PLASTIC FENESTRATION PRODUCT

Abstract

A fenestration product such as a skylight or a window assembly is provided having a frame with a peripheral wall with a light transmitting central region and a plastic dome formed of a light transmitting material mounted to the frame. The plastic dome has a central region which transmits light, a downwardly extending peripheral wall extending about and mounted to the peripheral frame, and an outwardly extending flashing flange for mounting the assembly to a building structure. Various embodiments of the part illustrated include a skylight assembly having a frame formed of a plastic layer formed into an inverted ‘U’ shape cross-section forming an annular channel filled with insulating foam. A sealed, vertically mounted window unit is also disclosed. Other embodiments have an insulating layer of transparent plastic material spaced from the dome forming an enclosed, gas filled insulating region. Methods of forming and installing a fenestration assembly are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 11/832,417 filed Aug. 1, 2007, which is incorporated by referenced herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to fenestration products composed primarily of plastic.

2. Background Art

Plastic is used in a variety of fenestration products such as skylights and windows in buildings as an alternative to a glass panel. Plastic and glass fenestration panels each have their respective advantages and disadvantages. Glass is relatively inexpensive, has good optical properties, is scratch resistant and stable in a variety of harsh environments. Glass, however, is relatively heavy, susceptible to catastrophic failure and can be difficult to handle and fabricate. There is a wide a variety of plastics available for use in fenestration products. Some are low cost, tough, readily formable and environmentally stable. Many plastics, however, are susceptible to scratching, lose their physical properties with age or exposure to environmental factors, and can be relatively expensive.

The use of plastic and fenestration products, although a very small portion of the market compared to glass, is still quite significant. Plastic panels are used in doors for example, particularly storm doors to minimize the risk of injury due to glass fracture. Acrylic dome panels are used in both residential and industrial building skylights, as illustrated in U.S. Pat. Nos. 3,434,257; 4,514,944, and 4,344,261. Recently, the plastic dome skylight has been introduced having acrylic dome mounted in a polyurethane frame molded in situ about the dome peripheral edge, as illustrated in published U.S. patent application 2005/0178078, illustrated in website, www.viechindustries.com/products.html and available from Vtech Industries, Inc. and Carlisle SynTec, Inc.

The focus of the development efforts in the plastic fenestration product area has been, how to mount the plastic panel to the building opening in a secure leak proof manner, while securely supporting the plastic panel on a frame or curb in a structural manner Many of the mounting systems are comprised of multiple component parts which require assembly and have joints which are susceptible to water leaks. Some skylights are deck mounted, others use raised curbs. The molded polyurethane frame of the VTech™ skylight is a simple one piece molded structure which is securely bonded to the plastic dome in a leak proof manner resulting in a very high performance skylight. This skylight, however, is expensive to manufacture as the tooling and production equipment needed is costly and the raw material cost of the high performance polyurethane utilized prevents this construction system from being used in low price point skylight applications.

A number of issues have arisen as skylights have become more popular in housing. The presence of a skylight on a roof interrupts the aesthetics of the rooflines. Therefore, it would be advantageous to design skylights that are relatively unobtrusive.

In high-velocity wind zones, such as along hurricane-prone costal areas, skylights are exposed to severe pressure differentials between the exterior and interior of the house. These pressure differentials may be either positive or negative. The magnitude of the differentials may be sufficient to pull skylight fasteners from the roof panel or increase the stress on the skylight mounting flange to the point where a flange fails and releases the skylight while the fastener remains fixed to the roof panel.

In some new houses, the sealing systems are very effective. As a consequence, build-up of toxic or nauseous gasses can occur. Many of these gasses accumulate in the areas near the interior roof. Skylights may provide extra functionality for venting these gasses, such as skylights that open using cranking mechanisms. But opening the skylight provides an opportunity for insects and airborne particulates to enter the house even if a screen is provided.

SUMMARY OF THE INVENTION

One embodiment of the invention further includes the fenestration product assembly including a dome formed of a first plastic. The dome transmits a portion of the visible light spectrum. The dome also has a central panel, a peripheral side, and a peripheral flange attached to at least a portion of the side. An interior layer formed of a second plastic has a first peripheral edge, a peripheral flange, and a second peripheral edge connected to the dome. The edges and flange form a first cavity between the interior layer and the dome. The first cavity is capable of receiving air from the atmosphere. The interior layer has a plurality of apertures capable of transporting air from the first cavity. A third layer formed of a third plastic has a peripheral edge connected to at least one of the dome or the interior layer. The third layer and the interior layer form a second cavity. The third layer has a second plurality of apertures capable of transporting air from the second cavity.

An additional embodiment of the invention further includes a fenestration product assembly including a frame having an upward extending peripheral wall portion defining an aperture. The fenestration product assembly also includes a dome formed of a plastic material which transmits at least a portion of visible spectrum light. The dome is mounted to the frame and has an exterior side away from the frame. The dome also has a downwardly extending peripheral edge which extends about the peripheral wall. The dome also has an outwardly extending flashing flange. A decorative layer is connected to the exterior side of the dome.

A further embodiment of the invention also includes a skylight having a light transparent panel region sized to span a generally planar building panel opening. The skylight also includes an integrally-formed circumferential wall extending about the light transparent panel region and oriented relative thereto to attach and space the light transparent region above the building panel. The wall has a generally planar peripheral flange extending outwardly from the wall for attaching an opening formed therein to a portion of the building panel.

Another embodiment of the invention also includes a skylight having a generally planar circumferential securing flange for attaching to building panel. The flange has at least one web portion oriented about and spaced apart from the peripheral edge of the flange. The web portion defines, at least in part, at least one opening sized to receive one of a plurality of spaced-apart hook-shaped fasteners affixed to the building panel. The flange, thereby, can move within a plane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a first skylight embodiment of the invention;

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

FIG. 2a is a cross-sectional view of an alternative embodiment of the FIG. 1 skylight;

FIG. 2b is a cross-sectional view of a second alternative embodiment of the FIG. 1 skylight;

FIG. 3 is a cross-sectional side elevation of a light pipe alternative embodiment of the invention;

FIG. 4 is a side view of a window assembly embodiment of the invention;

FIG. 5 is a cross-sectional plan view taken along line 5-5 of FIG. 4;

FIG. 6 is an exploded cross-sectional side elevation taken along line 6-6 of FIG. 4;

FIG. 7 is a top view of a window assembly embodiment of the invention;

FIG. 8 is an exploded cross-sectional top view of a window assembly embodiment as illustrated in FIG. 7;

FIG. 9 is a perspective view of another skylight embodiment of the invention;

FIG. 10 is a cross-sectional view taken along line 10′-10′ of FIG. 9;

FIG. 11 is a perspective view of another skylight embodiment of the invention;

FIG. 12 is a cross-sectional view taken along line 12′-12′ of FIG. 11;

FIG. 13 is a top view of a skylight embodiment of the present invention;

FIG. 14 is a top view of a skylight according to another embodiment of the present invention;

FIG. 15 is a cross-sectional view taken along 15-15 of FIG. 14;

FIG. 16 is a fragmentary top plan view of a skylight according to another embodiment of the invention;

FIG. 17 is a perspective view of a clip for fastening a skylight according to an embodiment of the invention;

FIG. 18 is a fragmentary cross-sectional side view taken along 18′-18′ of FIG. 16 and incorporating the clip of FIG. 17;

FIG. 19 is a cross-sectional view of another alternative embodiment of the invention; and

FIG. 20 is another cross-sectional view of the an additional alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to utilize the present invention.

Except where expressly indicated, all numerical quantities in this description indicating the amounts of material or conditions are understood as modified by the word “about” in describing the broadest scope of the present invention. Practice within the numerical limits is generally preferred.

Accordingly, a number of representative examples of the present invention are illustrated in the drawings and described herein. In the first example, skylight assembly 10 is illustrated in FIGS. 1 and 2. Skylight 10 has two main components as best seen in the FIG. 2 cross-sectional view illustrating the skylight mounted to an opening in a building roof 12. The skylight includes a dome member 14 and a frame member 16 which are both formed of sheets of plastic which have been thermoformed to a three dimensional shape using a conventional thermoforming process such as vacuforming, twin-sheet thermoforming or pressure assisted sag forming. Dome 14 is preferably formed of a light transparent and plastic material such as acrylic or polycarbonate. Depending on the application, the dome may be transparent or may be translucent. A translucent layer having a whitish color can allow light to pass through and act as a diffuser. Plastic dome 14 has a central panel 18 forming a dome shape, a downwardly extending peripheral wall 20 and an outwardly extending flashing flange portion 22. Dome 14 is secured to a peripheral wall portion 24 of frame 16. Frame 16 is also thermoformed of a plastic sheet with the peripheral outer wall 24 forming an annular ring to support dome 14. The frame 16 defines a light transmitting central region 26 to allow light passing through the dome 14 central panel 18 to freely enter the building roof 12.

In the first embodiment of the invention illustrated in skylight assembly 10, the frame 16 has a peripheral wall portion which in cross-section forms an inverted “U” shape having an inner wall portion 28 and upper wall 30. Extending radially outward from outer peripheral wall 24 is a flashing flange 32 which underlies flashing flange portion 22 of dome 14. Optionally, inner peripheral wall 28 extends downwardly into the building slightly below the level of the flashing flange 32 as illustrated in FIG. 2 in order to help align the skylight with the opening formed in the roof sheathing 34. Frame 16 may be formed of a different plastic material than the dome 14 since transparency is not required in the illustrated embodiment. The frame plastic material is preferably of a material which can easily be bonded to the frame using conventional adhesives, solvents or weldments. In the embodiment illustrated, the cavity formed within the inverted “U” shaped cross-section of frame 16 is filled with a foam insulation material 36.

In a typical 2′×4′ building opening size application, skylight 10 can be manufactured using a dome formed of acrylic having a wall thickness prior to thermoforming of 0.60 inches to 0.236 inches or the wall thickness capable of supporting an ultimate load needed in service or required by a regulation or an architect. These ultimate loads may include in excess of 20, 40, or 60 pounds per square feet as tested using procedure A of ASTM E330 after stabilization according to procedure A of ASTM D618. The frame may be formed of acrylic or a different plastic material such as acrylic polycarbonate, terephthalate, polyoxymethylene, polyolefin, and/or polyvinylchloride, since light transmission is not an issue. The wall thickness of the frame need not be thick, particularly when the frame filled with a rigid insulation foam 36. A wall thickness of the frame can range from 0.030 to 0.236 inches. Foamed insulation material such as polyurethane, expanded polystyrene, or polyisocyanurate can be used having densities between 1 pound per cubic foot and 40 pounds per cubic foot.

Preferably, the outwardly extending flashing flange 22 extends outwardly from a downwardly extending dome peripheral wall 28 at least 2″ to 9″ and more preferably, 3″ to 7″, in order to provide an adequate overlap to bond to the water barrier 38 mounted to the building sheathing 34 to allow adequate overlap with the roofing material 40 to prevent water leakage into the building opening. Flashing flange 22 also serves as a mounting flange for attaching the skylight assembly to the building roof sheathing 34. Preferably, corrosion resistant screws or nails are installed through the flashing flange portion 22 into the building roof sheathing 34. The mounting fasteners are preferably located significantly outboard of the dome downwardly extending peripheral wall 20 and well inboard of the outer peripheral edge of the mounting flange, but not necessarily aligned in a row, in order to minimize stress concentrations in the mounting flange caused by wind load on the skylight dome 18. Ideally, holes for fasteners do not have to be pre-drilled, that way assuring that any unused fastener holes do not provide an entry leak path for water. Holes for fasteners 42 may be drilled at the job site. In order to minimize screw pull out, the screws are preferably provided with a relatively large low profile head or be provided with an associated washer such as a compression washer.

FIG. 2a illustrates a cross-sectional view of an alternative embodiment of the skylight assembly. Skylight 44 is made up of three main components; a dome 46, a frame 48 and an insulating layer 50. Dome 46 and frame 48 are substantially similar to dome 14 and frame 16 described in reference to the embodiment invention of FIG. 2, except that the frame 48 terminates before the region in which fasteners are inserted. Insulating layer 50 is formed of a light transparent plastic material. Insulated layer 50 has a central region able to transmit visible light and an outer peripheral flange which is mounted to one of the dome 46 or frame 48 in order to define enclosed interior space 52 interposed between the central regions of dome 46 and insulated layer 50. Interior space 52 is filled with a gas such as air or argon and provides a relatively high thermal transmission resistant barrier between the interior of the building and the building exterior. Insulated layer 50 may be bonded to the upper most portion 54 of frame 48 with an adhesive material or weldment in order to bond the dome to the frame as illustrated. Preferably, one of the top region of frame 54 or the outer peripheral edge 56 of insulated layer 50 is provided with a groove 58 as illustrated for retaining a bead of adhesive or sealing material used to bond the insulated layer 50 to the frame 48. After the insulated layer 50 installed on the frame, the dome is attached using adhesives as described previously to form a completed assembly.

Yet another variation of the skylight assembly is illustrated in FIG. 2b. Skylight 62 is made up of a dome 64, a frame 66 and two insulating layers 68 and 70. Insulating layers 68 and 70 are preferably thermoformed into a dome shape and are formed of a light transmitting plastic material. When completely assembled, a first enclosed space 72 is defined between the dome and insulating layer 70 while a second adjacent enclosed space 74 is defined between insulating layers 68 and 70. These two isolated insulating spaces further enhance the thermal characteristics of the skylight assembly. Preferably, the frame 66 is provided with the pair of step annular recesses 75 and 77 to align insulating layers 68,70 within the assembly and provide a surface on which to secure the insulating layers 68 and 70. With reference to the insulating layers 50, 68 and 70 of skylight assembly 44 in FIG. 2a and skylight 62 in FIG. 2b, respectively, the insulating layers 50, 68 and 70 can be made of relatively thin material since the layers are not subject to a significant mechanical loading. Material such as acrylic, polycarbonate, terephthlate, polyoxmethylene, polystyrene, and/or polyvinyl chloride may be utilized for insulating layers and the material thicknesses can be as thin as 0.030. A sealing bead 73 may optionally be attached to the frame 66 to provide a water resistant bed of sealant between the roof and frame 66.

FIG. 3 illustrates a domed skylight 76 which is part of a larger, tubular skylight assembly 78. Skylight 76 is made up of a dome 80, a frame 82 and an insulating layer 84 which defines an enclosed space 86 between the insulating layer 84 and dome 80. The upper portion of frame 82 forms an annular trough 88 which serves to trap condensate forming on the inner surface of insulating panel 84.

Trough 88 prevents condensate from forming on the skylight interior and dripping into the building interior space. Trough 88 is sufficiently large so that the condensate would be collected during periods of condensate formation and subsequently evaporated when the humidity and/or temperature changes sufficiently to cause the condensate to evaporate. The tubular skylight assembly 78 includes the skylight assembly 76 as well as a light pipe 90 and light diffuser panel 92. Light diffuser panel 92 is mounted to the ceiling of a room within the building and the light pipe 90 extends between the diffuser and skylight assembly 76 to carry light from the skylight dome 80 through the light reflective interior surface of light pipe 90 into the room via the light transparent diffuser 92. Light pipe 90 can be made of a flexible conduit as illustrated or a sheet metal duct structure.

FIGS. 4-6 illustrate a different type of fenestration product constructed in accordance with the teachings of the present invention, namely, a window assembly 100. Window assembly 100 is adapted for permanent installation in a building opening such as a window into a building basement, crawlspace, or a fixed window in a garage, a garage door, or an entry system. Window 100 is specifically designed to simulate a glass block window commonly seen in building basements. Other textures may be incorporated as desired, such as a texture simulating camed glass. As illustrated in the FIG. 5 cross-sectional view, the window assembly 100 includes a dome 102, a frame member 104 structure and an interior layer 106 all formed of a thermoformed plastic material which transmits visible light. Dome 102 has a central panel portion 108, an outer peripheral wall 110 and an outwardly extending flashing flange 112. Frame 104 is also formed of a transparent plastic material having an outer peripheral wall portion 114 and a transparent central wall portion 116. The frame 104 is further provided with an outwardly extending flashing flange 118 overlying flashing flange 112 of the dome 102. Interior layer 106 is provided and bonded to frame 104 thereby defining two enclosed interior spaces between interior layer 106 and the central panel 108 of dome 102. First enclosed space 120 is interposed between interior layer 106 and frame central wall portion 116 and second enclosed region 122 interposed between transparent central wall portion 116 and the central panel portion 108 of dome 102. All three components; dome, frame and interior layer 102, 104 and 106 are forms of visible light transmitting thermoplastic sheet thermoformed to the desired shape. The panels are then joined together to form a secure assembly. Examples of joining methods may include, but are not limited to, ultrasonic welding, heat staking, and/or adhesives. It is understood that joining may also include fastening the three components 102, 104 and 106 to the building with screws, staples, nails or similar mechanical fasteners.

In the window assembly embodiment illustrated in FIGS. 4-6, the central panel 108 and interior layer 106 are provided with simulated grout lines 124 molded into the panels. Preferably, the remainder of the visible portion of panels 108 and 106 are provided with a textured pebble-like surface simulating the appearance of glass block. To further provide a visible barrier, the frame 104 may be formed of a translucent plastic material allowing light to pass, but, impeding the person's view through the window.

Window assembly 100 can be manufactured in standard basement window sizes. Windows can alternatively be designed to be mounted from the exterior or mounted from the interior of the building depending upon the architect's specification. The window assembly 100 can be attached to the wood framed window opening with conventional fasteners such as screws and nails. One or more bezels 126 may likewise be utilized either on the building exterior, building interior or both in order to further seal the joint between the building opening and the window assembly and to enhance the aesthetic appearance of the window.

The plastic sheets utilized to fabricate the three panels 102, 104 and 106 forming window assembly 100 may be of a variety of materials as described previously. While the frame material can be relatively thin, the panel facing the exterior of the building should be sufficiently thick to provide adequate security and provide acceptable aesthetic appearance. The plastic sheets may also be formed of composite sheets of plastic to provide desired enhancements. Examples of the composite sheets may include UV and/or heat transfer resistant films sandwiched between acrylic plastic. Another example may include an intrusion-resistant mylar film bonded between two thin sheets of polycarbonate plastic. It should be further appreciated that additional thin layers of thermoformed plastic material may be utilized in fabricating window 116 placed between dome 102 and inner layer 106 to increase the number of enclosed zones within the window to further improve the thermal resistance of the assembly.

Referring to FIGS. 7 and 8, these figures illustrate an alternative embodiment of a window assembly 130 in accordance with the teachings of the present invention. Window assembly 130 is adapted for permanent installation into a building opening such as window into a basement in a concrete block construction house member. As illustrated in the FIG. 8, an exploded top cross-sectional view, the window assembly 130 includes a dome 132 positioned in an opening in the concrete block wall section 134. The dome has a central panel 136, a peripheral wall 138 and a peripheral flange 142. The window assembly 130 is shaped like a top hat, and defines a cavity 146 into which an interior layer 148 may be inserted. The interior layer 148 includes a central wall panel 150 and a peripheral flange 152. The interior layer 148 may be inserted into the cavity 146 with the distal ends 140 of the flange 152 pointed toward the center panel 136 of the dome 132. It is understood that the distal ends 140 of the flange 152 may be directed away from the central panel 136 without exceeding the scope of this invention. The flange 152 may vary in size based on the number of inserts desired. Typically, the flange 152 may range in length from 0.25 to 4.0 inches and preferably 0.5 to 2.0 inches.

As an option, a sealed insulating unit 156 may be inserted adjacent to the interior layer 148. The sealed unit 156 may include a first central panel 158, a second central panel 160, a peripheral flange 162. The first central panel 158 is hermetically sealed to flange 162 creating an enclosed air space 166. Alternatively, a gas may be injected to space 166 to improve the thermal transmission resistance of the sealed unit 156. An example of the gas that may be injected is an insulator like argon. Alternatively, other insulators may be in the sealed unit. The insulator may include a vacuum, an aerogel, or a nanogel. The cavity 166 should be less than 0.625 inches in thickness and preferably less than 0.5 inches in thickness in order to prevent creation of convection cells within the cavity. The convection cells increase heat transmission. It is desirable that the flange 162 be less than 1.25 inch in length so that when placed adjacent to the interior layer 148, that they form a second air space 168 that may improve the thermal transmission resistance of the window assembly 130. Optional additional interior layers such as a second interior layer 170 may be inserted into cavity 146 to further improve the thermal transmission resistance of the window assembly 130. A coating, a deposition or a film may be applied to at least one of the components of the window assembly 130 including the dome 132, the interior layer 148, the sealing unit 156, and the second interior layer 170.

A cap 172 opposes the central panel 136 and provides closure to the cavity 146. The cap 172 has a peripheral flange 174 which is adjacent to the flange 142 of the dome 136. The cap 172 may also have positioning ribs 178 to assist in centering the cap in the opening in flange 142. The window assembly 130 including the dome 132 and the cap 172 are fastened to the concrete wall structure 134 using fasteners known in the art. An example of the fastener is a molly anchor 180. For aesthetic purposes, an interior trim bezel 182 may be attached to the cap flange 174 using a double stick transfer tape 184. It is understood that other means of attaching the interior trim bezel 182 that are known in the art may be used without exceeding the scope of the invention. Likewise, an exterior trim bezel 186 may be attached to the exterior of the concrete block structure 134 using a barbed insert 188. An example of the barbed insert 188 is commonly referred to as a “Christmas Tree”. It is understood that the barbed insert 188 may have individual prongs or be part of a more continuous ridge of barbed inserts. The window assembly 130 may optionally be insulated by injecting a foamed sealer 190, such as a foaming polymer like foamed polyurethane into a gap between the dome 132 and concrete block wall section 134 before application of the bezel 186.

The invention further includes a method of forming a fenestration product assembly. The method includes steps of thermoforming a first sheet of plastic into a ring shape frame having a cross-section and the general shape of an inverted “U”. A plastic dome is thermoformed from a second sheet of plastic material which transmits visible light defining a dome having a central region and a downwardly extended peripheral flange and a flashing flange extending outwardly from the outer peripheral wall. In one preferred embodiment of the method the central portion of the ring shape frame is cut out forming a central opening through which light can pass. The ring shaped frame and dome are then joined in a nested manner with the dome downwardly extending peripheral wall cooperating with the outer frame peripheral wall. Alternatively, the flashing flange may be omitted from the dome and provided on the ring shaped frame or flashing flanges may be included on both the dome and the ring shape frame.

The method of forming the fenestration product further includes the step of forming a transparent or translucent insulating layer which is interposed between the frame and the dome and bonded to at least one of the frame and the dome to define an enclosed space between the insulating layer and the dome to increase the thermal resistance value of the assembly. Alternatively, the method may include forming a second insulating layer interposed between the first insulating layer and the dome in order to define two separate enclosed regions between the dome and the two insulating layers to further increase the thermal resistance value of the assembly. It is understood that enclosed regions may include ventilating holes to allow relatively small transfers of gas to relieve pressure differentials or other issues associated with a sealed chamber exposed to temperature extremes.

The method may further include the step of filling the “U” shaped channel formed in the frame with the insulating material, such as a polymer foam which is preferably cured in place to substantially fill the “U” shaped trough defined by the frame.

FIG. 9 is perspective view of a skylight 200 embodiment of the invention. The skylight includes a dome 202 formed of a plastic material which transmits visible light. The dome has a central panel 204, a peripheral side 206 and a peripheral flange 208. The peripheral flange 208 is attached to at least a portion of the peripheral side 206. The skylight 200 also includes an interior layer 210 formed of a second plastic. The interior layer 210 has a peripheral edge 212, a peripheral flange 214 and a peripheral edge attached to the dome 216. The interior layer 210 and the dome 204 define a cavity 218. The cavity 218 is capable of receiving air from the atmosphere. The interior layer 210 has at least one small aperture 220 that is capable of transporting air from the cavity 218. Skylight 200 also includes a third layer 222 formed of a third plastic. The third layer has a peripheral edge 224 connected to at least one of dome 204 or interior layer 210. Third layer 222 and interior layer 210 form a cavity 226. Third layer 222 has at least one small aperture 228 capable of transporting air from cavity 226 to an interior space 230. Interior space 230 has active air exchange with the interior of the building.

Cavity 226 may be used to provide functionality to the skylight. A non-limiting example of such functionality is embodied by the inclusion of an air filter 232 within the cavity 226. The air filter 232 allows fresh air to enter the building while excluding insects, air particulate matter and potential allergens. A particularly effective air filter is a high-efficiency particulate air filter (HEPA). Over time, the filter will need to be refreshed. The third layer 222 may include an access door 234 allowing exchange of the old air filter for a new air filter. It is contemplated that the access door may be of any conventional design including, but not limited to, a sliding access door or a hinged access door.

Skylight 200 may also include an air flow controller 236 on the third layer 222 that may partially block the apertures 228 in order to restrict the amount of fresh air entering the room. This is particularly useful during periods of extreme temperature. It is understood that air flow controller 236 may block any fraction of the incoming air ranging from completely blocked to relatively unhindered air flow. While the air flow controller 236 is illustrated in FIG. 10 as being positioned on the third layer 222, it is also contemplated that air flow controller 236 may be placed on interior layer 210. Further, air flow controller 236 may be incorporated into the access door 234. Examples of air flow controller 236 may include, but are not limited to, a slidable panel having apertures similar to apertures 228 on the third layer 222. The apertures on the air flow control panel can be slid to align with all or part of aperture 228 as well as to completely avoid overlapping aperture 228 shutting off airflow from cavity 226 to interior space 230. Another example of an air flow controller may be a louvered vent.

FIG. 11 is a perspective view of another skylight embodiment of the invention. FIG. 12 is a fragmentary cross-sectional view taken along line 12-12 of FIG. 11. The skylight 250 has a frame 252 with an upward-extending peripheral wall 254 defining an opening 256. The skylight also includes a dome 258 which has an exterior side 260. Dome 258 is formed of a plastic material which transmits at least a portion of light of a visible spectrum. Dome 258 is mounted to frame 252 with exterior side 260 spaced away from the frame 252. Dome 258 has a downwardly extending peripheral edge 262 which extends about peripheral wall 254. The dome also has an outwardly-extending flashing flange 264.

Dome 258 has a decorative layer 266 connected to the exterior side 260. Decorative layer 26 as illustrated in FIGS. 11 and 12 includes a graphic that appears to be a shingle for a roof. It is understood that the graphic may be of any suitable image. The shingle graphic is illustrated as being formed by dots. The dots have a density in the range from 10-600 dots per inch. In another embodiment the density of dots is in the range from 100-300 dots per inch. It is understood that the dots may be opaque, semi-transparent, or transparent. It is further contemplated that the graphic may be a continuous film carrying an image that has a portion that is, at least, partially transparent. It should be further understood that the graphic may use more than one layer to convey the graphic. Certain embodiments of the graphic mimic the surrounding roof surface so as to make the skylight less intrusive to the aesthetic of the roof.

The graphic can also be used to control the quantity of visible spectrum light passing from the outside to the inside of the skylight. The quantity of visible light passing through may range from 20%-90% of the light impinging upon decorative layer 266.

FIGS. 13-18 illustrate embodiments of connecting the skylight to the building roof. In FIG. 13, the skylight 300 includes a number of return flanges 302 positioned at the peripheral edge 304 of skylight 300. It is not desirable to have rigid contact with a fixed fastener because the stress will build-up as the material expands or contracts. Return flange 302 allows the plastic to expand and contract as the ambient temperature fluctuates when return flange 302 is slidably connected to the roof. As is illustrated in FIG. 13, the return flanges need not be continuous. In FIG. 13, the expansion of the plastic will radiate from the center point 306. To minimize the stress at the corners, the return flange is angled so that axis of slidable connection of a fixed roof fastener and return flange 302 can be substantially parallel to the axis of expansion or contraction of the skylight 300.

In FIG. 14, the expansion and contraction of the plastic is not symmetrical. However, a skylight 310 embodiment in FIG. 14 has a return flange 312 shaped like a “J”. The return flange interacts with a J-shaped clip 314 as illustrated in FIG. 15. It is advantageous that neither of the J shapes 312 or 314 bottom-out on the complementary J shape during maximum expansion or contraction of the skylight 310. To provide improved holding, a resilient member 316 may be placed at the bottom of the J in either J shape 312 or 314. resilient member 316 may include a foam, a gel, or an elastomeric material. The material may have a Shore durometer ranging from Shore OO 40 to Shore A 80. In another embodiment, the durometer may range from Shore A 25 to A 70. The Shore durometer is measured using ASTM D2240.

A return 318 for the clip 314 is positioned above at least a portion of the peripheral flange 320. The return 312 of the peripheral flange 320 defines a channel 322 which is capable of mating with the return 318 for the clip 314.

In another embodiment, a skylight 340 has a generally planar circumferential securing flange 342 for attaching to a building panel. Flange 342 has at least one web portion 344 oriented about and spaced apart from a peripheral edge of flange 346. The web portion defines at least in part an opening 348 sized to receive a hook-shaped fastener 350 as illustrated in FIGS. 17-18. The hook-shaped fastener 350 may also include a foam band 352 which functions as a resilient member in certain embodiments. It is understood that other resilient members may be used with clip 350.

The generally planar circumferential securing flange 342 may be integrated with a visible light transparent plastic panel 354. The visible light transparent plastic panel 354 is generally non-planar relative to the securing flange 342.

In FIGS. 19 and 20, embodiments are illustrated with relatively low-profile skylights. Low-profile skylights minimize the aesthetic obtrusiveness of the skylight on the roof as well as minimize the vacuum-force trying to pull the skylight out of the roof during high wind velocity events. Further, a low-profile skylight minimizes the cross-section that may be impacted by a debris missile during high wind velocity events. Low profile dome embodiments bearing relatively small slopes of peripheral walls may deflect debris missiles more readily. The force of an impact may be broken into parallel and perpendicular vectors, thereby reducing the missile impact force transverse to the peripheral wall. The low-profile skylight, such as a skylight 370 embodiment in FIG. 19, may have a maximum height above the roof surface ranging from 1-8 inches. In another embodiment, low-profile skylight 370 may have a maximum height ranging from 1.5 inches to 6 inches above the roof.

In a skylight 380 embodiment illustrated in FIG. 20, skylight 380 may include two or more layers beneath a dome 382. A central layer 384 may rest on a frame 386 which mates with the outer dome 382. It is understood that the central layer 384 may be bonded to either the outer dome 382 or the frame 386. Further, the central panel may be free-standing and separable from the outer dome 382 and/or the frame 386.

An additional functional layer 388 may be positioned adjacent to or resting upon the frame 386. The functional layer 388 may also be bonded or otherwise connected to the frame 386 or the central panel 384. Frame 386 may have molded into it a condensation catch 390.

The angle of frame 386 may be sloped so as to maximize the amount of captured light that is directed to the interior. The dome 382 has an upward standing portion 392 which, when combined with the height dome above the roof, defines a ratio of the area of the light-transmitting panel region 394 relative to the interior opening size 396. For example, when a skylight interior dimension 396 is approximately 16 inch then the angle of the dome, theta 398 may range from 15° to 45° relative to an axis perpendicular to the roof, so that the visible light transmitting panel region 394 is equal to or greater than the interior dimension 396. In another embodiment, the angle may range from 20° to 35°.

In another example, when the profile height is one inch, and the theta 398 is 20°, the ratio of the light transmitting panel dimension 394 to the interior dimension 396 is 2. In another example, when the profile height is 8 and the angle theta 398 is 35°, the ratio of the visible light panel dimension 394 to the interior dimension 396 is 1.7. In other embodiments, the range of the visible light panel dimension 394 to the interior dimension 396 ranges from 1.5 to 1.95. In another embodiment, the range of the visible light panel dimension 394 divided by the interior dimension 396 ranges from 1.8 to 1.9.

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 fenestration product assembly comprising:

a frame having a first vertically extending peripheral wall portion defining a central opening, a second vertically extending peripheral wall portion spaced outboard from the first wall portion and an upper region therebetween forming an integral trough for collecting condensate; and

a dome formed of a first plastic material which transmits visible light, the dome mounted to the frame and having a central panel portion overlying the frame central opening, a vertically extending peripheral dome wall having a lower edge which extends about the frame second peripheral wall, and an outwardly extending flashing flange extending outward of the dome wall lower edge, the flashing flange being permanently securable about its periphery to a building structure for mounting the assembly.

2. The fenestration product assembly of claim 1 wherein the frame comprises a unitary plastic ring portion.

3. The fenestration product assembly of claim 2 wherein the frame forms has an inverted U-shaped cross section.

4. The fenestration product assembly of claim 3 wherein the frame further comprises a thermal insulation material which substantially fills the inverted U-shaped cross section.

5. (canceled)

6. The fenestration product assembly of claim 3 wherein the frame further comprises a flashing flange portion extending outward from the wall portion and at least partially underlying the flashing flange of the dome.

7. The fenestration product assembly of claim 1 further comprising an insulating layer formed of a plastic material which is transparent to visible light, the insulating layer mounted to at least one of the frame and the dome, and having a central panel portion overlying the frame central opening and a peripheral edge which is mounted to at least one of the frame and the dome to define an enclosed cavity between the insulating layer and the dome.

8. The fenestration product assembly of claim 7 further comprising a second insulating layer formed of a plastic material which is transparent to visible light, the second insulating layer mounted between the insulating layer and the dome, and having a central panel portion overlying the frame central opening and a peripheral edge which is mounted to at least one of the frame peripheral wall, the insulating layer and the dome, thereby subdividing the enclosed cavity between the insulating layer and the dome.

9.-27. (canceled)

28. A fenestration product assembly comprising:

a dome formed of a first plastic, which transmits a portion of the visible light spectrum, the dome having a central panel, a peripheral side, and a peripheral flange attached to at least a portion of the side;

an interior layer formed of a second plastic, the interior layer having a first peripheral edge, a peripheral flange, and a second peripheral edge connected to the dome, forming a first cavity between the interior layer and the dome, the first cavity capable of receiving air from the atmosphere, the interior layer having a plurality of apertures capable of transporting air from the first cavity; and

a third layer formed of a third plastic, the third layer having a peripheral edge connected to at least one of the dome and the interior layer, the third layer and the interior layer forming a second cavity, the third layer having a second plurality of apertures capable of transporting air from the second cavity to a building interior space.

29. The fenestration product assembly of claim 28, wherein the second cavity includes an air filter.

30. The fenestration product assembly of claim 29, wherein the air filter includes a high efficiency particulate air (HEPA) filter.

31. The fenestration product assembly of claim 29, wherein the third layer includes an access door.

32. The fenestration product assembly of claim 31, wherein the third layer includes an airflow controller.

33. The fenestration product assembly of claim 28, wherein an angle between the dome's peripheral side and the roof ranges from 15 degrees to 45 degrees.

34. (canceled)

35. A fenestration product assembly comprising:

a frame having an upward extending peripheral wall portion defining an aperture;

a dome formed of a plastic material which transmits at least a portion of visible spectrum light, the dome being mounted to the frame and having a exterior side away from the frame and having a downwardly extending peripheral edge which extends about the peripheral wall, and an outwardly extending flashing flange; and

a decorative layer connected to the exterior side of the dome.

36. The fenestration product of claim 35, wherein the decorative layer includes a shingle graphic.

37. The fenestration product of claim 36, wherein the shingle graphic comprises dots having a density in the range from 10 to 600 dots per inch.

38. The fenestration product of claim 36, wherein the shingle graphic admits a quantity of visible spectrum light to the aperture ranging from 20% to 90% of the visible spectrum light impinging upon the decorative layer.