Plastic fenestration product

Abstract

A fenestration product such as a skylight or a window assembly is provided having a frame with a peripheral wall with a light transmitting central region and a plastic dome formed of a light transmitting material mounted to the frame. The plastic dome has a central region which transmits light, a downwardly extending peripheral wall extending about and mounted to the peripheral frame, and an outwardly extending flashing flange for mounting the assembly to a building structure. Various embodiments of the part illustrated include a skylight assembly having a frame formed of a plastic layer formed into an inverted “U” shape cross-section forming an annular channel filled with insulating foam. A sealed, vertically mounted window unit is also disclosed. Other embodiments have an insulating layer of transparent plastic material spaced from the dome forming an enclosed, gas filled insulating region. Methods of forming and installing a fenestration assembly are also described.

1 . A fenestration product assembly comprising:
 a frame having an upwardly extending peripheral wall portion defining a light transparent central region; and   a dome formed of a plastic material which transmits visible light, the dome mounted to the frame and having a central panel portion overlying the frame central region, a downwardly extending peripheral edge which extends about the frame peripheral wall, and an outwardly extending flashing flange for mounting the assembly to a building structure.   
   
   
       2 . The fenestration product assembly of  claim 1  wherein the frame comprises a unitary plastic ring portion having a central opening. 
   
   
       3 . The fenestration product assembly of  claim 2  wherein the frame peripheral wall portion has an inverted U-shaped cross section. 
   
   
       4 . The fenestration product assembly of  claim 3  wherein the frame further comprises a thermal insulation material which substantially fills the inverted U-shaped cross section of the frame peripheral wall portion. 
   
   
       5 . The fenestration product assembly of  claim 4  wherein the thermal insulation material comprises a polymeric foam material which is formed in situ. 
   
   
       6 . The fenestration product assembly of  claim 3  wherein the frame further comprises a flashing flange portion extending outward from the wall portion and at least partially underlying the flashing flange of the dome. 
   
   
       7 . The fenestration product assembly of  claim 1  further comprising an insulating layer formed of a plastic material which is transparent to visible light, the insulating layer mounted to at least one of the frame and the dome, and having a central panel portion overlying the frame central region and a peripheral edge which is mounted to at least one of the frame peripheral wall and the dome to define an enclose cavity between the insulating layer and the dome. 
   
   
       8 . The fenestration product assembly of  claim 7  further comprising a second insulating layer formed of a plastic material which is transparent to visible light, the second insulating layer mounted between the insulating layer and the dome, and having a central panel portion overlying the frame central region and a peripheral edge which is mounted to at least one of the frame peripheral wall, the insulating layer and the dome, thereby subdividing the enclosed cavity between the insulating layer and the dome. 
   
   
       9 . The fenestration product assembly of  claim 7  wherein the frame peripheral wall portion has an inverted U-shaped cross section. 
   
   
       10 . The fenestration product assembly of  claim 9  wherein the frame further comprises a thermal insulation material which substantially fills the inverted U-shaped cross section of the frame peripheral wall portion. 
   
   
       11 . The fenestration product assembly of  claim 1  wherein the frame comprises a unitary plastic ring portion and a light transmitting panel oriented in the frame central region in spaced apart relation to the dome central panel portion forming an enclosed cavity there between. 
   
   
       12 . The fenestration product assembly of  claim 11  further comprising an exterior panel formed of plastic material having a light transmitting central portion overlying and spaced from the frame central region forming a second central cavity there between. 
   
   
       13 . The fenestration product assembly of  claim 12  wherein the exterior panel is formed of a translucent plastic material have embossed thereon selected from a group consisting of a simulated glass block pattern and a camed glass pattern. 
   
   
       14 . The fenestration product assembly of  claim 11  wherein the light transmitting panel further comprises a peripheral flange overlying and affixed at least indirectly to the dome peripheral flange. 
   
   
       15 . A fenestration product assembly comprising:
 a plastic ring shaped frame having an inverted U-shaped cross-section defining a central opening and an outer peripheral wall portion; and   a dome formed of a plastic material which transmits visible light, the dome mounted to the frame and having a central panel portion overlying the frame central region, a downwardly extending peripheral edge which extends about the frame peripheral wall;   wherein at least one of the frame and dome is further provided with an integrally formed outwardly extending flashing flange for mounting the assembly to a building structure.   
   
   
       16 . The fenestration product assembly of  claim 15  wherein an upper region of the frame is provided with an integrally formed trough for collecting condensate forming on an interior surface of the assembly spanning the central opening in the frame. 
   
   
       17 . The fenestration product assembly of  claim 15  further comprising an insulating layer formed of a plastic material which transmits visible light, the insulating layer having a peripheral edge which is mounted to the frame and a central panel portion overlying the frame central opening forming an enclosed cavity between the insulating layer and the dome. 
   
   
       18 . The fenestration product assembly of  claim 17  further comprising a secondary insulating layer formed of a plastic material which transmits visible light, the secondary insulating layer mounted between the insulating layer and the dome, and having a central panel portion overlying the frame central opening and a peripheral edge which is mounted to at least one of the frame, the insulating layer and the dome, thereby subdividing the enclosed cavity between the insulating layer and the dome. 
   
   
       19 . The fenestration product assembly of  claim 18  wherein the frame further comprises a thermal insulation material which substantially fills the inverted U-shaped cross section of the frame. 
   
   
       20 . A method of forming a fenestration product assembly, the method comprising:
 thermoforming a first sheet of plastic into a ring shape frame having an inverted U-shaped cross section with an outer peripheral wall portion;   thermoforming a second sheet of plastic material which transmits visible light into a dome having a domed central panel portion and a downwardly extending outer peripheral wall;   joining the ring shaped frame and dome in a nested manner with the dome downwardly extending peripheral wall cooperating with the frame outer peripheral wall portion;   wherein at least one of the frame and dome is formed with an integral flashing flange extending outwardly from a bottom edge of the outer peripheral wall for mounting the assembly to a building structure.   
   
   
       21 . A fenestration product assembly comprising:
 a dome formed of a first plastic material which transmits visible light, the dome having a first central panel, a peripheral side, and a peripheral flange attached to the side, the side and central panel defining a cavity;   an interior layer of a second plastic material which transmits visible light, the interior layer having a second central panel and a peripheral rib perpendicular to the second central panel, the interior layer being nested within the cavity and providing a first barrier to thermal transmission through the fenestration product; and   a cap of a third plastic material which transmits visible light, the cap having opposed aligning ribs perpendicular to a third central panel, the aligning ribs engaging the dome to connect the cap to the dome.   
   
   
       22 . The fenestration product assembly of  claim 21 , further comprising:
 a sealed insert of a fourth plastic material which transmits visible light nested in the cavity, the sealed insert having a fourth center panel, a sealing sheet and a peripheral flange, the sealing sheet being connected to the flange of the sealed insert at a distance of less than 0.625 inches from the fourth center panel forming a chamber between the sealing sheet and the flange and capable of retaining an insulator within the chamber.   
   
   
       23 . The fenestration product assembly of  claim 22 , wherein the flanged sealed insert is adjacent to the interior layer, defining an unsealed chamber between the sealing insert and the interior layer, the unsealed chamber having a thickness of less than 0.625 inches. 
   
   
       24 . A method of installing a fenestration product assembly to a building, the method comprising:
 inserting a fenestration product of  claim 21  into an opening in the building;   securing the fenestration product with a fastener passing through the flange and attaching to the building; and   applying the cap to the dome.   
   
   
       25 . The method of  claim 24 , further comprising injecting a foaming polymer into a joint between the dome and the building. 
   
   
       26 . The method of  claim 25 , further comprising securing a bezel to the exterior of the building covering the joint. 
   
   
       27 . The method of  claim 24 , further comprising securing an interior trim part covering at least a portion of the flange.