SKYLIGHT WITH WIDE BASE TO ACCOMMODATE VARIOUS SIZES OF CURBS WITH CONVERTIBLE FIXED AND OPERABLE PORTIONS

Abstract

A skylight includes a transparent member such as glass and a frame holding the transparent member. The frame has a rectilinear horizontal top overlapping a top of the transparent member, a rectilinear horizontal base parallel to the horizontal top and overlapping a bottom of the transparent member, and a rectilinear vertical side connecting the top to the base. The base is wider than the top to accommodate plural differently sized curbs. To provide for an operable assembly, an operable base may first be engaged with the roof and the skylight hinged to the base to open and close.

Description

FIELD

The present application relates to skylights with wide bases to accommodate various sizes of curbs with convertible fixed and operable portions.

BACKGROUND

Skylights originally made for new construction can require replacement over time, and as understood herein the skylights may have been made in many different sizes to accommodate the requirements of the particular build they were designed for. As also understood herein, this means that manufacturers must carry a large number of different-sized replacement skylights or bear the expense of making custom skylights for each replacement.

SUMMARY

Accordingly, a skylight includes a transparent member and a frame holding the transparent member. The frame includes a rectilinear horizontal top overlapping a top of the transparent member, a rectilinear horizontal base parallel to the horizontal top and overlapping a bottom of the transparent member, and a rectilinear vertical side connecting the top to the base. The base is wider than the frame top to accommodate plural differently sized curbs.

In some embodiments, at least one spacer is installed between the vertical side and an outer surface of a roof curb. The spacer abuts both the vertical side and the outer surface of the curb when the skylight is engaged with the curb, with a top of the curb abutting the base. At least one fastener can extend through the vertical side and curb to hold the skylight to the curb when the skylight is engaged with the curb, with the spacer preventing urging of the vertical side and curb toward each other.

The at least one spacer may include a first spacer snappingly engaged with a second spacer.

If desired, an operable base may be hingedly engaged with the frame to move the frame between an open configuration, in which an opening in a roof to which a curb is attached is open, and a closed configuration, in which the opening is closed by the skylight. An operating mechanism in the operable base can be coupled to the skylight to move the skylight. In non-limiting example the operating arm may be actuated by a solar-power motor.

The transparent member may include one or more glass panes. For example, dual glass panes separated from each other by a space may establish the transparent member.

The base can be at least two inches wide along at least of four sides of the base. If desired all four sides of the base may be at least two and one quarter inch wide and may be at least three inches wide for accommodating various curb sizes.

In another aspect, an assembly includes a fixed skylight with a transparent member engaged with a frame defining a base having a width sufficient to accommodate first and second sizes of roof curbs. An operable base can be engaged with the curb. The fixed skylight is mountable to the operable base to move the fixed skylight relative to the operable base to open and close a roof opening bounded by the curb. The fixed skylight is engageable with the curb without the operable base to provide a fixed skylight installation and is engageable with the operable base which in turn is engageable with the curb to provide an operable skylight installation.

In another aspect, a skylight to cover a roof curb includes a parallelepiped-shaped frame with a top end covered by at least one transparent member to allow light to pass through. The frame defines four sides. At least two of the sides of the frame have a respective top layer partially overlapping a top of the transparent member, a respective vertical base flange depending downwardly from the respective top layer, and a respective horizontal base extending from the respective base flange inwardly to partially overlap a bottom of the transparent member. Each respective base extends further inwardly than the respective top layer. At least one spacer is disposed between at least a first one of the respective base flanges and an outer surface of the curb such that the spacer abuts both the first base flange and the outer surface of the curb when the skylight is engaged with the curb with a top of the curb abutting the respective base. At least one fastener extends through the first base flange and curb to hold the skylight cover to the curb when the skylight is engaged with the curb, with the spacer preventing urging of the first base flange and curb toward each other. At least two of the respective bases are at least two inches in a width dimension perpendicular to an optical axis defined by the frame generally along which light propagates, such that a curb of a first size can engage each base near an outer edge thereof and a curb of a second size can engage each base near an inner edge thereof to facilitate use of the skylight with plural differently sized curbs.

The details of the present application, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a fixed skylight on a curb surrounding an opening in a roof;

FIG. 2 illustrates a top plan view of the skylight in FIG. 1;

FIG. 3 illustrates a sectional view as taken along the line 3-3 in FIG. 2;

FIG. 4 illustrates detail “4” in FIG. 3;

FIGS. 5 and 6 illustrate perspective views of nested spacers;

FIG. 7 illustrates an exploded view of a fixed skylight mounted on an operable based engaged with a roof opening;

FIG. 8 illustrates a side view of the assembly of FIG. 7;

FIG. 9 illustrates the motor linkage in the operable base along with a detail view thereof, with portions cut away for clarity;

FIG. 10 illustrates in example flow chart format an example assembly method for engaging the fixed skylight with the operable base;

FIGS. 11, 12, and 12A illustrate a modular embodiment of the frame;

FIGS. 13-19 illustrate snap together corners on the operable base; and

FIGS. 20-23 illustrate spacer configuration details

DETAILED DESCRIPTION

Referring initially to FIG. 1, a skylight 10 includes a transparent member 12 such as a pane of glass or multiple panes of glass separated from each other by a space to provide insulation. Plastic alternatively may be used. A parallelepiped-shaped or rectilinear frame 14 holds the transparent member 12. The frame 14 has a rectilinear horizontal top 16 partially overlapping a top of the transparent member 12, a rectilinear horizontal base (not shown in FIG. 1) parallel to the horizontal top 16 and partially overlapping a bottom of the transparent member, and a rectilinear vertical side 18 connecting the top to the base. As disclosed further below, the base 26 is wider than the top to accommodate plural differently sized curbs such as a curb 20 extending upwardly from a roof 22 and bounding an opening the roof. Shapes other than rectilinear may be used depending on the geometry of the roof opening and the curb surrounding it.

FIGS. 2-4 illustrate further details, and in particular attention is directed to the detail view of FIG. 4. FIG. 4 shows the top 16, which may be tape, of the frame 14. FIG. 4 also shows the vertical side 18 of the frame 14, also referred to herein as a base flange. A sealant 24 may be disposed between the edge of the transparent member 12 and side or base flange 18 and top 16 to seal the side or base flange to the transparent member, which is illustrated in FIG. 4 as being composed of two panes of glass with a space between them.

The side or base flange 18 extends down past the transparent member 12 to the above-mentioned horizontal base 26, which is implemented in the embodiment shown by one or more parallel spaced-apart extruded segments. The width “W” of the base 26 is wider than the width of the top 16 such that the base 26 extends further inwardly under the transparent member 12 than the top 16. In some examples the width “W” of some or all of the sides of the base 26 is at least two inches and may be three inches or more. The width dimension, as can be appreciated from the figures, is perpendicular to the axis along which light substantially propagates through the transparent member 12.

An L-shaped cleat 28 may attached to the side or base flange 18 to retain the base 26. In the example shown, one segment is attached to the side 18 and the other perpendicular segment extends within the space between the two spaced-apart extruded segments of the base 26. A closed cell foam layer 30 may be disposed on the top of the base 26.

As shown in FIG. 4, the top of the curb 20 abuts the bottom of the base 26 when the skylight is engaged with the curb. One or more fasteners 32 such as screws may extend through the wide or base flange 18 and into the curb to couple the curb to the frame 14. To avoid deforming the assembly as the fastener is secured, one or more spacers 34 are disposed between the outer surface of the curb 20 and the inside wall of the side or base flange 18. The spacer train abuts both the vertical side 18 and the outer surface of the curb when the skylight is engaged with the curb to prevent urging of the vertical side or base flange 18 and curb 20 toward each other. As set forth further below, spacers are interchangeable and can be snapped together in Lego-like fashion as appropriate to fill the distance between the wise or base flange 18 and the outer surface of the curb 20.

Because of the relatively wide width “W” of the base 26, a curb of a first size can engage the base 26 near an outer edge thereof and a curb of a second size can engage the base 26 near an inner edge thereof to facilitate use of the skylight with plural differently sized curbs. As many spacers 34 as needed can be used to provide lateral support for the curb against the side or base flange 18. In this way, a single skylight 10 can be used with multiple different-sized curbs, i.e., the skylight can accommodate curbs of varying sizes.

FIGS. 5 and 6 illustrate plural spacers 34, each of which is generally shaped as a hollow triangle in the non-limiting example shown. Each spacer 34 may be formed with a circular passage 500 near its top apex to receive a fastener therethrough and a slot 502 near or on its bottom base to receive a complementarily shaped land 504 of another spacer, e.g., in a snap fit or other interference fit.

Turn now to FIGS. 7-9 for an additional feature. An assembly 700 in FIG. 7 includes a fixed skylight 702 that in all essential respects is identical to the skylight 10 shown in FIG. 1. As discussed above, the skylight 702 is engageable with a curb 704 to provide a fixed skylight installation. However, to provide an operable skylight installation should the customer so desire (to enable open and closing the skylight), an operable base 706 can be engageable with the curb 704. The fixed skylight 702 can be mounted to the operable base 706 to move relative to the operable base to open and close a roof opening bounded by the curb 704. The operable base may include the same wide rectilinear lower base structure described above to accommodate plural differently sized curbs.

In the example shown, the operable base 706 is hingedly engaged with the frame of the fixed skylight 702 at one end of the frame and operable base to pivot the frame relative to the operable base between an open configuration, in which an opening in a roof to which the curb 704 is attached is open, and a closed configuration, in which the opening is closed by the skylight.

In FIG. 8, one or more hinges 800 couple an end of the skylight frame to the operable base. At the end of the assembly opposite to the hinge 800, an operating mechanism such as an arm 802 in the operable base 706 is coupled to the skylight 702 to move the skylight. The operating mechanism is actuatable up-and-down by a motor 804 powered by solar cells 806. FIG. 9 illustrates that the operating mechanism 802 can be coupled to an L-shaped carrier 900 extending through the frame of the operable base 706 via an eyelet in the carrier 900, which in turn is coupled to the operating mechanism and hence to the motor.

FIG. 10 illustrates an example method for installing the operable installation shown in FIGS. 7-9. Commencing at block 1000, the parts of the kit including a rectilinear sash of the operable base are laid out. At block 1002 the solar motor operation is checked using, e.g., a wireless remote once the motor is connected to the solar cells and prior to installation.

The rectilinear sash is assembled at block 1004. Moving to block 1006, a polyvinylchloride (PVC) rectilinear frame of the operable base 706 is dropped into the sash and fastened to the sash. The solar panel 806 is attached to the end of the frame of the operable base 706 at block 1008, and the operable base then placed on the roof curb at block 1010.

Proceeding to block 1012, spacers such as spacers 34 described above can be used to center the operable base 706 to the internal drywall bounding the roof opening. The motor 804 is connected to the solar panel 806 at block 1014. In non-limiting examples a rain sensor may be provided to automatically actuate the motor to close the skylight in the presence of rain, and it likewise may be connected at block 1014.

Moving to block 1016, holes may be drilled into the fixed skylight 702 to mate with registered holes in the operable base 706. Proceeding to block 1018, the bracket to hold the operating mechanism (which may be referred to as a “chain”) is attached to the fixed skylight 702 and the actuating mechanism also attached. The fixed skylight 702 is then hingedly attached to the operable base at block 1020.

FIGS. 11 and 12 illustrate a modular assembly embodiment for a frame 1100 holding one or more transparent members 1102. The embodiment of FIGS. 11 and 12 illustrate an example assembly substantially identical to the relevant structure described previously with the following exceptions. The frame in the example shown is rectilinear and a respective support bracket 1104 is engaged with each respective side of the frame as shown. Each support bracket 1104 includes a side surface 1106 that substantially covers completely the respective side of the frame and a respective top surface 1108 that extends inwardly from the side surface 1106 perpendicular to the side surface 1106 to partially overlap the top edge of the side of the frame.

The corners of adjacent support brackets 1104 are joined by respective joining bracket 1110, which as shown in FIGS. 12A and 12 may be longer in the vertical dimension (relative to the horizontal plane of the frame) than it is in the other two dimensions. FIGS. 12 and 12A illustrate the joining bracket 1110 in an inverted orientation. FIG. 12A shows the joining bracket from the inside perspective relative to the frame and FIG. 12 shows the joining bracket from the outside perspective.

The top surface 1200 of each joining bracket 1110 is substantially square, and two side surfaces 1201, 1204 are perpendicular to each other to form the bracket configuration. It will be appreciated that the top surface 1200 extends inwardly beyond the side surfaces 1202, 1204. The end of adjacent support brackets 1104 meet at the seam between the side surfaces 1202, 1204 of the joining bracket, and fasteners (not shown) can be used to affix the support brackets to the joining brackets and the support brackets to the edges of the frame 1100, with the top surfaces 1200 of the joining brackets 1110 partially overlapping the top surface of the frame 1100 between the top sides 1108 of the respective adjacent support brackets 1100.

Refer now to FIGS. 13-19, which illustrate an example operative assembly 1300 substantially identical to the relevant structure described previously with exceptions noted below. A fixed skylight 1300 is coupled to an operable base 1302. A respective corner bracket 1304 is engaged with each respective corner of the operable base 1302.

FIGS. 14 and 15 illustrate inner and outer perspective views, respectively, of a corner bracket 1304. Each corner bracket 1304 includes an L-shaped portion with two vertical walls 1400 perpendicular to each other, and a partially (because only two walls) pyramidal portion 1402 extending from the walls 1400 above the walls 1400 and inclined inwardly as shown. At the top of the pyramidal portion 1402 is another pair of vertical walls 1404 perpendicular to each other, with the two sides of the structure being continuous as shown from top to bottom.

Two swagings 1406 are formed in a vertical column on one of the walls 1400 of the L-shaped portion for purposes to be shortly disclosed.

FIGS. 16 and 17 illustrate respective ends of respective sides 1600, 1700 of the operable base 1302 that are to be joined. As shown, a wall 1602 with vertically-spaced protrusions 1604 is provided at the end of the side 1600 in FIG. 16 perpendicular to the side 1600. The side 1700 is formed near its end with two vertically-spaced openings 1702 to receive the protrusions 1602 therein to hold the sides 1600, 1700 together. The side 1600 also is formed with vertically-spaced holes 1606.

Once the sides 1600, 1700 are joined by the protrusions/openings, the resulting edge between the sides can be covered by a corner bracket 1304 as illustrated in the respective outer perspective and inner perspective views of FIGS. 18 and 19. Specifically as shown in FIG. 19, the L-shaped portion 1400 of the corner bracket 1304 is attached by swaging 1406 to the side 1600 in vertically spaced openings 1606. The side 1700 can then be inserted into the combined L-shaped portion 1400/side 1600 assembly to allow the vertically spaced protrusions 1602 to snappingly engage the vertically spaced openings 1702. The L-shaped portion 1400 of the corner bracket 1304 works in conjunction with the side 1600 to capture and lock in the side 1700. Each side of the L-shaped portion 1400 of the corner bracket 1304 lies flush against a respective side 1600, 1700 of the operable base 1302.

FIGS. 20-23 illustrate spacer principles discussed above. FIGS. 20 and 21 show a fixed skylight installation 2000 that is substantially similar in configuration and operation to the assembly shown in FIGS. 1-6 supported on, respectively, a relative large curb 2002 (FIG. 20) consequently requiring only a single spacer 34 disposed between the outer surface of the curb and the inside wall of the side or base flange, and supported on (FIG. 21) a relatively smaller curb 2100 and consequently requiring plural spacers 34 disposed between the outer surface of the curb and the inside wall of the side or base flange.

FIGS. 22 and 23 show an operable skylight installation 2200 that is substantially similar in configuration and operation to the assembly shown in FIGS. 7-9 supported on, respectively, a relative large curb 2202 (FIG. 22) consequently requiring only a single spacer 34 disposed between the outer surface of the curb and the inside wall of the side or base flange, and supported on (FIG. 23) a relatively smaller curb 2300 and consequently requiring plural spacers 34 disposed between the outer surface of the curb and the inside wall of the side or base flange.

While particular techniques are herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims.

Components included in one embodiment can be used in other embodiments in any appropriate combination. For example, any of the various components described herein and/or depicted in the Figures may be combined, interchanged, or excluded from other embodiments. “A system having at least one of A, B, and C” (likewise “a system having at least one of A, B, or C” and “a system having at least one of A, B, C”) includes systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.

Claims

1. A skylight comprising:

a transparent member;

a frame holding the transparent member, the frame comprising a rectilinear horizontal top overlapping a top of the transparent member, a rectilinear horizontal base parallel to the horizontal top and overlapping a bottom of the transparent member, and a rectilinear vertical side connecting the top to the base, the base being wider than the top to accommodate plural differently sized curbs.

2. The skylight of claim 1, comprising:

at least one spacer disposable between the vertical side and an outer surface of a roof curb, the spacer abutting both the vertical side and the outer surface of the curb when the skylight is engaged with the curb, a top of the curb abutting the base;

at least one fastener extendable through the vertical side and curb to hold the skylight to the curb when the skylight is engaged with the curb, the at least one spacer preventing urging of the vertical side and curb toward each other.

3. The skylight of claim 2, wherein the at least one spacer comprises a first spacer snappingly engaged with a second spacer.

4. The skylight of claim 1, comprising an operable base hingedly engaged with the frame to move the frame between an open configuration, in which an opening in a roof to which a curb is attached is open, and a closed configuration, in which the opening is closed by the skylight.

5. The skylight of claim 1, wherein the transparent member comprises at least one glass pane.

6. The skylight of claim 4, comprising at least one operating mechanism in the operable base and coupled to the skylight to move the skylight.

7. The skylight of claim 1, wherein the base is at least two inches wide along at least of four sides of the base.

8. An assembly, comprising:

a fixed skylight comprising a transparent member engaged with a frame defining a base having a width sufficient to accommodate first and second sizes of roof curbs;

an operable base engageable with the curb and to which the fixed skylight is mountable to move the fixed skylight relative to the operable base to open and close a roof opening bounded by the curb;

wherein the fixed skylight is engageable with the curb without the operable base to provide a fixed skylight installation and is engageable with the operable base which in turn is engageable with the curb to provide an operable skylight installation.

9. The assembly of claim 8, wherein the frame comprises a rectilinear horizontal top overlapping a top of the transparent member, the base comprises a rectilinear horizontal base parallel to the horizontal top and overlapping a bottom of the transparent member, and a rectilinear vertical side connecting the top to the base, the base being wider than the top to accommodate plural differently sized curbs.

10. The assembly of claim 9, comprising:

at least one spacer disposable between the vertical side and an outer surface of a roof curb, the spacer abutting both the vertical side and the outer surface of the curb when the skylight is engaged with the curb, a top of the curb abutting the base;

at least one fastener extendable through the vertical side and curb to hold the skylight to the curb when the skylight is engaged with the curb, the at least one spacer preventing urging of the vertical side and curb toward each other.

11. The assembly of claim 10, wherein the at least one spacer comprises a first spacer snappingly engaged with a second spacer.

12. The assembly of claim 8, wherein the operable base is hingedly engaged with the frame to move the frame between an open configuration, in which an opening in a roof to which a curb is attached is open, and a closed configuration, in which the opening is closed by the skylight.

13. The assembly of claim 8, wherein the transparent member comprises at least one glass pane.

14. The assembly of claim 12, comprising at least one operating mechanism in the operable base and coupled to the skylight to move the skylight.

15. The assembly of claim 8, wherein the base is at least two inches wide along at least of four sides of the base.

16. A skylight to cover a roof curb, comprising:

a frame with a top end covered by at least one transparent member to allow light to pass through, the frame defining four sides;

at least two of the sides of the frame comprising a respective top layer partially overlapping a top of the transparent member, a respective vertical base flange depending downwardly from the respective top layer, and a respective horizontal base extending from the respective base flange inwardly to partially overlap a bottom of the transparent member, each respective base extending further inwardly than the respective top layer;

at least one spacer disposed between at least a first one of the respective base flanges and an outer surface of the curb, the spacer abutting both the first base flange and the outer surface of the curb when the skylight is engaged with the curb, a top of the curb abutting the respective base;

at least one fastener extending through the first base flange and curb to hold the skylight to the curb when the skylight is engaged with the curb, the at least one spacer preventing urging of the first base flange and curb toward each other, wherein

at least two respective bases being at least two inches in a width dimension perpendicular to an optical axis defined by the frame generally along which light propagates, such that a curb of a first size can engage each base near an outer edge thereof and a curb of a second size can engage each base near an inner edge thereof to facilitate use of the skylight with plural differently sized curbs.

17. The skylight of claim 16, wherein each base is at least three inches wide.

18. The skylight of claim 16, comprising at least one operable base interposed between the frame and a roof

19. The skylight of claim 16, wherein the at least one spacer comprises a first spacer snappingly engaged with a second spacer.

20. The skylight of claim 16, wherein the transparent member comprises at least first and second glass panes.