Support structures on roofs

• US 20120233942A1
• Filed: 04/14/2011
• Published: 09/20/2012
• Est. Priority Date: 03/14/2011
• Status: Active Grant

• Current Assignee: T&M Inventions LLC
• Original Assignee: T&M Inventions LLC
• Inventors: McLain, Michael J., Pendley, Timothy
• Granted Patent: US 8,438,801 B2
• Time in Patent Office: Days
• US Class Current: 52/200
• CPC Class Codes: E04B 2103/06 of metal
• CPC Class Codes: E04B 7/02 with plane sloping surfaces, e.g. saddle roofs E04B7/12 takes precedence
• CPC Class Codes: E04B 7/18 Special structures in or on roofs, e.g. dormer windows in connection with roof coverings E04D13/00, especially domes E04D13/03
• 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 13/0305 Supports or connecting means for sky-lights of flat or domed shape
• CPC Class Codes: E04D 13/031 characterised by a frame for connection to an inclined roof
• CPC Class Codes: E04D 13/0315 characterised by a curb frame
• CPC Class Codes: E04D 13/032 Supports or connecting means for sky-lights of vaulted shape
• CPC Class Codes: E04D 13/04 Roof drainage; Drainage fittings in flat roofs, balconies or the likegutter tiles E04D1/30; gutter slabs E04D3/40; vessels for collecting rainwater E03B3/03; street gullies E03F5/04
• CPC Class Codes: E04D 13/0404 Drainage on the roof surface
• CPC Class Codes: E04D 13/0481 Drainage guiding provisions, e.g. deflectors or stimulation by inclined surfaces
• CPC Class Codes: E04D 13/1475 wherein the parts extending above the roof have a generally rectangular cross-section
• CPC Class Codes: E04D 2013/0486 Deflectors
• CPC Class Codes: E04D 3/30 of metal

Abstract

Roof load supports support e.g. skylights and/or smoke vents, optionally including two or more closures in end-to-end relationship, from ribs of a metal roof. Where skylights are end-to-end over an aperture, mating strips support the skylights between upper and lower ends of the support structure. Supports of the invention are mounted above the water line whereby the number of water leaks about the mounting structure is greatly reduced. Water leakage is further reduced by re-designing the upper diverter and the lower closure, and providing for a second installation step. Condensation is further reduced by lifting the insulation inside the building to cover the sides of the closure support structure and providing a no-fastener securement of the insulation at an upper location in the closure support structure, and by providing thermally insulating materials as barriers to penetrating portions of fasteners, penetrating from outside the climate controlled building envelope.

Claims

1. Apparatus adapted to be assembled to form a closed-perimeter closure support structure about a perimeter of an aperture extending through a roof of a building, such closure support structure extending up from such roof of such building and closing off access to such aperture from any side of such aperture, said apparatus comprising

a plurality of closure members adapted to be mounted on such roof and about such aperture in such roof thereby to provide such closing off of access to such aperture from any side of such aperture,

each such closure member comprising one or more closure member panels, including one or more cavity panels which define a cavity portion extending along the length of such closure member, and an elongate slot portion defining an access path into the respective elongate cavity portion,

such closure members, when assembled to each other, end to end, to thereby define such closed-perimeter closure support structure,

including an elongate cavity extending about a perimeter of such assembled closure support structure, the elongate cavity comprising the cavity portions of the respective closure members, and

an elongate slot, comprising the slot portions of said closure members, providing an elongate path into such single elongate cavity.

2. Apparatus as in claim 1, said closure members comprising

(i) a first elongate side rail, comprising one or more elongate rail panels which define a first such cavity portion,

(ii) a second elongate side rail, comprising one or more elongate rail panels which define a second such cavity portion,

(iii) an upper diverter, comprising one or more diverter panels which define a third such cavity portion, and

(iv) a lower closure, comprising one or more lower closure panels which define a fourth such cavity portion.

3. Apparatus as in claim 1, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture, a layer of insulation product being disposed below such roof, such layer of insulation product comprising a vapor barrier sheet, and a layer of thermally-insulating material, edge portions of said vapor barrier sheet being drawn upwardly about the perimeter of the aperture and trapped inside the elongate cavity.

4. Apparatus as in claim 3, said vapor barrier sheet trapping a portion of such thermally-insulating material between itself and one or more of said closure member panels.

5. Apparatus as in claim 3, such roof of such building comprising a plurality of elongate upstanding ribs extending between a ridge and an eave of such building roof, such ribs terminating in upstanding edges having folded-over terminal ends of the respective adjacent roof panels, the width dimension of the elongate slot being defined between a first cavity panel and one of a second cavity panel and such upstanding edge of the respective such rib,

said apparatus further comprising an elongate resilient rod, having a cross-section dimension greater than the width of the elongate slot, said elongate resilient rod being disposed in the elongate cavity and trapping said vapor barrier sheet inside the elongate cavity.

6. Apparatus as in claim 3, said apparatus further comprising an elongate rod having a cross-section dimension greater than the width of the elongate slot, said elongate rod being disposed in the elongate cavity and trapping said vapor barrier sheet inside the elongate cavity.

7. Apparatus as in claim 3, a closure panel being mounted over said closure support structure and closing off access to such roof aperture, and fasteners mounting said closure panel to said closure support structure, said fasteners terminating in said elongate rod.

8. Apparatus as in claim 1, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture,

said closure members comprising

(i) a first elongate side rail, comprising one or more elongate rail panels which define a first such cavity portion,

(ii) a second elongate side rail, comprising one or more elongate rail panels which define a second such cavity portion,

(iii) an upper diverter, comprising one or more diverter panels which define a third such cavity portion, and

(iv) a lower closure, comprising one or more lower closure panels which define a fourth such cavity portion,

such roof of such building comprising a plurality of elongate upstanding ribs extending between a ridge and an eave of such building, and panel flats between such ribs,

said first and second side rails being mounted on adjacent ones of such ribs on opposing sides of a single such panel flat,

said upper diverter extending between said first and second side rails and across the respective panel flat and providing closure, and sealing, of the closure support structure, across the panel flat at an up-slope end of said closure support structure,

said lower closure extending between said first and second side rails and across the respective panel flat and providing closure, and sealing of the closure and support structure, across the panel flat at a down-slope end of said closure support structure.

9. Apparatus as in claim 8, said side rails comprising outer rail panels extending upwardly from such ribs, such ribs terminating in upstanding edges having folded-over terminal ends of the respective adjacent roof panels, a space being disposed between the folded-over terminal ends and underlying portions of such ribs, further comprising, where such space is adjacent a said outer rail panel, a closely-fitting rib plug in the space at a joint between the respective said side rail and a respective one of said upper diverter and said lower closure, further comprising sealant extending about said rib plug and closing off a remainder of the space between said rib plug and said outer rail panel and between said rib plug and the folded-over terminal ends.

10. Apparatus as in claim 8, said upper diverter comprising an upstanding end panel extending between said first and second side rails, and diverter ears extending from said end panel and folded over, and secured to, said side rails, such that said side rails are between said diverter ears and such roof aperture.

11. Apparatus as in claim 1, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture,

said closure members comprising

(i) a first elongate side rail,

(ii) a second elongate side rail,

(iii) an upper diverter, and

(iv) a lower closure comprising a bottom portion and an upper rail,

the bottom portion comprising

(A) a closure web extending upwardly from a panel flat, and

(B) a lower flange extending, from said closure web, toward the roof aperture, said lower flange being secured to such roof panel at the panel flat,

said upper rail being mounted to said closure web and extending, as a bearing panel, from said closure web toward the roof aperture, and extending, from- said bearing panel, downwardly as an inside panel of the respective cavity portion.

12. Apparatus as in claim 1, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture,

said closure members comprising

(i) a first elongate side rail,

(ii) a second elongate side rail,

(iii) an upper diverter,

(iv) a lower closure, and

(v) first and second mating strips, extending across the roof aperture between said first and second side rails, and being disposed between said upper diverter and said lower closure, said first and second mating strips being mounted to said first and second side rails and being mated to each other so as to close a joint therebetween.

13. Apparatus as in claim 12, said first and second mating strips further comprising bearing panels adapted to receive closure structure thereon, overlying portions of such roof aperture.

14. Apparatus as in claim 1, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture,

said closure support structure comprising

(i) first and second elongate side rails mounted to such roof in end-to-end relationship, and a first connecting plate extending between and mounted to both of said first and second side rails,

(ii) third and fourth elongate side rails mounted to such roof in end-to-end relationship, and a second connecting plate extending between and mounted to both of said third and fourth side rails,

(iii) an upper diverter, and

(iv) a lower closure.

27. Apparatus as in claim 1, the cavity having a cavity length, a cavity height, and a cavity width, a dimension of at least one of the cavity height and the cavity width being less than a width dimension of the elongate slot.

28. Apparatus as in claim 11, further comprising a stiffener support plate underlying said lower flange of said bottom portion of said lower closure, and fasteners extending through said bottom portion, through the panel flat of the respective roof panel and into said underlying stiffener support plate, said fasteners firmly securing said lower flange, such roof panel, and said stiffener support plate to each other, with such roof panel between said lower flange and said stiffener support plate.

29. A building, comprising a plurality of upright walls and a roof, apparatus as in claim 1 being mounted on said roof of said building.

15. Apparatus adapted to be assembled to form a closed-perimeter closure support structure about a perimeter of an aperture extending through a roof of a building, such closure support structure extending up from such roof of such building and closing, off access to such aperture from any side of such aperture, said apparatus comprising:

(a) a plurality of closure members adapted to be mounted on such roof and about such aperture in such roof thereby to provide such closing off of access to such aperture, said closure members comprising

(i) a first elongate side rail,

(ii) a second elongate side rail,

(iii) an upper diverter,

(iv) a lower closure, comprising a bottom portion and an upper rail,

the bottom portion comprising

(A) a closure web adapted to extend upwardly from a panel flat, and

(B) a lower flange extending in a first direction transverse to said closure web,

said upper rail being configured to be mounted to said closure web and thereby to extend, as a bearing panel, from said closure web in a direction in common with said lower flange.

16. Apparatus as in claim 15, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture, said lower flange extending, from said closure web, toward such roof aperture, said upper rail being mounted to said bottom portion and lying in overlying relationship with respect to said lower flange and extending, from said closure web, toward such roof aperture.

17. Apparatus as in claim 15, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture, further comprising a closure panel mounted over said closure support structure and closing off access to such aperture.

18. A method of mounting a load to a metal roof of a building, the method comprising mounting a support structure to such metal roof, and subsequently mounting an overlying load to the support structure, the metal roof having upstanding ribs at joints between respective metal roof panels, and panel flats between the ribs, the method comprising:

(a) mounting first and second side rails in side-by-side relationship to adjacent ones of the ribs and across a single panel flat and at a target roof location;

(b) mounting an upper diverter between the first and second side rails, across the panel flat and closing off access to the target roof location from lateral directions, at an up-slope end of the target roof location;

(c) mounting a lower closure between the first and second side rails, across the panel flat and closing off access to the target roof location from lateral directions, at a down-slope end of the target roof location, the lower closure comprising a bottom portion and an upper rail, the bottom portion comprising a closure web and a lower flange extending transversely to the closure web, the method comprising

(i) mounting the lower closure to the roof panel by driving fasteners through the lower flange and into the roof panel in the panel flat, with the lower flange extending from the closure web toward the roof aperture, and

(ii) mounting the upper rail to the bottom portion, with a bearing panel of the upper rail extending from the bottom portion toward the roof aperture such that the bearing panel is in an overlying relationship over the lower flange.

19. A method as in claim 18, further comprising mounting a closure structure over the closure support structure and thereby closing off access to the target roof location from all directions outside the building.

20. Support structure apparatus adapted to be assembled to form a closed-perimeter closure support structure and mounted on a roof of a building about a perimeter of an aperture extending through such roof of such building, such closure support structure extending from an up-slope end thereof on such roof to a down-slope end thereof on such roof, and extending in an upwardly direction from such roof of such building and closing off access to such aperture from any side of such aperture, said apparatus comprising

(i) first and second elongate side rails adapted to be mounted to such roof in end-to-end relationship as a first side of such closure support structure, with said first side rail being disposed toward the up-slope end of such closure support structure and said second side rail being disposed toward the down-slope end of such closure support structure,

(ii) third and fourth elongate side rails adapted to be mounted to such roof in end-to-end relationship as a second opposing side of such closure support structure, with said third side rail being disposed toward the up-slope end of such closure support structure and said fourth side rail being disposed toward the down-slope end of such closure support structure,

(iii) an upper diverter adapted to extend between said first and third side rails at the up-slope end of such closure support structure,

(iv) a lower closure adapted to extend between said second and fourth side rails at the down-slope end of such closure support structure, and

(v) as part of said support structure apparatus, first and second mating strips adapted to extend across the roof aperture, from side rail to side rail, between the up-slope end and the down-slope end of such closure support structure, said first and second mating strips being adapted to be mounted to respective ones of said side rails and to be mated to each other so as to close a joint therebetween.

21. Support structure apparatus as in claim 20, said first and second mating strips further comprising bearing panels adapted to receive closure structure thereon, overlying portions of such roof aperture.

22. Support structure apparatus as in claim 20, said apparatus being assembled into a said closure support structure and mounted on such roof of such building about such aperture, a first side of said closure support structure comprising said first and second elongate side rails, a second opposing side of said closure support structure comprising said third and fourth elongate side rails, said upper diverter extending between said first and second sides at the up-slope end of said closure support structure, said lower closure extending between said first and second sides at the down-slope end of said closure support structure, said first and second mating strips extending across the roof aperture intermediate the up-slope end and the down-slope end, said first and second mating strips being mounted to respective ones of said side rails and being mated to each other so as to close a joint therebetween.

23. Support structure apparatus as in claim 22, said side rails, said upper diverter, and said lower closure, defining bearing panels which collectively extend about a perimeter of said closure support structure in a common imaginary plane, said first and second mating strips extending across the roof aperture intermediate the up-slope and down-slope ends of said closure support structure and also including mating strip bearing panels in the same imaginary plane, thereby to define a first bearing panel perimeter adapted to receive a first closure panel over a first portion of the roof aperture, including over at least a first one of said mating strips, and a second bearing panel perimeter adapted to receive a second closure panel over a second portion of the roof aperture, including over at least a second one of said mating strips.

24. Support structure apparatus as in claim 23, further comprising first and second closure panels over the respective first and second portions of the roof aperture, including over the first and second mating strips.

25. Support structure apparatus as in claim 24 wherein the first and second closure panels comprise skylight lenses.

26. Support structure apparatus as in claim 25 wherein said first and second closure panels, collectively with portions of said closure support structure, overlie the entirety of the single roof aperture.