EP2383400A1

EP2383400A1 - Illuminated roofing structure and method of construction

Info

Publication number: EP2383400A1
Application number: EP11003438A
Authority: EP
Inventors: John P. Canavan
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-04-30
Filing date: 2011-04-27
Publication date: 2011-11-02

Abstract

An illuminated exterior roofing structure (20) has rafters (10) supported by the building, a plurality of pan tiles (30) supported by the rafters (10), and a plurality of convex roof tiles (50) positioned over the pan tiles (30). Each of the pan tiles (30) has a concave body (32) having a top surface (34) and an opposed bottom surface (36) connected by a perimeter edge (38), and is constructed of a light transmitting material. A light generating element (68) is mounted adjacent the perimeter edge (38) to direct generated light into the pan tile (30). A power distribution network (74) provides electric power to the light generating elements (68) of the pan tiles (30). The plurality of convex roof tiles (50) are mounted on top of and partially covering the pan tiles (30), and are adapted to resemble traditional roof tiles.

Description

FIELD OF THE INVENTION:

This invention relates generally to roofing structures, and more particularly to an illuminated exterior roofing structure and method.

DESCRIPTION OF RELATED ART:

The prior art teaches many different forms of illuminated roofing constructions and related devices. The following art defines the present state of this field:

Teeters, U.S. 7,549,784 , teaches an LED (light emitting diode) device for use with glass floor tiles and glass blocks. The LEDs are housed in flexible strips having bendable transparent housing sleeves with ends that can interconnect by male and female ends to one another with various types of interconnectors. The glass floor tiles can be laid out to uniform joint spacings between the glass tiles. The LED strips can be placed on a surface layer of transparent grout that has been laid in the joint spacing, followed by a top layer of transparent grout. The transparent grout can be removable grout and include clear silicon.
Edmonds, U.S. 7,410,284 , teaches a self-supporting roof lighting system that accepts low elevation light and rejects high elevation light. The lighting system includes arrays of parallel laser cuts partly through a flat sheet of transparent acrylic. The sequence may be changed so that a saddle, pyramid or higher order structure is first formed by folding or molding transparent acrylic and, subsequently, an array of parallel laser cuts is made in each facet of the structure to produce an angle-selective roof lighting system.
Kim, U.S. 2007/0133193 , teaches a ceiling lighting system adapted for use in low-clearance rooms (e.g., with drop down ceilings). The lighting system includes a plurality of light emitting diodes positioned on at least two side surfaces of a light ceiling tile or a plurality of external electrode fluorescent lights within an encasement of a light tile, a reflecting plate at a back surface of the light tile, and a metal frame for supporting the light tile and having exterior dimensions suitable for insertion into a ceiling-grid of a drop-ceiling.
Coleman, U.S. 5,806,263 , teaches a connector strip for assembling a building wall of glass blocks. The strip includes a longitudinal center section having a pair of oppositely disposed and longitudinally extending grooves dimensioned to receive a centrally located ridge extending peripherally around the outer edge surfaces of a molded building block to which the strip is to be mounted. U-shaped channels extend along the center groove for receiving wiring such as fiber optics for illuminating the glass block wall.
Inzeo et al., U.S. 6,922,951 , teaches a lighted roof edge assembly that may be formed as a conventional coping or fascia. The assembly includes a cover plate attachable to a roof edge through the use of an anchor member secured to the roof edge. The cover plate includes a channel in which is disposed a retainer. The retainer is releasably engageable with a lighting element that can be selectively switched on to illuminate the area of the structure to which the assembly is attached directly around the assembly.

Other patents of interest, enclosed, include Johnson, U.S. 2,587,855 , Ruud et al., U.S. 5,375,045 , Krause, DE 20 2007 005 103 , and Cardins, BR 9803622 .
The prior art also teaches various light-transmissive roofing constructions. The following art defines the present state of this field:

Gaston, U.S. 5,493,825 , discloses a light-transmissive decking section for use in a decking assembly for allowing light through the decking assembly. The light transmissive decking section is provided with a light-transmissive top section. The transmissive properties of the light-transmissive decking section increase the aesthetic appeal of the decking assembly and allow the light to be used below the decking assembly for illumination and heat. The light-transmissive decking section may also be provided with a light or solar panel to alternatively emanate light or generate power from ambient light.
Magee, U.S. 5,303,525 , discloses a building structure partially covered with siding panels, the outer surface of which are transparent to solar energy, the panels being slightly spaced from an insulating wall of the building to allow a fluid flow, preferably air, therebetween with effective heat exchange from solar radiation absorbing surface with the fluid being selectively utilizable for space heating purposes or other purposes. The air can be moved by fans or convection or both. A preferred embodiment employs small horizontal lenticular lenses in the transparent material on the surface of the siding together with a mask, which may be three dunensional, on the back of the siding with the result that when the siding is viewed from the horizontal it displays a decorative color while it is highly reflective for solar rays at high angles of elevation and is transparent for solar rays at low angles of elevation, as during winter months. A black absorbent metallic foil surface may be provided on the insulating wall for absorbing the unmasked solar radiation, and the siding is structured to direct airflow to enhance heat transfer from the radiation absorbing surface.
Whitlock, U.S. 3,998,017 , discloses a building structure which utilizes logs or timbers of readily available dimensions. Timbers are horizontally disposed in parallel, vertically spaced relationship to form wall sections. Intermediate each pair of adjacent horizontal timbers there is a pair of convex panels of flexible synthetic resinous material, symmetrically disposed about the vertical axis. Upper and lower edges of each panel are inserted into oblique panel-receiving slots provided in the upper and lower surfaces of each horizontal timber. The panels are preferably inserted after assembly of the timbers and support no direct load. Insulating material is placed between each pair of panels. The panels may be inserted during or after assembly of overlapping end surfaces of timbers of end-adjacent vertical walls. If desired, insulating material may be inserted in the confined zone between panels and successive logs. Preferably, substantially light-permeable panel members are used and substantially light-permeable insulting means is used between panel members to permit natural lighting of the interior of the building structure during daylight hours.
Further inventions include Kessler, U.S. 3,332,192 , Pradal, U.S. 3,282,012 , Miller, U.S. 3,261,132 , Hobbie, U.S. 2,093,559 , Lytle, U.S. 2,159,665 , and Turnley, U.S. 640,338 . None of these structures teach a roofing structure with the structure and benefits disclosed in the present invention. All of the prior art cited above is hereby incorporated by reference in full.

The prior art teaches the use of transparent or translucent roofing materials to allow light through the roof. The prior art also teaches some roofing constructions that provide illumination. However, the prior art does not teach a roofing construction that offers the a aesthetic appeal of traditional roofing structures, while also providing illumination beneath the roofing structure. The present invention fulfills these needs and provides further related advantages as described in the following summary.

SUMMARY OF THE INVENTION

There is provided an illuminated exterior roofing structure for a building. The illuminated exterior roofing structure comprises rafters, a plurality of pan tiles supported by the rafters, and a plurality of convex roof tiles. Each of the pan tiles has a concave body having a top surface and an opposed bottom surface connected by a perimeter edge, and is constructed of a light transmitting material. A light generating element is mounted adjacent the perimeter edge to direct generated light into the pan tile. A power distribution network provides electric power to the light generating elements of the pan tiles. The plurality of convex roof tiles are mounted on top of and partially covering the pan tiles, and are adapted to resemble traditional roof tiles.
An aim of the present invention is to provide an improved illuminated exterior roofing structure.
According to one aspect, there is provided an illuminated exterior roofing structure for a building, the roofing structure comprising: rafters supported by the building; a plurality of pan tiles supported by the rafters, each of the pan tiles comprising: a concave body formed of a light transmitting material, the concave body having a top surface and an opposed bottom surface connected by a perimeter edge; and a light generating element mounted adjacent the perimeter edge to direct generated light into the pan tile; a power distribution network for providing electric power to the light generating elements of the pan tiles; and a plurality of convex roof tiles mounted on top of and partially covering the pan tiles, the convex roof tiles being constructed of non-translucent material adapted to resemble traditional roof tiles.
According to a further aspect, there is provided an illuminated exterior roofing structure for a building, the roofing structure comprising: rafters for supporting the illuminated exterior roofing structure above or adjacent the building; a plurality of pan tiles mounted on the rafters, each of the pan tiles comprising: a concave body formed of a light transmitting material, the concave body having a top surface and an opposed bottom surface connected by a perimeter edge; a receiving chamber formed in the perimeter edge; and a light generating element mounted in the receiving chamber to direct generated light into the concave body of the pan tile to illuminate the pan tile; a power distribution network for providing electric power to the light generating elements of the pan tiles; a plurality of convex roof tiles mounted on top of and partially covering the pan tiles, the convex roof tiles being constructed of non-translucent material adapted to resemble traditional roof tiles; and fasteners for fastening the convex roof tiles to the rafters.
According to a third aspect, there is provided a method for constructing an illuminated exterior roofing structure in a building, the method comprising the steps of: providing rafters supported by the building; providing a plurality of pan tiles, each of the pan tiles comprising:

a body formed of a light transmitting material, the body having a top surface and an opposed bottom surface; and a light generating element providing a plurality of convex roof tiles, the convex roof tiles being constructed of non-translucent material adapted to resemble traditional roof tiles; mounting the light generating element adjacent each pan tile such that light generated by the light generating element is directed into the pan tile; mounting the pan tiles on the rafters;
mounting the convex roof tiles on top of and partially covering the pan tiles; and electrically connecting the light generating elements of the pan tiles with a power source.

The embodiments described below provide an illuminated exterior roofing structure that allows for the transmission of natural light, and also provides a source of illumination when desired.
The embodiments described below provide an illuminated exterior roofing structure that resembles a traditional roof, without any of the undesirable aesthetic qualities of prior art roofing structures.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the present invention. In such drawings:

FIGURE 1 is a perspective view of one embodiment of an illuminated exterior roofing structure installed on a building having lodge pole rafters that are positioned perpendicular to the edge of the roof;
FIGURE 2 is a front elevational view thereof taken along line 2-2 in Figure 1;
FIGURE 3 is a perspective view of a single pan tile; and
FIGURE 4 is a sectional view thereof taken along line 4-4 in Figure 3; and
FIGURE 5 is a perspective view of the illuminated exterior roofing structure installed on a building having rafters positioned parallel to the edge of the roof.

DETAILED DESCRIPTION OF THE INVENTION

The above described drawing figures illustrate a preferred embodiment of the invention, an illuminated exterior roofing structure 20 for a building having spaced apart rafters 10. For purposes of this application, the term "rafters" is hereby defined to include any form of rafters, poles, or other similar structures that form a roof. The illuminated exterior roofing structure 20 includes a plurality of concave pan tiles 30 mounted on, attached to, or otherwise supported by the rafters 10, with a plurality of convex roof tiles 50 attached to the rafters 10 and overlapping the pan tiles 30 on either side. The pan tiles 30 are made of a light transmitting material, causing the illuminated exterior roofing structure 20 to simulate a skylight. The roof tiles 50 are similar to or resemble traditional roof tiles 50. Since the roof tiles 50 are mounted on top of the pan tiles 30, the roof tiles 50 give the illuminated exterior roofing structure 20 an overall appearance similar to that of a traditional roof.
The specific size and shape of the illuminated exterior roofing structure 20 will vary to accommodate the specific construction of the building. In a first configuration, shown in FIGURES 1 and 2, the building has spaced apart lodge pole rafters 10 that are positioned perpendicular to the edge of the roof. In a second configuration, shown in Fig 5, the building further includes 2x4 skip nailers 10 positioned parallel to the edge of the roof. The rafters 10 are adapted for supporting the illuminated exterior roofing structure 20 above the building. The term "rafters" is hereby defined to include any structure known in the art for supporting a roof in the manner described herein, and further includes the skip nailers and similar additional structures that operate in conjunction with the rafters to support the roof. For purposes of this application, the term "above the building" is defined to include roofing structures that are directly above the building, extend from above the building, and/or immediately adjacent the building, or otherwise associated with the building using constructions known in the art. Obviously, the rafters 10 may vary according to the design of the building, as known to those skilled in the art, and such alternatives should be considered within the scope of the present invention.
FIGURE 3 is a perspective view of a single pan tile 30. FIGURE 4 is a sectional view thereof taken along line 4-4 in Figure 3. As illustrated in Figs. 1-5, the pan tiles 30 are generally rectangular in shape with a generally U-shaped cross section. The pan tiles 30 are each wide enough to overlap the pair of adjacent rafters 10 on the building on which they are used. An average pan tile 30 in one embodiment is approximately 18 inches long and 8 inches wide, although these measurements will vary according to the requirements of a specific installation. The pan tiles 30 may be tapered.
The pan tiles 30 each have a concave body 32 formed of a light transmitting material. The concave body 32 has a top surface 34 and an opposed bottom surface 36 connected by a perimeter edge 38. The perimeter edge 38 may include a top edge 40, and opposed bottom edge 42, and side edges 44. The top surface 34 faces upwardly when the concave body 32 is installed on the roof, and is concave, preferably with a generally U-shaped cross section. The bottom edge 42 may merely follow the top surface 34 (convex) so that the concave body 32 has a generally equal cross section; however, other shapes, and varying thickness, may also be utilized. Also, while side edges 44 are described, the term "edge" is hereby defined to include alternative embodiments. In one embodiment, the edges of two or more pan tiles 30 may be integrally formed, so that a single integral piece may provide multiple pan tiles 30.
The pan tiles 30 may each have a longitudinal axis 46 that is generally parallel to the side edges 44, or to the longitudinal center of the tile (if the edges are tapered). Each pan tile 30 may further have a U-shaped cross section when cut perpendicular to the longitudinal axis 46 (the term "U-shaped" is hereby defined to include equivalent shapes, such as V-shaped, and similar curved or formed shapes). When installed, the pan tiles 30 may be arranged in aligned courses 60 wherein each of the aligned course includes a group of pan tiles 30 that overlap along a common longitudinal axis 46, and wherein an overlapping course 62 of the convex roof tiles 50 overlaps the side edges 44 of two adjacent aligned courses 60 of the pan tiles 30.
The perimeter edge 38 may include a receiving chamber 66 for receiving a light generating element 68. The light generating element 68 may be mounted or otherwise positioned in the receiving chamber 66 to direct generated light into the concave body 32 of the pan tile 30 to illuminate the pan tile 30. In one embodiment, the receiving chamber 66 is positioned in the top edge 40. In another embodiment, the receiving chamber 66 may be positioned elsewhere in the pan tile 30. In yet another embodiment, the light generating element 68 may be otherwise positioned adjacent the perimeter edge 38 so that light is directed into the pan tile 30, as described.
The light generating element 68 may be, for example, an LED strip that includes light emitting diodes (LEDs) 70 electrically connected and mounted on a backing 72 (e.g., rigid semiconductor, flexible base, etc.). While LEDs 70 are used in the current embodiment, other illumination materials may also be used (e.g., incandescent bulbs, phosphorescent/ luminescent material, and other materials or devices that can provide the necessary illumination).
As shown in Figs. 1 and 2, the pan tiles 30 are positioned between the rafters 10 such that the convex side of each pan tile 30 fits between the pair of adjacent rafters 10 and faces downwards towards the rafters 10. Each side of each of the pan tile 30 is then attached to one of the rafters 10 with a fastener (e.g. nails, screws, other suitable fastening device or method). The pan tiles 30 are arranged in overlapping courses 62 down the length of the roof. If the top edge 40 of the pan tile 30 is somewhat larger than the bottom edge 42, the pan tiles 30 are easier to overlap, although this feature is not required. Each of the pan tiles 30 is made of a light transmitting material, such as a polycarbonate or polystyrene material, although other plastics, resins, or other suitable materials may also be used. The material must be at least partially translucent, and the material is transparent in acceptable embodiments. The material is colored or tinted in other embodiments, providing a desired character and diffusion to the light entering the building.
The illuminated exterior roofing structure 20 further includes a plurality of convex roof tiles 50. The convex roof tiles 50 may be traditional tiles (e.g., clay, terra cotta, stone, etc.) such as those commonly used in the construction of residential homes and apartments. The roof tiles 50 may also be constructed of a more lightweight material (e.g., polycarbonate, polystyrene, plastic, resin, etc.) that has an integral color, or is painted, coated, or otherwise treated to resemble traditional clay roof tiles.
The roof tiles 50 have opposite edges 52 and are adapted to be mounted on top of and partially cover the pan tiles 30 such that the edges overlap the sides edges 44 of the adjacent pan tiles 30. The roof tiles 50 are fastened to the rafters 10, preferably with the fasteners 64. These convex roof tiles 50 are the only part of the invention that is plainly visible to a casual observer looking at the exterior of the building, so the roof tiles 50 provide an aesthetically pleasing exterior that covers the less visually pleasing look of the pan tiles 30.
In the second configuration, illustrated in Fig. 5, the pan tiles 30 and the roof tile 50 are positioned perpendicular to and across the skip nailers 12 rather than parallel to and between the rafters 10. The pan tiles 30 are fastened to the skip nailers 12 with the fasteners 64. The roof tile 50 may also be fastened to the rafters 10 with the fasteners 64. The pan tiles 30 and the roof tiles 50 are arranged in overlapping courses 62 down the roof. The pan tiles 30 and the roof tiles 50 may overlap enough so that the fasteners 64 are covered by the next higher pan tile 30 or roof tile 50, thereby both improving the appearance and preventing leakage. These general construction techniques are well known in the art, and can be modified as required to adapt the invention to any given roof having any given rafter structure.
Also illustrated in Figs. 3-5, the illuminated exterior roofing structure 20 further includes a power distribution network 74 for providing electric power to the light generating elements 68 of the pan tiles 30. The power distribution network 74 may include electrically conductive wires that are electrically connectable to a power source 76 (e.g. battery, power grid, power generation device, etc.). The electrically conductive wires may be individually connectable to the power source 76, or may be daisy-chained to form the network. While one embodiment of the power distribution network 74 is illustrated, those skilled in the art may devise many alternative embodiments that provide the necessary power to the pan tiles 30.
There is also provided a method for constructing the above-described illuminated exterior roofing structure 20 on the building. The first step of this method is to provide the illuminated exterior roofing structure 20 as described above, including both the pan tiles 30 and the convex roof tiles 50. A plurality of the pan tiles 30 are then fastened to the rafters 10 (and/or to skip nailers 12 or similar structures) near the eaves of the roof, such that the pan tiles 30 are generally parallel, either adjacent each other or spaced a short distance from each other. In the embodiment of Fig. 2, the pan tiles 30 span the space between the pair of rafters 10, with the convex side of each pan tile 30 adjacent to the rafters 10. The pan tile 30 may be fastened to the rafters 10 with a fastener 64 such as a pan screw, nail, or similar fastener. Additional pan tiles 30 are then added to the illuminated exterior roofing structure 20 in overlapping courses 62 until the roof is covered with spaced rows of pan tiles 30 running perpendicular to the edge of the roof. In the embodiment of Fig. 5, the pan tiles 30 are positioned across the skip nailers 12, as described above. Alternative arrangements may be utilized, depending upon the roof structure that is preferred, and such alternatives should be considered within the scope of the present invention.
The light generating elements 68 of the pan tiles 30 may be electrically connected to the power source 76, or at least to the electrically conductive wires that will later be connected to the power source 76. The roof tiles 50 are then fastened on top of the pan tiles 30 such that the edges of the roof tiles 50 overlap the sides of the adjacent pan tiles 30. The roof tiles 50 may be fastened to the rafters 10 with the fasteners 64. Cement may also added to further strengthen the roof and secure the roof tiles 50 to the roof. Additional roof tiles 50 are added to the illuminated exterior roofing structure 20 in overlapping courses 62 until the roof is covered with spaced rows of roof tiles 50 running parallel to and overlapping the rows of pan tiles 30. In its most preferred configuration, well known in the art, additional roof tiles 50 are added to the illuminated exterior roofing structure 20 near the eaves of the roof, to improve the aesthetics of the illuminated exterior roofing structure 20. The pan tiles 30 and the roof tiles 50 may be positioned concurrently, working up the roof, as is known in the art.
There is therefore described the combination of translucent pan tiles 30, the roof tiles 50 that resemble traditional clay tiles, and the illumination of the pan tiles 30 with the light generating elements 68. While the roof tiles 50 must conform to a traditional look in order to provide the aesthetic qualities desired by the consumer, the pan tiles 30 are not constrained to any specific shape except by the convenience of the roofing installer. Using a pan tile 30 having a different shape is equivalent to the current invention if that pan tile 30 is light transmitting and capable of being covered with traditional pan tiles 30. As an example, instead of using individual tiles, the pan tiles 30 could be formed as a large single sheet of light transmitting material.
The terminology used in the specification provided above is hereby defined to include similar and/or equivalent terms, and/or alternative embodiments that would be considered obvious to one skilled in the art given the teachings of the present patent application. Additionally, the words "a," "an," and "one" are defined to include one or more of the referenced item unless specifically stated otherwise. Also, the terms "have," "include," "contain," and similar terms are defined to mean "comprising" unless specifically stated otherwise.
While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims.

Claims

An illuminated exterior roofing structure for a building, the roofing structure comprising:
a plurality of rafters;

a plurality of pan tiles supported by the rafters, each of the pan tiles comprising:
a concave body formed of a light transmitting material, the concave body having a top surface and an opposed bottom surface connected by a

perimeter edge;

a light generating element mounted adjacent the perimeter edge to direct generated light into the pan tile; and

a plurality of convex roof tiles mounted on top of and partially covering the pan tiles, the convex roof tiles being constructed of non-translucent material adapted to resemble traditional roof tiles.
A structure according to any preceding claim, further comprising a power distribution network for providing electric power to the light generating elements of the pan tiles
A structure according to any preceding claim, wherein the perimeter edge of each of the pan tiles includes a top edge, an opposed bottom edge, and side edges.
A structure according to any preceding claim, wherein the pan tiles each have a longitudinal axis that is generally parallel to the side edges, and wherein each pan tile has a U-shaped cross section when cut perpendicular to the longitudinal axis.
A structure according to any preceding claim, wherein the pan tiles are arranged in aligned courses wherein each of the aligned course includes a group of pan tiles that overlap along a common longitudinal axis, and wherein an overlapping course of the convex roof tiles overlaps the side edges of two adjacent aligned courses of the pan tiles.
A structure according to any preceding claim, wherein the roof tiles are constructed of polycarbonate, polystyrene, or similar plastic or resin, and the roof tiles are painted, coated, or otherwise treated to resemble traditional clay roof tiles.
A pan tile adapted for use in the roofing structure according to any preceding claim, including means for mounting the light generating element.
A pan tile comprising a concave body formed of a light transmitting material, the concave body having a top surface and an opposed bottom surface connected by a perimeter edge, and means for mounting a light generating element adjacent the perimeter edge to direct generated light into the pan tile.
A pan tile according to claim 8, wherein the mounting means comprises a recessed chamber or channel formed in the perimeter edge.
An illuminated exterior roofing structure for a building, the roofing structure comprising:
rafters for supporting the illuminated exterior roofing structure above or adjacent the building;

a plurality of pan tiles mounted on the rafters, each of the pan tiles comprising:
a concave body formed of a light transmitting material, the concave body having a top surface and an opposed bottom surface connected by a perimeter edge;

a receiving chamber formed in the perimeter edge; and

a light generating element mounted in the receiving chamber to direct generated light into the concave body of the pan tile to illuminate the pan tile;

a power distribution network for providing electric power to the light generating elements of the pan tiles;

a plurality of convex roof tiles mounted on top of and partially covering the pan tiles, the convex roof tiles being constructed of non-translucent material adapted to resemble traditional roof tiles; and

fasteners for fastening the convex roof tiles to the rafters.
A method for constructing an illuminated exterior roofing structure in a building, the method comprising the steps of:
providing rafters for being supported by a building;

proving a plurality of pan tiles, each of the pan tiles comprising:
a body formed of a light transmitting material, the body having a top surface and an opposed bottom surface;

providing a light generating element;

providing a plurality of convex roof tiles, the convex roof tiles being constructed of non-translucent material;

mounting the light generating element adjacent each pan tile such that light generated by the light generating element is directed into the pan tile;

mounting the pan tiles on the rafters; and

mounting the convex roof tiles on top of and partially covering the pan tiles.