Roof curb with integral burglar bars

Abstract

A method and apparatus for use in a roof curb assembly. The apparatus typically includes an outer shell, the outer shell including first and second portions attachable to one another to form a polygonal shape. The apparatus also typically includes a base plate assembly attachable to the shell and a bar assembly. The base plate assembly is typically receptive of the bar assembly. The apparatus further includes an inner liner arranged interior to the outer shell and an insulator disposed between the inner liner and the outer shell. The bar assembly includes a plurality of integral crisscrossing bars that operate as a restriction to unauthorized access to the interior of the roof curb assembly.

What is claimed is:  
     
         1 . A roof curb assembly comprising: 
 an outer shell, the outer shell comprising first and second portions attachable to one another to form a polygonal shape;    a base plate assembly attachable to the shell, the base plate assembly being receptive of a bar assembly;    an inner liner arranged interior to the outer shell; and    an insulator disposed between the inner liner and the outer shell.    
     
     
         2 . The roof curb assembly of  claim 1 , wherein the outer shell further comprises sheet metal stock.  
     
     
         3 . The roof curb assembly of  claim 2 , wherein the sheet metal stock further comprises galvanized steel.  
     
     
         4 . The roof curb assembly of  claim 2 , wherein the sheet metal stock further comprises aluminum.  
     
     
         5 . The roof curb assembly of  claim 2 , wherein the sheet metal stock further comprises galvalume™ or other aluminum-zinc alloy coated sheet steel.  
     
     
         6 . The roof curb assembly of  claim 1 , wherein the first and second portions of the outer shell each comprise two substantially perpendicular faces of the outer shell, the first and second portions being attachable to one another by a plurality of spot clinches to form a generally rectangular configuration.  
     
     
         7 . The roof curb assembly of  claim 1 , wherein the outer shell further comprises a first shell flange.  
     
     
         8 . The roof curb assembly of  claim 7 , wherein the base plate assembly further comprises first and second base plate flanges arranged substantially normal to one another.  
     
     
         9 . The roof curb assembly of  claim 8 , wherein the first base plate flange further comprises a plurality of spaced slots extending at least partially therethrough, the slots being receptive of a plurality of rods.  
     
     
         10 . The roof curb assembly of  claim 8 , wherein the second base plate flange is arranged adjacent to the first shell flange and attached thereto.  
     
     
         11 . The roof curb assembly of  claim 10 , wherein the attachment between the second base plate flange and the first shell flange is accomplished by a plurality of spot clinches.  
     
     
         12 . The roof curb assembly of  claim 1 , wherein the inner liner further comprises a face and a liner flange arranged substantially normal to one another.  
     
     
         13 . The roof curb assembly of  claim 12 , wherein the face further comprises a plurality of slots adapted to engage ends of the bar assembly.  
     
     
         14 . The roof curb assembly of  claim 12 , further comprising a wood nailer disposed between the insulator and the inner liner flange.  
     
     
         15 . The roof curb assembly of  claim 8 , wherein the inner liner is disposed between the first base plate flange and the insulator.  
     
     
         16 . The roof curb assembly of  claim 1 , wherein the bar assembly further comprises a plurality of independent crisscrossing rods.  
     
     
         17 . The roof curb assembly of  claim 16 , wherein the plurality of crisscrossing rods exhibit a plurality of intersections therebetween, wherein at least one of the intersections between the rods is welded.  
     
     
         18 . A method of fabricating a roof curb comprising the steps of: 
 providing first and second sheets of stock material, each sheet having a face, first and second ends, a longitudinal axis, first and second longitudinal edges, and a predetermined length and width;    cutting at least one notch in the first and second longitudinal edges of each sheet of stock material;    bending each sheet of stock material around a first axis transverse to the longitudinal axis to form a first substantially right angle in the sheets; and    attaching said first and second sheets together to form a substantially rectangular shell.    
     
     
         19 . The method of  claim 18 , further comprising the step of folding the first and second longitudinal edges of each of the first and second sheets around axes parallel to the longitudinal a axis of each sheet to form first and second sheet flanges substantially normal to the face of each sheet of stock metal.  
     
     
         20 . The method of  claim 18 , further comprising the step of bending the first end of each sheet of stock material around a second axis transverse to the longitudinal axis to form a second substantially right angle in the sheets.  
     
     
         21 . The method of  claim 20 , wherein the step of attaching first and second sheets further comprises overlapping the first end of the first sheet with the second end of the second sheet, and overlapping the first end of the second sheet with the second end of the first sheet.  
     
     
         22 . The method of  claim 21 , wherein the step of attaching the first and second sheets further comprises fastening the first and second sheets with a plurality of spot clinches.  
     
     
         23 . The method of  claim 18 , further comprising the step of: 
 providing a base plate assembly, the base plate assembly comprising first and second base plate flanges, wherein the first and second base plate flanges are substantially perpendicular to one another.    
     
     
         24 . The method of  claim 23 , wherein the first base plate flange comprises a plurality of spaced slots.  
     
     
         25 . The method of  claim 23 , further comprising the step of attaching the second base plate flange to the first sheet flanges of each of the first and second sheets.  
     
     
         26 . The method of  claim 24 , further comprising the step of inserting a first plurality of rods into the plurality of spaced slots in a first direction.  
     
     
         27 . The method of  claim 26 , further comprising the step of inserting a second plurality of rods into the plurality of spaced slots in a second direction, the inserting of the second plurality of rods creating a plurality of intersections between the first and second pluralities of rods.  
     
     
         28 . The method of  claim 27 , further comprising the step of welding the plurality of intersections between the first and second pluralities of rods.  
     
     
         29 . The method of  claim 23 , further comprising the step of inserting a liner between the substantially rectangular shell and the first base plate flange.  
     
     
         30 . The method of  claim 29 , wherein the liner further comprises a plurality of slots engagable with a bar assembly.  
     
     
         31 . The method of  claim 29 , further comprising inserting an insulator between the liner and the substantially rectangular shell.  
     
     
         32 . The method of  claim 19 , further comprising the step of attaching a wood nailer to the second sheet flange.  
     
     
         33 . A method of fabricating a roof curb with integral burglar bars comprising the steps of: 
 providing first and second portions of an outer shell;    providing a bar assembly;    attaching first and second portions of the outer shell in a substantially rectangular configuration;    placing the outer shell over the bar assembly; and    attaching the outer shell to the bar assembly.    
     
     
         34 . A roof curb assembly comprising: 
 an outer shell;    a base plate assembly attachable to the outer shell;    a plurality of rods arranged across the base plate; and    an inner liner attached to the outer shell and arranged to engage and secure the plurality of rods in place across the base plate.