Skylight with curb design

Abstract

A skylight assembly includes a curb which supports the skylight above the roof surface. The curb is formed from four mechanically connected structural insulated panels. The panels include an outer fastener-receiving member such as OSB with an intermediate polystyrene foam layer and an innermost melamine layer. The curb is assembled on site and fastened to the roof structure with brackets. The melamine surface provides a finished interior surface and the curb itself provides thermal insulation.

Description

BACKGROUND OF THE INVENTION[0001]Skylights can be applied to a roof deck using several installation methods. Certain skylights are supported on a curb which raises the skylight above the surface of the roof.[0002]Foam insulated curbs have been utilized, such as those disclosed, for example, in Kiekhaefer U.S. Pat. No. 3,417,522; Jentoft et al. U.S. Pat. No. 4,073,097; and Moench et al. U.S. Pat. No. 4,233,493, as well as several others. Generally, these foam insulated curb structures are unitary structures formed in a mold. They may have limited structural integrity and, further, require a separate mold for each different size skylight. Further, since they are unitary in structure, they use a large amount of space during shipping and are difficult to transport and use at the construction site.[0003]Other structures have been used to form curbing, such as simply dimensional lumber, such as 2×6's, and the like. These are difficult to assemble on site and, further, lend themselves to i...

AI Technical Summary

Benefits of technology

[0004]The present invention is premised on the realization that a skylight curb can be formed from structural insulated panels (SIP). More particularly, the structural insulated panels take the form of elongated plank components with an outer fastener engaging portion and an inner finish portion and an intermediate foam core. The edge structures of each of these planks are designed to provide for easy assembly. An edge of a first SIP plank includes a fastener-receiving insert at the end of the foam core, while the adjacent edge of a second SIP plank includes an elongated fastener-receiving portion, or wood portion, which overlaps the first SIP plank, allowing the two to be screwed together forming a precise 90° angle. Four SIP planks are fastened together to form a curb.

Problems solved by technology

They may have limited structural integrity and, further, require a separate mold for each different size skylight.

Further, since they are unitary in structure, they use a large amount of space during shipping and are difficult to transport and use at the construction site.

These are difficult to assemble on site and, further, lend themselves to irregularities in size and variations in plumb.

Further, the wood itself provides less than adequate thermal insulation, making the curb only minimally efficient portion of the skylight.

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