BACKGROUND

[0001] The present invention relates generally to a mounting system and assembly for a skylight. More particularly, the invention relates to a skylight mounting system that incorporates a skylight assembly having interfitting frames for easy assembly and a gasket configuration that drains condensation from the skylight cover.

[0002] Skylights are commonly incorporated into buildings, houses, and other structures. They often reduce energy consumption because they infuse desirable natural light into the interior of a structure, which thereby decreases dependency on artificial lighting. To exploit the benefits of using a skylight, it is preferred to maximize the amount of light entering the skylight's exterior cover.

[0003] A typical skylight system may include an exterior cover mounted on a building roof, an interior lens at the building interior, and a light channel disposed between the exterior cover and the interior lens. The exterior cover is affixed to the system with a mounting system. An exemplary typical skylight system is described in US 4,928,445 A.

[0004] Because of temperature differences between a building interior and the building's exterior environment that is bridged by a skylight, moisture condensation within a skylight can be a concern when selecting a particular skylight design.

[0005] Thus, there is a need for a skylight mounting system and assembly that drains condensation from the skylight cover while also maximizing the amount of light entering the lens of the skylight and allows for easy assembly. SUMMARY

[0006] The present invention includes a skylight assembly. In one embodiment of the skylight assembly, the assembly includes an upper frame having a first surface and a first and a second downwardly extending leg from the first surface. The first and second downwardly extending legs of the upper frame define an upper channel therebetween. The skylight assembly also includes a lower frame having a second surface and a first and a second upwardly extending leg from the second surface. The first and second upwardly extending legs of the lower frame define a lower channel therebetween. The lower frame further includes a downwardly extending leg from the second surface. The skylight assembly also includes a connector clip for securing the upper frame to the lower frame and a gasket secured to the surface of the lower frame. Further, the skylight assembly includes a first lens secured between the upper frame and the gasket. Further, the connector clip forms a generally U-shape and includes at least two extenders angled downward towards each other into the generally U-shape of the connector clip.

[0007] In an alternative embodiment of the skylight assembly, the assembly includes a frame and a gasket. In this embodiment, the gasket includes a first lateral surface and a second lateral surface resides below the first lateral surface. The first lateral surface includes a first end and a second end wherein the first end is disposed adjacent to the frame. The first lateral surface further includes respective first, second, and third longitudinal members. The first longitudinal member is disposed positioned at the first end of the first lateral surface and extends upwardly from the first lateral surface. The third longitudinal member is disposed at the second end of the first lateral surface and includes an upwardly extending leg from the first lateral surface. The second longitudinal member includes an upper end and a lower end and intersects the first lateral surface between the first and third longitudinal members. The second lateral surface extends outwardly from the lower end of the second longitudinal member. The skylight assembly also includes a lens secured between the frame and the gasket.

[0008] The present invention also concerns a method of mounting a skylight system. The method includes providing skylight assembly components which includes an upper frame having a downwardly extending upper channel and inside and outside legs bordering the channel, a lower frame having an upwardly extending lower channel, a connector clip, a gasket having a first gutter channel and a second gutter channel, and a lens. The method of mounting a skylight system further includes mounting the skylight assembly components, which includes the steps of securing the lower frame to the gasket, securing the connector clip within the lower channel of the lower frame, securing the lens above the first and second gutter channels of the gasket, and inserting the inside leg of the downwardly extending upper channel into the connector clip secured within the lower channel of the lower frame.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of an embodiment of the skylight assembly of the present invention secured to a curb and a roof structure.

[0010] FIG. 2 is a cross-sectional elevation view, taken at A:A in Fig. 1 , of an embodiment of the skylight assembly of the present invention secured to a curb.

[0011] FIG. 3 is a perspective cross-sectional view, taken at B:B, C:C in Fig. 1 , of an embodiment of the skylight assembly of the present invention secured to a curb. [0012] FIG. 4 is an exploded cross-sectional view of selected components of the skylight assembly of Fig. 3.

[0013] FIG. 5 is a exploded cross-sectional view of selected components of the embodiment of the skylight assembly of Fig. 3.

[0014] FIG. 6 is a perspective cross-sectional view of selected components of the embodiment of the skylight assembly of Fig. 3.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

[0015] The present invention relates to a skylight mounting system and assembly. The skylight mounting system and assembly of the present invention controls and drains moisture condensate upon the interior of the skylight exterior cover. The skylight mounting system and assembly also maximizes the amount of light transmitted into the light channel and building interior. Additionally, the skylight mounting system and assembly of the present invention preferably allows for easy assembly.

[0016] The composition, components, materials, sizes, and shapes of the skylight mounting system and assembly may vary. For example, the skylight mounting system and assembly may vary depending upon size and shape of the curb upon which the assembly is mounted. Additionally, the apparatus may vary depending upon the degree of incline of the mounting surface, the potential moisture levels for a particular mounting environment, and the amount of desired natural light sought to be infused into a structure. Although primarily described herein in terms of its use to increase natural light within a structure and to decrease energy consumption, it will be clear that the apparatus and method of the present invention provides additional benefits. Further, the primary components of the skylight mounting system and assembly as described herein may be combined with additional components and materials without departing from the spirit and the scope of the present invention. The invention will be described with reference to the figures which are an integral non-limiting component of the invention. Throughout the description similar elements will be numbered accordingly.

[0017] Fig. 1 discloses an embodiment of an assembled skylight assembly 10 of the present invention. As shown, the skylight assembly includes a frame 20 and at least one lens 100. The frame 20 is preferably for securing to a skylight curb 16 that is built on the top of a roof structure 14. The skylight assembly 10 forms a number of different shapes. For example, in the illustrated embodiment, the skylight assembly is generally rectangular. In alternative embodiments of the present technology, however, the skylight assembly may be of shapes other than rectangular. Furthermore, the skylight assembly may be mounted on a horizontal or angled roof structure.

[0018] Fig. 2 discloses a side view of a cross-sectional cut-out portion 1 1 of an embodiment of the assembled skylight assembly 10 of the present invention. Fig. 3 discloses a perspective view of a cut-out portion 1 1 of an embodiment of the assembled skylight assembly 10 of the present embodiment. As illustrated in the embodiments of Figs. 2 and 3, the skylight assembly includes a frame 20 for securing to a curb 16, a gasket 70, and at least one lens 100.

[0019] As discussed above, the skylight assembly includes a frame 20. In the embodiments of Figs. 2 and 3, the frame 20 includes an upper frame 30 and a lower frame 40. As shown in the exploded view of Fig. 4, which discloses the cut-out portion 1 1 of exemplary components of the skylight assembly 10 of the present invention, the upper frame 30 includes a surface 32 and first and second legs 34, 36, respectively, that extend downwardly from the surface 32. In the illustrated embodiment, the surface is generally planar. The first and second downwardly extending legs 34, 36, respectively, combined with a portion of the surface 32, preferably form a channel 38 therebetween. Because the legs 34, 36 extend downwardly from the surface 32, channel 38 likewise opens downwardly. In the embodiment of Fig. 2, the first downwardly extending leg 34 and the second downwardly extending leg 36 of the upper frame 30 are parallel to each other and perpendicular to the surface 32 of the upper frame 30.

[0020] The lower frame 40 preferably includes a surface 42 having a first end 51 and a second end 52. Like surface 32, surface 42 is also generally planar. The lower frame 40 also preferably includes first and second legs 44, 46 that extend upwardly from the surface 42. The first and second legs 44, 46, combined with a portion of the surface 42, form a channel 48 therebetween. Because legs 44, 46 extend upwardly from the surface 42, channel 48 likewise opens upwardly. In the embodiment of Fig. 2, first and second legs 44, 46, respectively, are positioned between the first and second ends 51 , 52, respectively, of the surface 42 of the lower frame 40. Further, the first upwardly extending leg 44 and the second upwardly extending leg 46 of the lower frame 40 are preferably parallel to each other and perpendicular to the surface 42 of the lower frame 40.

[0021] As shown in the embodiment of Fig. 2, the lower frame also preferably includes a downwardly extending leg 50 from the surface 42. In the embodiment shown in Fig. 2, the downwardly extending leg 50 is also positioned between first and second ends 51 , 52, respectively, of the surface 42 of the lower frame 40. Leg 50 is positioned adjacent to a curb 16 on a structure and is used to secure the skylight assembly to a structure. Leg 50 therefore includes openings for insertion of securing mechanisms 18, such as screws or nails. Additionally, because the lower portion of leg 50 is exposed around the curb 16, a termination 56 is incorporated at the bottom of leg 50 to strengthen leg 50 against flexing outwardly from curb 16 or inwardly toward curb 16. Terminations, such as termination 56, assists with the management of rainfall, sleet, or snow away from the skylight assembly 10.

[0022] The surface 42 of lower frame 40 includes an arcuate termination 57 at the first end 51 of the surface 42, such as shown in Fig. 2. The arcuate termination 57 to strengthen first end 51 and to assist with the management of rainfall, sleet, or snow away from the skylight assembly 10. The second end 52 of the surface 42 includes a tab 58. By its shape, tab 58 is used for securing the gasket 70 to the lower frame 40, such as shown in Fig. 2 and as further discussed below.

[0023] As shown in Fig. 2, an embodiment of the skylight assembly of the present invention further includes a connector clip 60. The connector clip preferably secures the upper frame 30 to the lower frame 40, or vice-versa. Thus, as shown in Fig. 2, the legs forming the channel where the connector clip is being inserted preferably includes ridges 61 at its ends to secure the connector clip 60 within the channel, such as channel 48, such as by snap-fit engagement with connector clip 60.

[0024] In the embodiment of Fig. 4, the connector clip includes an outer body 62 that forms a generally U-shape. Additional shapes are contemplated without departing from the spirit and the scope of the present invention. As shown in Fig. 4, the outer body 62 includes extenders 64 extending inward from a first side 65 of the outer body 62 and extenders 66 extending inward from a second side 67 of the outer body 62. The extenders 64 and 66 angle towards each other and depend downwardly to form a V shape with a slot 68 at the apex therebetween. In the embodiment of Fig. 4, two extenders 64 extend inwardly and are formed from the first side 65 of the outer body 62 and two extenders 66 extend inwardly and are formed from the second side 67 of the outer body 62. In an alternative embodiment, a single extender extends from each side 65, 67 of the outer body 62. In yet another alternative embodiment, three or greater extenders extend from each side 65, 67 of the outer body 62.

[0025] In the illustrated embodiments, the connector clip 60 is a separable component from the frame 20. In an alternative embodiment, the connector clip is integrally formed within a channel 48. For example, extenders 64 and 66 are formed directly along the legs 44 and 46 of lower frame 40 within channel 48. Further, in one embodiment, multiple connector clips 60 are inserted along a length of a channel. In an alternative embodiment, a single connector clip 60 is inserted within a channel and the connector clip 60 may or may not extend the entire length of the channel.

[0026] In the embodiments of Figs. 2 and 4, the connector clip 60 is inserted within the channel 48 of the lower frame 40 of the skylight assembly 10. The extenders 64 and 66 depend downwardly into the channel 48. Leg 36 of upper frame 30 is inserted into the slot 68 of connector clip 60 to secure the upper frame to the lower frame. Alternatively, the connector clip 60 is inserted within the channel 38 of the upper frame 30 of the skylight assembly 10. In this alternative embodiment, the extenders 64 and 66 extend upward into the channel 38. Leg 44 of lower frame 40 is inserted into the slot 68 of connector clip 60 to secure the upper frame to the lower frame.

[0027] In addition to the connector clip 60, the upper frame 30 and lower frame 40 may also be secured using securing mechanisms 18, such as bolts, screws, or the like. As shown in Fig. 2, aligned openings are incorporated into leg 34 of upper frame 30 and leg 44 of lower frame 40. A securing mechanism 18 is inserted through the openings to secure the upper frame 30 to the lower frame 40. Furthermore, the components of the present invention may be secured using adhesives between the respective components. For example, adhesive may be incorporated between surface 32 of upper frame 30 and lens 100 where those components overlap.

[0028] As discussed above, the skylight assembly 10 preferably further includes a gasket 70 secured to the frame 20. Gasket 70 preferably seals the skylight assembly from air and water leakage and creates gutters for moisture and condensation control and flow away from lens 100.

[0029] In the embodiment of Fig. 2, the gasket 70 includes an upper lateral surface 72 and a lower lateral surface 74. The upper lateral surface 72 includes a first end 75 and a second end 76 wherein the first end 75 is positioned adjacent to the frame 20. The upper lateral surface 72 also includes longitudinal members 77, 78, 79. In the embodiment of Fig. 2, three longitudinal members are incorporated. The first longitudinal member 77 includes a base 80 and a top 81 wherein the base is positioned adjacent to the upper lateral surface 72. The first longitudinal member 77 is positioned at the first end 75 of the upper lateral surface 72 and at least extends upward from the upper lateral surface 72. The third longitudinal member 79 is positioned at the second end 76 of the upper lateral surface 72. As shown, the third longitudinal member 79 extends both upwardly and downwardly from the upper lateral surface 72. In one embodiment, the third longitudinal member is L-shaped and includes a leg 82 that extends laterally from the bottom of third longitudinal member 79. The second longitudinal member 78 includes an upper end 84 and a lower end 85 and intersect the upper lateral surface 72 between the first and third longitudinal members 77 and 79, respectively. The lower lateral surface 74 extends outward from the lower end 85 of the second longitudinal member 78.

[0030] Gasket 70 further includes angled wings. As illustrated in Fig. 2, a first angled wing 86 is positioned at the top of the first longitudinal member 77. A second angled wing 87 is positioned at the upper end 84 of the second longitudinal member 78. A third angled wing 88 is positioned below the lower lateral surface 74. Further, a fourth angled wing 89 is positioned below the lower lateral surface 74 and adjacent to the third wing 88. In one embodiment, the angled wings are composed of flexible material, such a rubber-based material.

[0031] The lower lateral surface 74 as illustrated in Figs. 2, 4, and 5 includes a first end 91 and a second end 92. The second end 92 of the lower lateral surface 74 is adjacent to the lower end 85 of the second longitudinal member 78. Further, the first end 91 of the lower lateral surface 74 includes a downward sloped leg 94. Additionally, the first longitudinal member 77 also includes an arced leg 95. To assist with moisture drainage, arced leg 95 extends upwardly to create a valley for moisture retention and flow.

[0032] The skylight assembly 10 preferably further includes a at least one lens 100. Lens 100 may be flat, slightly angled, dome-shaped such as shown in Fig. 1 , or of any other advantageous configuration. Indeed, practically any lens shape works with the present invention without departing from the scope herein.

[0033] In the embodiments shown in Figs. 2 and 3, an inner lens 102 and an outer lens 104 are incorporated and together form the cover of the skylight assembly. When multiple lenses are used, a spacer 106 may be used. For example, as shown in Fig. 2, the horizontal surfaces 103 and 105 of inner lens 102 and outer lens 104, respectively, are separated by a spacer 106. The spacer 106 provides a cushion between the lenses 102 and 104. In one embodiment, the spacer 106 is composed of a foam material, such as a closed cell foam pad. The spacer may be adhesively secured to the horizontal surfaces 103 or 105. For example, the spacer 106 extends around the entire outer circumference of a horizontal surface of a lens 102. In an alternative embodiment, multiple spacers are inserted at varying locations around the outer circumference of a lens 102.

[0034] In the embodiments of Figs. 2 and 3, the horizontal surfaces 103 and 105 of lenses 102 and 104 are secured between the upper frame 30 and the gasket 70, respectively. In one embodiment, adhesive is used to secure the lens 100 to the upper frame and/or gasket. In another embodiment, frictional and/or compressive forces secure the lens 100 to the upper frame and/or gasket.

[0035] As shown in Fig. 2, the gasket 70 is secured to the surface 42 of the lower frame 40 between the upper lateral surface 72 and the lower lateral surface 74 of gasket 70. In the illustrated embodiment, the gasket is secured to the lower frame 40 by tab 58 of surface 42, which is inserted between lower lateral surface 74 and the base 80 of first longitudinal member 77. Once tab 58 is moved past the first longitudinal member 77, tab 58 becomes fixed within the gasket between the upper lateral surface 72 and the lower lateral surface 74, with first longitudinal member 77 urging tab 58 from sliding out of gasket 70. [0036] As most easily shown in Fig. 5, the first longitudinal member 77, the second longitudinal member 78, and the upper lateral surface 72 of the gasket 70 form a first gutter 96. Further, the second longitudinal member 78, the third longitudinal member 79, and the upper lateral surface 72 of the gasket 70 form a second gutter 97.

[0037] The skylight assembly 10 of the present invention includes multiple sides with angles therebetween to form its outer shape. In the embodiment of Fig. 5, for example, the cut-out portion 1 1 includes a right angle, which signifies a rectangularly-shaped skylight assembly 10, such as shown in Fig. 1 . At this angle, a gap 1 10 is formed in leg 46 of lower frame 40. Further, gaps 1 12 and 1 14 are formed at this angle in longitudinal member 77 and longitudinal member 78, respectively. Because longitudinal members 77 and 78 of the embodiment shown in Fig. 5 include angled wings 86 and 87, respectively, gaps 1 12 and 1 14 extend through angled wings 86 and 87. Gaps 1 10, 1 12, and 1 14 allow for insertion of a wick 120, typically composed of a moisture-absorbent material. In one embodiment, the wick 120 is a polyester material, such as polyethylene terephthalate. In an alternative embodiment the wick 120 is a cotton material. As shown in Fig. 6, wick 120 is inserted into gaps 1 10, 1 12, and 1 14. Alternatively, the wick is only inserted into gaps 1 12 and 1 14.

[0038] When moisture is present on the inside of the skylight assembly 10, such as interior to inner lens 102, gravity drives the moisture down to gasket 70 typically at gutter 96 and/or 97. The moisture will travel through gutter 96 or 97 toward the wick 120. When moisture reaches wick 120, wick 120 pull the moisture through gaps 1 10, 1 12, and 1 14, as the case may be, to the exterior of skylight assembly 10. Alternatively, should environmental factors, such as wind or such as higher ambient pressure outside of skylight system 10, drive moisture outside of skylight assembly 10 toward the interior of skylight assembly 10, wick 120 impedes such moisture from entering the interior of skylight system 10.

[0039] Preferably, no gaps are included in leg 44 of lower frame 40 or third longitudinal member 79 of gasket 70. This configuration preferably allows for increased moisture control away from the lenses 100 because the elimination of gaps in leg 44 of lower frame 40 forecloses pathways for moisture to enter into the skylight assembly 10 from the outside. Further, gaps in third longitudinal member 79 are likewise unnecessary, and eliminating such gaps limits moisture seepage from the wick 120 back toward the lens.

[0040] Strengthening and/or compression ribs are incorporated along frame 20 without departing from the scope of the present invention. For example, as shown in Figure 4, a rib 130 is incorporated along the underside of surface 32 of upper frame 30. As shown in Fig. 2, rib 130 is positioned above the horizontal surface 105 of outer lens 104. Further, as shown in Fig. 4, another rib 131 is positioned along the underside of surface 42 of lower frame 40 at the center of and below channel 48. Ribs 132 are also incorporated within channel 48 along legs 44 and 46.

[0041] Optional accessories may be incorporated into the skylight assembly 10 of the present invention without departing from the spirit and scope of the present invention. For example, as shown in Fig. 3, a tray 134 and diffuser 136 may be incorporated. Alternatively, for example, an insulated glazing unit may be incorporated into tray 134.

[0042] The skylight mounting system of the present invention incorporates the skylight assembly 10 as described above and preferably provides for constructing the skylight assembly 10 described above. For example, the skylight assembly 10 is constructed by forming the skylight assembly components discussed above. Particularly, an upper frame having a downwardly extending upper channel is preferably formed as well as a lower frame having an upwardly extending lower channel. A connector clip, lens, and a gasket having a first gutter channel and a second gutter channel are also preferably formed. The skylight assembly components are then secured together. For example, the lower frame is secured to the gasket. Further, the connector clip is secured within the lower channel of the lower frame and the lens is secured above the first and second gutter channels of the gasket. Also, an inside leg of the downwardly extending upper channel is inserted into the connector clip to secure the upper frame within the lower channel of the lower frame to create an embodiment of the skylight assembly 10 of the present invention. Additionally, the skylight mounting system provides for securing the skylight assembly to a curb on a roof structure.

[0043] The skylight mounting system and assembly of the present invention is particularly suitable for use with many different types and forms of structures, including commercial, industrial, and residential structures. Further, the frame design of the skylight mounting system and assembly of the present invention preferably provides a lower height profile than most known skylight systems and therefore allows for increased light into one or more lenses of the skylight assembly. Additionally, the skylight assembly design preferably provides a decreased frame width from most known skylight systems and therefore further allows for increased light into one or more lenses of the skylight assembly. Moreover, as discussed above, the inventive gutter and wick design of the gasket of the skylight assembly preferably decreases and limits the flow of moisture and condensation onto a lens of the skylight assembly of the present invention. [0044] While various embodiments and examples of this invention have been described above, these descriptions are given for purposes of illustration and explanation, and not limitation. Variations, changes, modifications, and departures from the apparatuses, systems, and methods disclosed above may be adopted without departure from the spirit and scope of this invention. In fact, after reading the above description, it will be apparent to one skilled in the relevant art(s) how to implement the invention in alternative embodiments. Thus, the present invention should not be limited by any of the above described exemplary embodiments.

[0045] Further, the purpose of the Abstract is to enable the various Patent Offices and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is not intended to be limiting as to the scope of the invention in any way.