flange as shown in FIG. 10, whereas the parts 80, 86, 88 delimiting the flashing reception groove 85 are advantageously made from a dimensionally stable material, so that they maintain their shape during insertion of the flange 1017.

[0073] In all of the embodiments shown, the interface units 8 further comprise sealing lips 891, 892, 893, these reference numbers having been added only in FIG. 11 and FIG. 12 for the sake of clarity of the drawing. These sealing lips may be made from the same material as the protrusions or from one or more different materials depending on the sealing requirements. Sealing lips are not linked to the reception of the flanges 1017 of the flashing members in the flashing reception groove 85 and are therefore not necessary to the invention.

[0074] In FIG. 12 parts of the interface unit made from a soft material, i.e. the protrusions 85a and the sealing lips 891, 892, 893, are indicated with a dotted pattern, and parts 80, 86, 87, 88 made from a dimensionally stable material are indicated with hatching. Even though made from different materials, they form a coherent monolithic structure, being made by co-extrusion. The protrusion 85a5 at the groove opening 85b and the sealing lip 892 above it are here interconnected by a thin layer 894 covering an upwards wall 87 of the dimensionally stable material. As may be seen from FIG. 8 and FIG. 9, the upwards wall 87 is the only part of the interface unit, which will be exposed in the mounted state and by covering it, the dimensionally stable may be made from a wider range of materials, which do not necessarily have a good resistance to weather-related effects such as exposure to ultraviolet radiation.

[0075] Interconnecting the protrusion 85a5 and the sealing lip 892 may further contribute to reducing the risk of them coming loose, for example due to mechanical action.

[0076] Components of the roof window 1 are easily disassembled and each component may in principle be reused, be recycled by appropriate environmentally responsible disposal means, or the material be recovered for other uses.

LIST OF REFERENCE NUMERALS

[0077] 1 Roof window [0078] 10 Covering assembly [0079] 1011 Top flashing member [0080] 1011a corner section [0081] 1011g Gutter [0082] 1012 Side flashing member [0083] 1012g Gutter [0084] 1012o Outer side of side flashing member [0085] 1013 Side flashing member [0086] 1013o Outer side of side flashing member [0087] 1014 Bottom flashing member [0088] 1017 Flange [0089] 1017a corner flange [0090] 1017i Marking [0091] 1021 Cladding member [0092] 1022 Cladding member [0093] 1023 Cladding member [0094] 1024 Cladding member [0095] 11 Roof structure [0096] 112 Roofing material [0097] 2 Frame [0098] 200 Frame opening [0099] 21 Top frame member [0100] 22 Side frame member [0101] 23 Side frame member [0102] 24 Bottom frame member [0103] 3 Sash [0104] 4 Pane [0105] 8 Interface unit [0106] 80 Lower wall [0107] 801 Anchor section [0108] 81 Top element of interface unit [0109] 82 Side element of interface unit [0110] 85 Flashing reception groove [0111] 85a Protrusion [0112] 85b Groove opening [0113] 86 End wall [0114] 88 Upper wall [0115] 891 Inner sealing lip [0116] 892 Outer sealing lip [0117] 892 Additional inner sealing lip [0118] F Frame plane [0119] I Direction of inclination [0120] L Length direction