Daylighting tube segment connection systems and methods

• US 8,958,157 B2
• Filed: 04/22/2013
• Issued: 02/17/2015
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Solatube International, Inc. (Kingspan Group PLC)
• Original Assignee: Solatube International, Inc. (Kingspan Group PLC)
• Inventors: Rillie, David Windsor, Griego, Thomas P., Robertson, Jeffrey S.
• Primary Examiner(s): Mahoney, Christ
• Application Number:
  US13/867,846
• Publication Number:
  US 20140268347A1
• Time in Patent Office: 666 Days
• Field of Search: 359592-593, 359/597
• US Class Current: 359/593
• CPC Class Codes: E04D 13/03 Sky-lights; Domes; Ventilating sky-lights E04D13/14 takes precedence; structures therefor, e.g. dormer windows E04B7/18; saw-tooth roofs with light-transmission E04B7/12
• CPC Class Codes: E04D 2013/0345 with skylight shafts extending from roof to ceiling
• CPC Class Codes: F21S 11/007 characterised by the means for transmitting light into the interior of a building
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Certain disclosed embodiments provide internally-reflective tube assemblies for use in a tubular daylighting device configured to direct daylight into an interior of a building when installed on a roof of the building. A tube assembly may include multiple tube segments including connection projections, such as hook-type structures, for weaving or otherwise connecting and/or securing tube segments together. In some embodiments, sidewalls of tube segments connected together are substantially parallel to one another at or near the connection region.

Claims

1. An internally-reflective tube assembly for use in a tubular daylighting device configured to illuminate an interior space of a building with natural daylight received through a roof-mounted daylight collector, the tube assembly comprising:

a first internally-reflective tube segment comprising;

a first lower end;

first intermittently positioned projections, wherein the first projections extend from the first lower end and are spaced around a perimeter of the first lower end;

a first upper end that is closer to a daylight collector of a tubular daylighting device than the first lower end when the first tube segment is positioned to receive daylight from the daylight collector of the tubular daylighting device; and

a first tube segment sidewall extending between the first lower end and the first upper end, wherein the first tube sidewall has an interior surface having luminous reflectance greater than or equal to about 98% when measured with respect to CIE Illuminant D₆₅; and

a second internally-reflective tube segment comprising;

a second upper end;

second intermittently positioned projections, wherein the second projections extend from the second upper end and are spaced around a perimeter of the second upper end such that the second projections are capable of being woven together with the first projections;

a second lower end that is further from the daylight collector of the tubular daylighting device than the second upper end when the second tube segment is positioned to receive daylight from the daylight collector of the tubular daylighting device; and

a second tube segment sidewall extending between the second lower end and the second upper end, wherein the second tube sidewall has an interior surface having luminous reflectance greater than or equal to about 98% when measured with respect to CIE Illuminant D₆₅;

wherein the first tube segment sidewall and the second tube segment sidewall are substantially parallel when the first projections and the second projections are woven together.

2. The tube assembly of claim 1, further comprising a tensioning assembly configured to be applied around a woven connection junction between the first and second tube segments.

3. The tube assembly of claim 2, wherein the tensioning assembly comprises a belt portion and a latch portion.

4. The tube assembly of claim 1, wherein the first projections comprise hooks configured to interlock with corresponding hooks of the second projections.

5. The tube assembly of claim 1, wherein the first projections and second projections are configured to be weaved together at least partially through vertical placement of the first tube segment on the second tube segment.

6. The tube assembly of claim 1, wherein the first projections and second projections are configured to be weaved together at least partially through rotational movement of the first tube segment with respect to the second tube segment about a longitudinal axis of the tube assembly when the first lower end is touching the second upper end.

7. The tube assembly of claim 1, wherein the first lower end includes a first perimeter edge having a first surface generally perpendicular to a longitudinal axis of the first tube segment and the second upper end includes a second perimeter edge having a second surface generally perpendicular to a longitudinal axis of the second tube segment, wherein at least a portion of the first surface is substantially flush with at least a portion of the second surface when the first and second projections are woven together.

8. The tube assembly of claim 1, wherein the first tube segment and the second tube segment have sidewalls that at least partially overlap and that are not tapered when the first tube segment and the second tube segment are connected together.

9. A method of manufacturing an internally-reflective tube assembly for use in a tubular daylighting device, the method comprising:

forming one or more sheets of at least partially flexible rigid material;

cutting a first tube segment form out of tube sidewall sheet material having first top, bottom, left and right edges, wherein the first tube segment form comprises one or more first projections along the first bottom edge;

cutting a second tube segment form out of tube sidewall sheet material having second top, bottom, left and right edges, wherein the second tube segment form comprises one or more second projections along the second top edge;

wherein the first tube segment is configured to attach to a roof-mounted daylight collector of the tubular daylighting device;

wherein the first projections and the second projections are configured to be woven together when the first and second tube segments are bent into a tubular shape; and

wherein the first and second tube segment forms have right-edge-to-left-edge dimensions that are substantially equal and uniform over top-edge-to-bottom-edge dimensions of the first and second tube segment forms.

10. The method of claim 9, wherein the first projections comprise hooks.

11. The method of claim 9, further comprising forming a belt configured to be wrapped around a connection junction between the first and second tube segments when the first and second tube segment forms are bent into a tubular shape and connected to each other.

12. The method of claim 11, wherein the belt and the first and second tube segment forms are made of the same material.

13. The method of claim 12, further comprising connecting a tensioning latch assembly configured to securely friction fit the belt around the connection junction.

14. A method of installing an internally-reflective tube assembly in a building having a roof-mounted daylight collector, the method comprising:

positioning a first lower end of a first tube segment such that first lower end touches a second upper end of a second tube segment, wherein the first and second tube segments have a substantially uniform width through a longitudinal height of both tube segments, and wherein the first and second tube segments are positioned to receive daylight from the roof-mounted daylight collector; and

connecting the first and second tube segments at least in part by weaving first projections of the first tube segment with second projections of the second tube segment;

wherein, when connected, sidewalls of the first and second tube segments are substantially parallel.

15. The method of claim 14, wherein the first and second tube segments are generally cylindrical.

16. The method of claim 14, further comprising wrapping a belt around the tube assembly and operating a tensioning member configured to create a secure friction fit between the belt and the sidewalls of the first and second tube segments.

17. The method of claim 14, further comprising:

positioning an upper end of the first tube segment to receive daylight through the roof-mounted daylight collector; and

connecting the upper end to the daylight collector.

18. The method of claim 14, further comprising connecting the second tube segment to a light diffuser positioned inside of the building.

19. The method of claim 14, further comprising disposing the tube assembly between a ceiling and roof of a building structure, wherein daylight is permitted to pass from a region exterior to the building to an interior target area through the tube assembly.

20. The method of claim 14, wherein weaving the first and second projections together includes deflecting the first or second projections radially inward or outward.