Fenestration Product Such as a Skylight Having a Laminated Glazing Unit

Abstract

A fenestration is provided having a peripheral frame defining a frame opening, the frame being adapted to being installed upon an opening in a building panel. Cooperating with the peripheral frame is a laminated panel which is structurally mounted to and sealingly spans the peripheral frame opening to form a structural and leak proof interconnection. The laminated panel is formed of three structural layers; an outer and inner plastic sheet and a resin layer interposed therebetween which are collectively bonded together to form a structural laminate, the laminated panel being capable of transmitting visible light therethrough.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to fenestration products, particularly, a skylight having a laminated glazing unit.

2. Background Art

Fenestration building products have been used to allow light into residential, commercial, and industrial buildings and typically fit in an opening in the building. Examples of fenestration products include skylights and tubular skylights. Skylights typically do not require the same degree of optical quality of windows. Therefore, low cost and lightweight plastic panels can be used in place of glass. Skylights are typically formed of a light transparent panel of glass or plastic mounted in a peripheral frame formed of wood, metal or extruded plastic. In order to achieve structural rigidity the plastic panels are frequently outwardly domed in a convex manner, the peripheral edges of the plastic panels being mounted in a rectangular or circular mounted frame.

Skylights are typically mounted on non-vertical surfaces of the building, particularly a roof. As a consequence, they are subjected to damage when items fall on them. Examples of these items may include hail, swaying tree limbs, or wind driven missiles such as during a hurricane. Sudden breaching of the skylight window subjects the underlying room to potentially substantial water damage and possibly could pressurize or depressurize the building causing the failure of other windows or doors. In extreme situations, breaching a skylight can allow strong winds to pressurize a building leading to the loss of a roof or other major structural failures.

In order to address missile impact failures, skylights in hurricane regions frequently use laminated tempered glass panels or very thick wall domed acrylic panels. However, laminated glass canopies are relatively heavy and relatively expensive. Their weight often demands stronger, more expensive support structures, like the door, larger roof joists, and larger size equipment for installation. Both of these increase the overall cost of the skylights.

What is needed is an inexpensive fenestration product which is inexpensive and lighter in weight that prevents catastrophic breaching such as with skylights by falling or windblown debris.

SUMMARY OF THE INVENTION

In its simplest form, the present invention comprises a fenestration product, such as a window or a skylight, to be mounted in a building opening. The fenestration product is provided with a peripheral frame to be mounted on the building defining a frame opening. Within the frame opening is a laminated panel capable of transmitting visible light into the building. The laminated panel is an outer periphery which is held by the peripheral frame spanning the panel opening. The laminated panel is made up of a first sheet of plastic, a second sheet of plastic and an interposed layer of resin which bonds the first and second sheets of plastic internal resin layer into a structural member. The laminated panel is selectively formable into a three-dimensional shape.

A preferred embodiment of the invention is a skylight assembly having a peripheral frame defining a frame opening. Within the frame opening is a laminated panel which sealingly cooperates with the peripheral frame to close the peripheral frame opening. The laminated panel is transparent to visible light and is made up of three layers, a first sheet of plastic, an intermediate sheet of resin and a second sheet of plastic which are collectively bonded together to form a laminate. Preferably, the laminate is selectively thermal formed so that the central region of the laminate forms a dome.

Another preferred embodiment of the invention, the dome laminated panel has a the peripheral frame molded in situ about to form a leak resistant bond between the single piece molded frame and the laminated panel.

In yet another embodiment of the invention, the skylight assembly described above having a peripheral frame and a laminated panel is further provided with the secondary transparent panel located in spaced relation to the laminated panel and cooperating with the frame to define an enclosed space which is filled with gas to improve the insulating qualities of the skylight assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side elevational view of a skylight used as part of a tubular skylight assembly installed in a building on a roof;

FIG. 2 illustrates a perspective view of a skylight according to an embodiment of the present invention;

FIG. 3 illustrates a fragmentary cross-sectional view taken along line 3-3 of FIG. 2 according to an embodiment of the present invention;

FIG. 4 illustrates a perspective view of an alternative rectangular skylight embodiment of the present invention; and

FIG. 5 illustrates a fragmentary cross-sectional view taken along line 5-5 of FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Reference will now be made in detail to compositions, embodiments, and methods of the present invention known to the inventors, however it should be understood that the disclosed embodiments are merely exemplary of the present invention which may be embodied in various alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting rather merely as a representative basis for teaching one skilled in the are to variously employ the present invention. Except where expressly indicated all numerical quantities in this description indicating the amounts of material or conditions it is understood as modified by the word “about” in describing the broadest scope of the present invention. Practice within the numerical limits is generally preferred.

In referring to FIG. 1, a building 2 is illustrated with a non-vertical surface, namely a roof 4. The roof 4 has an opening 6 into which a skylight assembly 8 is fitted. The skylight assembly 8 includes a skylight canopy 10 connected to a frame 12. The frame 12 is optionally provided with a curb 14 and a flashing 15. The skylight assembly 8 has a collector 16 reflective interior surface which is adjacent to a joist 18 of the roof 4. The reflective interior surface of collector 16 is connected to a light pipe 20 which will conduct light to an interior room below defined by the ceiling of the room 22. The ceiling of the room 22 has an opening 24 through which the light pipe 20 passes and is connected to an interior flange 26 that is adjacent to the interior room side of the ceiling 22. Attached to the interior flange 26 is a diffuser 28 that permits light from the skylight to be spread more broadly about the room below.

It should be understood that the reflective interior surface of collector 16, the light pipe 20, the interior flange 26, and the diffuser 28 are optional items in the skylight assembly 8.

The optional curb 14 and flashing 15 may be secured to the roof by methods known in the art. It should be understood that the frame 12 may include other securing elements without exceeding the spirit of the invention.

It should be further understood that while illustrations of certain embodiments are directed to skylight assemblies, other fenestration products may not exceed the spirit of the invention. Non-limiting examples of other fenestration products may include windows, patio doors, sidelights, doorlites, and transoms.

Referring now to FIG. 2, a circular skylight embodiment 8 is illustrated showing an example of the current invention. It should be understood that the shape of the skylight may be an architectually suitable shape providing sufficient structural and sealing integrity, such as round, oval, square, or rectangular shapes. In this example, the skylight directly opens into the building interior space without using a light pipe 20.

Referring to FIG. 3 which is an embodiment of the cross-section 3-3 shown in FIG. 2, the canopy 10 is illustrated as having a first sheet of plastic 40 having a periphery 42, a second sheet of plastic 44 having a periphery 46, and a resin layer 48 with a periphery 50.

The sheets of plastic 40 and 44 may be formable when laminated with the resin layer 48 in certain embodiments. These sheets range in thickness from 0.75 mm to 100 mm, with typical thicknesses independently selected from 2 mm, 3 mm, 4 mm, 5 mm, 10 mm or 20 mm. Non-limiting examples of forming processes for these sheets may include thermoforming, vacuum forming or pressure forming. The forming process in certain processes may occur at a temperature below a melting point of the selected plastics used in sheets 40 and 44. The processing temperature for forming should exceed a service temperature for the skylight, which in certain embodiments may range from 60-95° C. Examples of formable materials include acrylic and polycarbonate.

The sheets of plastic 40 and 44 are adjacent to the resin layer 48. It should be understood that the plastic 40 and 44 may be bonded, adhered or otherwise secured to the resin layer to form a multi-layer structural laminate. The fitness-for-use requirements of the inner plastic sheet 44 may be less stringent than the outer plastic sheet 40. The sheet 40 being on the outer layer may be exposed to a harsher environment than the sheet 44 on the inner layer in regards to temperature extremes, ultraviolet radiation, physical abrasion, and other conditions. It should be understood that the outer and inner sheets may be different or identical materials without violating the intent of the invention. Examples inner plastic sheets 44 may further include polyolefin, vinyl, and terephthalate. Since the inner plastic sheets 44 may not provide as much structural strength as the outer plastic sheets 40 the thickness of the inner sheet 44 may also be relatively thinner than the outer plastic sheet 40.

The resin layer 48 may be comprised of a resin. Non-limiting examples of the resin include polyvinyl butyral, ethylene vinyl acetate polymer or copolymer, or polyethylene. The resin layer may be applied as a liquid, a film or a sheet according to certain embodiments of this invention. Other physical forms of the resins may be used in this invention without violating the intent of the invention.

The periphery 51 of the canopy 10 which includes the periphery 42 of the first sheet 40, the second sheet 44 and the resin layer 48 is overmolded into the peripheral frame 12. It should be understood that other means of securing the canopy 10 to the frame 12 may be used without violating the spirit of this invention. Examples of securing means may include a gasket or a sealer. In certain embodiments, an optional spaced apart inner layer of plastic 52 may be included in the skylight assembly 8 in order to improve the thermal transmission resistance of the assembly 8. The multi-layer canopy 10 and the inner plastic layer 52 are preferably bonded together about their peripheral edges by a two-sided tape seal 53 to form an insulated unit. The two-sided tape seal 53 is described in detail in co-pending commonly owned U.S. patent application Ser. No. 11/671,657, entitled “Polymeric Insulated Glazing Unit with Molded Frame”, which is incorporated herein in its entirety.

The frame 12 may be formed of multiple pieces in a conventional manner. The multiple pieces may be fitted around the periphery of the canopy 10 to form the skylight assembly 8. An example is a rectangular frame having four individual frame sections that may corner-keyed and sealed. The frame is then sealed to the laminated panel using methods and materials known in the art.

Preferably the frame 12 is formed as a single piece. The single piece may be made as a separate molded part having no joints. The separate molded part then being sealed to the laminated panel. As an alternative, the frame 12 may be the single piece molded in-situ encapsulating the periphery of the laminated panel and simultaneously forming a watertight seal.

Materials that may be suitable for forming a single piece frame may include polymers, such as thermoset plastics like reaction injection molded plastics, thermoplastics, and fiber reinforced plastics. These materials may be shaped by processes known in the art, such as reaction injection molding, high pressure injection molding, extrusion, thermoforming, or compression molding.

Further, the skylight assembly 8 either alone or as part of a tubular skylight may have a reflective interior surface 54. This provides a good seal against dust and other small debris dropping from the inside of the roof, as well as allowing the skylight to be trim finished from an interior perspective. The reflective interior surface 54 aids in transmitting light to the room below. In addition, the reflective interior surface 54 may also connect with the light pipe 20 to further enhance the amount of light going to the room.

An example of the skylight assembly having the light pipe is disclosed in detail in co-pending, commonly owned U.S. patent application Ser. No. 11/671,726, entitled “Overmolded Fenestration Building Product and Method of Manufacture”, which is incorporated herein in its entirety.

As an option, a mar-resistant coating 56 may be applied to an exterior exposed surface of the plastic sheet 40 of the canopy 10. Siloxane or polymethyl methacrylate coatings or the like can be used to provide a hard, mar resistant exterior surface to the canopy 10.

To make the skylight assembly 8, take two sheets of plastic 40 and 44 which will be large enough to span the opening 6. In certain embodiments, the first 40 and second 44 sheets are bonded together by interposing the resin layer 48 between them. The sheets are laminated using methods known in the art. Non-limiting examples of methods may include pressure and/or heat, or heat under vacuum. Such a step removes any gas that may be trapped between the layers, as well as provides any curing or bonding necessary for the resin layer 48.

The laminated panel formed above optionally may be formed into a three-dimensional shape, such as a pyramid, a dome or similar convex configuration. The three-dimensional shape may provide additional structural strength relative to a flat sheet. Further, the three-dimensional configuration may less the impact force by deflecting the impact of some of the energy of relatively concentrated short-term loads such as 2″×4″ lumber missiles driven by a hurricane-force wind. These concentrated short-term loads are simulated by a missile impact test like TAS 201 used by the Miami-Date County Building Department. As described above, the laminated sheet may be formed using processes known for shaping. In an example of an embodiment of the method, a laminated panel may be positioned in a first mold half which is warmed sufficiently to soften the laminated panel. By applying a relatively mild pressure, the laminated panel, when softened, may then be shaped to conform to the first mold half. The laminated panel, once shaped, can be removed from the first mold half and positioned in a second mold that is a closed mold. The closed mold then is injected with a plastic in an area adjacent to the periphery of the laminated panel.

In this embodiment of the method of making the skylight assembly 8, a continuous frame 12 of plastic is molded in situ and the plastic forms a seal between the frame and the laminated panel. Once the frame 12 is cured, a substantially complete skylight assembly 8 can then be removed from the open mold. Forming the single piece frame encapsulating the laminated panel eliminates extra seals and joints, and is an example of the method to limit the opportunities for water to leak into a residence or commercial building. Seals and joints of other designs may deteriorate with environmental exposure, as well as fail due to fatigue originating with cyclic wind pressures and thermal expansions. The formation of a molded polymer frame is disclosed in published U.S. patent applications US2005/0178078A1 dated Aug. 18, 2005 and US2005/0055901A1 dated Mar. 17, 2005, both of which are co-pending, commonly owned, and incorporated by reference herein in their entirety.

The leak-tightness of the skylight assembly 8 may be tested according to ASTM E547-00 and ASTM E331-00. For areas of the United States that often suffer hurricane force winds and driven rain, an acceptance criterion for these standards is allowing no leakage during the period of the test. Structurally, the skylight assembly 8 may be tested according to ASTM E330-02 where there is a positive and negative wind load placed on the skylight assembly 8. The acceptance standard for a hurricane velocity wind zone is where the skylight assembly 8 exceeds the load of 250 pounds per square foot.

Even more significant performance criteria for the skylight assembly 8 are the missile impact test and a cycling test of TAS201 and TAS203 used by the Miami-Dade County Building Department. When measured using these two methods, an acceptance criterion is that no cracks or tears occur in the skylight assembly 8 at less than 90 pounds per square foot of force when measured using TAS203.

FIG. 4 illustrates an alternative embodiment of the invention; a rectangular skylight 60. The rectangular skylight 60 includes a peripheral frame 62 which is generally rectangular in shape defining a rectangular frame opening 64. Oriented within frame opening 64 is a laminate panel 66 which has a rectangular outer peripheral edge which cooperates with frame 62 in a secure and water-tight manner. Preferably, laminated panel 66 is convexly domed as shown. Laminated panel 66 is transparent to visible light, and it can either be transparent or translucent. Frame 62, as illustrated, is of a simple cap construction adapted to fit upon a raised curb mounted on the building roof opening. Alternatively, frame 62 can have an integrally formed curb and a flashing as illustrated in the FIG. 3 embodiment.

The skylight 60 of FIG. 4 is shown in cross-sectional side elevation in FIG. 5. In this embodiment, a single laminated panel 66 is provided, however, a spaced apart second panel similar to plastic sheet 52 shown in FIG. 3, can be provided if an insulated skylight is desired. Frame 62 is designed to fit over a curb 68 shown in phantom outline in FIG. 5. A sealant is preferably installed between the top surface of the curb and corresponding cooperating surface of peripheral frame 62. Once installed in place, the screws 70 would be driven through a skirt portion 72 of frame 62 to securely attach the skylight assembly 60 to the curb 68. Preferably, the roofing member 74 will extend between flange 72 and the curb to provide a water-tight roof system.

EXAMPLE 1

Commercial buildings are using large skylights to allow natural light into the building and reduce their reliance on florescent overhead lighting. Such a commercial skylight is a curb-mounted cap. In this example, a curb with the outside maximum diameter of 46″×94″ can be prepared in the commercial roof to receive the nominal 4′×8′ curb-mounted cap having a laminated panel. The laminated panel is comprised of two 3 mm thick sheets of polymethyl methacrylate with 1.5 mm thick layer of polyvinyl butyral resin between the two sheets of acrylic. The laminated panel then is thermoformed into the shape of a dome. The domed laminated panel is then encapsulated with a frame of aliphatic polyurethane material which is colored bronze for aesthetic purposes. This curb-mounted cap then is mounted on the roof on the prefabricated curb.

EXAMPLE 2

In this example, the skylight for a residence is mounted on the roof having less than a 20° slope. A 3′×3′ residential skylight assembly is fitted into a 30.5″×30.5″ rough opening with a self-flashing curb attached to the roof. A curb-mounted cap having maximum outside dimensions of 34.5″×24.5″ is attached to the seamless self-flashing curb. The curb is trimmed out on the interior using approximately ¼″ thick sheets of trim stock wood. Trim stock is attached to the roof joists and finished to meet with the interior ceiling.

The curb-mounted cap includes a laminated panel having a 3 mm acrylic sheet on the exterior layer and a 2.5 mm polyethylene terephthalate interior layer. Between the layers a sheet of 0.5 mm ethylene vinyl acetate copolymer is bonded. The laminated panel is shaped to a dome configuration using vacuum-assisted thermoforming at a temperature of approximately 120° C. to 150° C.

EXAMPLE 3

For a residence in a high velocity wind zone such as within one mile of the Florida coast, a higher impact material may be necessary for the canopy 10. A skylight having this higher impact resistance is formed with a laminated panel having 4 mm polycarbonate on the outer layer and 2 mm polycarbonate sheet on the interior layer. The polyvinyl butyral layer in between the two sheets of polycarbonate is 2.5 mm. The outer layer of polycarbonate is protected with a coating of polymethyl methacrylate for increased resistance to degradation by ultraviolet light. On top of the polymethyl methacrylate layer, a layer of tetraorgano polysiloxane is applied as a scratch resistant coating. The laminate is encapsulated in a frame of aliphatic polyurethane material. This forms the curb-mounted cap which is then applied to the residential seamless self-flashing curb as in Example 2. The cap is secured to the curb with deck screws or the like.

It should be appreciated that various fenestration products may be manufactured utilizing the novel laminated panel and frame assembly and the invention is not limited to skylights per se. While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

1. A skylight assembly, the assembly comprising:

a peripheral frame defining an opening; and

a laminated panel having a periphery, the panel cooperating with the peripheral frame and spanning the opening, the laminated panel having a first sheet of plastic, a second sheet of plastic, and an interposed layer of resin between the first and second sheets of plastic, the first sheet being bonded to the resin layer, the resin layer being bonded to the second sheet, the laminated panel being selectably formable into a three-dimensional shape.

2. The skylight assembly of claim 1, wherein the frame is a single piece frame.

3. The skylight assembly of claim 2, wherein a portion of the laminated panel is overmolded by the frame forming a watertight seal when measured by ASTM E547-00 and ASTM E331-00.

4. The skylight assembly of claim 2, wherein the single piece frame includes a curb.

5. The skylight assembly of claim 1, wherein the laminated panel is formed in the shape of an outwardly convex dome.

6. The skylight assembly of claim 1 wherein the dome comprises a thermoformed laminated panel.

7. The skylight assembly of claim 1, wherein the layer of resin includes polyvinyl butyral, ethylene vinyl acetate or polyurethane.

8. The skylight assembly of claim 1, wherein at least one sheet of plastic includes an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin sheet.

9. The skylight assembly of claim 8, further including a mar-resistant layer adjacent to the plastic sheet.

10. The skylight assembly of claim 1, further comprising:

a third sheet of plastic, wherein the third sheet of plastic and the second sheet of plastic define a cavity spanning a portion of the opening.

11. The skylight assembly of claim 1, further having a reflective interior surface positioned below the opening.

12. The skylight assembly of claim 11, wherein the reflective interior surface has an end adjacent to a roof member.

13. The skylight assembly of claim 1, further including a light pipe cooperating with the laminated panel, the light pipe extending to an interior room below the roof.

14. A skylight assembly comprising:

a laminated panel having a periphery, the laminated panel including a first sheet of plastic, a second sheet of plastic, and a layer interposed between the first sheet and the second sheet, the laminated panel being shaped into a convex configuration; and

a peripheral frame defining an opening, the frame being configured to connect to a roof and defining an opening, wherein the laminated panel spans the opening.

15. The skylight assembly of claim 14, wherein the peripheral frame is formed of a moldable polymeric material entrapping the periphery of the laminated panel and forming a leak-tight structural joint therewith, where the structural aspect of the joint is measured according to ASTM E330-02 at a positive/negative load exceeding 250 pounds per square foot, the leak-tightness aspect of the joint being measured according to ASTM E547-00 and ASTM E331-00, allowing no leakage.

16. The skylight assembly of claim 14, the laminated panel passing tests TAS201 and TAS203, wherein no cracks or tears occur at less than 90 pounds per square foot when measured according to TAS203.

17. The skylight assembly of claim 14, wherein at least one sheet of plastic is comprised of an acrylic, a polycarbonate, a terephthlate, a vinyl, or a polyolefin plastic.

18. The skylight assembly of claim 14, wherein the first sheet and the second sheet are comprised of different plastics.

19. The skylight assembly of claim 14, wherein the peripheral frame is formed of a material including at least one of a reaction injection molding material, a thermoplastic material, or a material filled with reinforcing fibers.

20. A method for making a skylight assembly, comprising:

forming a laminated panel having a periphery by providing a first sheet of plastic, providing a second sheet of plastic, bonding the first and second sheets together by interposing a resin layer therebetween;

attaching a frame to the periphery of the laminated panel, the frame adapted to receive the periphery of the laminated panel and configured to be connected to a roof.

21. The method of claim 20, wherein at least one sheet comprises an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin material.

22. The method of claim 20, wherein the resin layer includes polyvinyl butyral, ethylene vinyl acetate, or polyurethane.

23. The method of claim 20, wherein the frame is a single piece frame.

24. The method of claim 23, wherein attaching the single piece frame includes applying a plastic adjacent to the periphery of the laminated panel.

25. The method of claim 24, wherein the plastic includes a thermoset material, a thermoplastic material, or a fiber reinforced plastic.

26. A method for making a skylight assembly, comprising:

providing a first sheet of plastic having a first melting point;

providing a second sheet of plastic having a second melting point;

providing a layer of resin interposed between the first sheet of plastic and the second sheet of plastic;

forming a laminated panel including the first sheet of plastic, the second sheet of plastic, and the interposed layer of resin;

degassing the laminated panel to remove a gas from between the first sheet of plastic, the second sheet of plastic, and the interposed resin layer;

positioning the laminated panel within a first mold half;

warming the laminated panel to a temperature less than the lesser of the first or the second melting points;

conforming the laminated panel to the first mold half;

removing the formed laminated panel from the first mold half;

positioning the formed laminated panel in a closed mold;

closing the closed mold;

injecting a plastic adjacent to the periphery of the formed laminated panel, to form a continuous frame between the frame and the laminated panel;

opening the mold; and

removing the skylight assembly.

27. The method of claim 26, wherein at least one sheet of plastic includes an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin sheet.

28. The method of claim 26, wherein the resin includes polyvinyl butyral, ethylene vinyl acetate copolymer, or polyurethane.

29. The method of claim 26, wherein the plastic injected adjacent to the periphery of the laminated panel includes a reaction injection molded plastic, a thermoset, a thermoplastic, or a fiber reinforced plastic.

30. A fenestration product for installation within a building opening, the fenestration product comprising:

a peripheral frame defining a frame opening and the laminated panel cooperating with the peripheral frame and spanning the opening to provide a structural water-tight connection,

a panel formed of three structural layers; a first outer plastic layer, a second inner plastic layer and an intermediate resin layer interposed therebetween, laminated together to form a structural member;

wherein the peripheral frame is formed of a single piece of polymeric material which is molded in situ about the outer periphery of the laminated panel.

31. The fenestration product of claim 30, wherein the fenestration product passing tests TAS 201 and TAS 203, wherein no cracks or tears occur at less than 90 lbs. per square when measured according to TAS 203.

32. The fenestration product of claim 30, wherein the laminated panel includes a three-dimensional shape.