Fenestration Product Such as a Skylight Having a Laminated Glazing Unit

Abstract

A fenestration is provided having a peripheral frame defining a frame opening, the frame being adapted to being installed upon an opening in a building panel. Cooperating with the peripheral frame is a laminated panel which is structurally mounted to and sealingly spans the peripheral frame opening to form a structural and leak proof interconnection. The laminated panel is formed of three structural layers; an outer and inner plastic sheet and a resin layer interposed therebetween which are collectively bonded together to form a structural laminate, the laminated panel being capable of transmitting visible light therethrough.

1 . A skylight assembly, the assembly comprising:
 a peripheral frame defining an opening; and   a laminated panel having a periphery, the panel cooperating with the peripheral frame and spanning the opening, the laminated panel having a first sheet of plastic, a second sheet of plastic, and an interposed layer of resin between the first and second sheets of plastic, the first sheet being bonded to the resin layer, the resin layer being bonded to the second sheet, the laminated panel being selectably formable into a three-dimensional shape.   
   
   
       2 . The skylight assembly of  claim 1 , wherein the frame is a single piece frame. 
   
   
       3 . The skylight assembly of  claim 2 , wherein a portion of the laminated panel is overmolded by the frame forming a watertight seal when measured by ASTM E547-00 and ASTM E331-00. 
   
   
       4 . The skylight assembly of  claim 2 , wherein the single piece frame includes a curb. 
   
   
       5 . The skylight assembly of  claim 1 , wherein the laminated panel is formed in the shape of an outwardly convex dome. 
   
   
       6 . The skylight assembly of  claim 1  wherein the dome comprises a thermoformed laminated panel. 
   
   
       7 . The skylight assembly of  claim 1 , wherein the layer of resin includes polyvinyl butyral, ethylene vinyl acetate or polyurethane. 
   
   
       8 . The skylight assembly of  claim 1 , wherein at least one sheet of plastic includes an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin sheet. 
   
   
       9 . The skylight assembly of  claim 8 , further including a mar-resistant layer adjacent to the plastic sheet. 
   
   
       10 . The skylight assembly of  claim 1 , further comprising:
 a third sheet of plastic, wherein the third sheet of plastic and the second sheet of plastic define a cavity spanning a portion of the opening.   
   
   
       11 . The skylight assembly of  claim 1 , further having a reflective interior surface positioned below the opening. 
   
   
       12 . The skylight assembly of  claim 11 , wherein the reflective interior surface has an end adjacent to a roof member. 
   
   
       13 . The skylight assembly of  claim 1 , further including a light pipe cooperating with the laminated panel, the light pipe extending to an interior room below the roof. 
   
   
       14 . A skylight assembly comprising:
 a laminated panel having a periphery, the laminated panel including a first sheet of plastic, a second sheet of plastic, and a layer interposed between the first sheet and the second sheet, the laminated panel being shaped into a convex configuration; and   a peripheral frame defining an opening, the frame being configured to connect to a roof and defining an opening, wherein the laminated panel spans the opening.   
   
   
       15 . The skylight assembly of  claim 14 , wherein the peripheral frame is formed of a moldable polymeric material entrapping the periphery of the laminated panel and forming a leak-tight structural joint therewith, where the structural aspect of the joint is measured according to ASTM E330-02 at a positive/negative load exceeding 250 pounds per square foot, the leak-tightness aspect of the joint being measured according to ASTM E547-00 and ASTM E331-00, allowing no leakage. 
   
   
       16 . The skylight assembly of  claim 14 , the laminated panel passing tests TAS201 and TAS203, wherein no cracks or tears occur at less than 90 pounds per square foot when measured according to TAS203. 
   
   
       17 . The skylight assembly of  claim 14 , wherein at least one sheet of plastic is comprised of an acrylic, a polycarbonate, a terephthlate, a vinyl, or a polyolefin plastic. 
   
   
       18 . The skylight assembly of  claim 14 , wherein the first sheet and the second sheet are comprised of different plastics. 
   
   
       19 . The skylight assembly of  claim 14 , wherein the peripheral frame is formed of a material including at least one of a reaction injection molding material, a thermoplastic material, or a material filled with reinforcing fibers. 
   
   
       20 . A method for making a skylight assembly, comprising:
 forming a laminated panel having a periphery by providing a first sheet of plastic, providing a second sheet of plastic, bonding the first and second sheets together by interposing a resin layer therebetween;   attaching a frame to the periphery of the laminated panel, the frame adapted to receive the periphery of the laminated panel and configured to be connected to a roof.   
   
   
       21 . The method of  claim 20 , wherein at least one sheet comprises an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin material. 
   
   
       22 . The method of  claim 20 , wherein the resin layer includes polyvinyl butyral, ethylene vinyl acetate, or polyurethane. 
   
   
       23 . The method of  claim 20 , wherein the frame is a single piece frame. 
   
   
       24 . The method of  claim 23 , wherein attaching the single piece frame includes applying a plastic adjacent to the periphery of the laminated panel. 
   
   
       25 . The method of  claim 24 , wherein the plastic includes a thermoset material, a thermoplastic material, or a fiber reinforced plastic. 
   
   
       26 . A method for making a skylight assembly, comprising:
 providing a first sheet of plastic having a first melting point;   providing a second sheet of plastic having a second melting point;   providing a layer of resin interposed between the first sheet of plastic and the second sheet of plastic;   forming a laminated panel including the first sheet of plastic, the second sheet of plastic, and the interposed layer of resin;   degassing the laminated panel to remove a gas from between the first sheet of plastic, the second sheet of plastic, and the interposed resin layer;   positioning the laminated panel within a first mold half;   warming the laminated panel to a temperature less than the lesser of the first or the second melting points;   conforming the laminated panel to the first mold half;   removing the formed laminated panel from the first mold half;   positioning the formed laminated panel in a closed mold;   closing the closed mold;   injecting a plastic adjacent to the periphery of the formed laminated panel, to form a continuous frame between the frame and the laminated panel;   opening the mold; and   removing the skylight assembly.   
   
   
       27 . The method of  claim 26 , wherein at least one sheet of plastic includes an acrylic, a polycarbonate, a terephthalate, a vinyl, or a polyolefin sheet. 
   
   
       28 . The method of  claim 26 , wherein the resin includes polyvinyl butyral, ethylene vinyl acetate copolymer, or polyurethane. 
   
   
       29 . The method of  claim 26 , wherein the plastic injected adjacent to the periphery of the laminated panel includes a reaction injection molded plastic, a thermoset, a thermoplastic, or a fiber reinforced plastic. 
   
   
       30 . A fenestration product for installation within a building opening, the fenestration product comprising:
 a peripheral frame defining a frame opening and the laminated panel cooperating with the peripheral frame and spanning the opening to provide a structural water-tight connection,   a panel formed of three structural layers; a first outer plastic layer, a second inner plastic layer and an intermediate resin layer interposed therebetween, laminated together to form a structural member;   wherein the peripheral frame is formed of a single piece of polymeric material which is molded in situ about the outer periphery of the laminated panel.   
   
   
       31 . The fenestration product of  claim 30 , wherein the fenestration product passing tests TAS 201 and TAS 203, wherein no cracks or tears occur at less than 90 lbs. per square when measured according to TAS 203. 
   
   
       32 . The fenestration product of  claim 30 , wherein the laminated panel includes a three-dimensional shape.