Skylight with multi-layer polymeric panel

Abstract

A skylight is formed with a pair of plastic panels having outer peripheral flanges and a central region transparent to visible light, aligned in a stacked orientation with the peripheral flanges overlying one another and defining an enclosed central region in-between. An inner and outer pair of circumferentially oriented spacer frames are interposed between and bonded to the outer peripheral flanges of elastic panels to form a sealed enclosed region. A peripheral frame is formed in situ about the plastic panels from a moldable polymeric material which entraps the peripheral flanges forming an integral leakproof structure with the spacer frames preventing intrusion of the moldable polymeric frame material into the enclosed region.

1 . A skylight assembly comprising:
 a pair of plastic panels each having a generally similarly sized outer peripheral flange and a central region which is at least semi-transparent to visible light, the pair of plastic panels when aligned in stacked relation with the outer peripheral flanges generally overlying the inner periphery flanges;   an inner and outer pair of circumferentially oriented spacer frames interposed between and bonded to the outer peripheral flanges of the pair of plastic panels to form a central enclosed region which is filled with gas and bounded by the inner spacer frame and a central section of the pair of plastic panels; and   a peripheral frame formed in situ of a moldable polymeric material bonded to the outer spacer frame and the peripheral flanges of the pair of plastic panels, entrapping the peripheral flanges and forming a leak tight structural joint therewith;   wherein the outer spacer frame provides a seal between the peripheral flanges of the pair of plastic panels as the peripheral frame is molded preventing intrusion of the moldable polymeric material into the central enclosed region.   
   
   
       2 . The skylight assembly of  claim 1  wherein the inner and outer pair of circumferentially oriented spacer frames each have an upper and lower surface coated with adhesive. 
   
   
       3 . The skylight assembly of  claim 1  wherein the inner and outer pair of circumferentially oriented spacer frames each have a width of 0.20 to 0.50 inches. 
   
   
       4 . The skylight assembly of  claim 1  wherein the inner and outer pair of circumferentially oriented spacer frames each comprises a segment having a hollow generally rectangle cross-section. 
   
   
       5 . The skylight assembly of  claim 4  wherein the inner and outer pair of circumferentially oriented spacer frames are spaced apart 0.2 to 1.00 inches. 
   
   
       6 . The skylight assembly of  claim 4  wherein the inner and outer pair of circumferentially oriented spacer frames comprise a plurality of linear segments interconnected by corner keys to form a pair of continuous frames. 
   
   
       7 . The skylight assembly of  claim 6  wherein the linear segments forming the inner and outer pair of circumferentially oriented spacer frames each have a width of 0.20 to 0.50 inches and a height of 0.40 to 0.80 inches. 
   
   
       8 . The skylight assembly of  claim 1  wherein the outer spacer frame is inwardly inset from the outer most edge of the peripheral flange by 0.10 to 0.25 inches. 
   
   
       9 . The skylight assembly of  claim 1  wherein the plastic panels are formed of acrylic. 
   
   
       10 . The skylight assembly of  claim 1  wherein the plastic panels are formed of poly carbonate. 
   
   
       11 . The skylight assembly of  claim 1  wherein the peripheral frame is formed of a RIM material. 
   
   
       12 . The skylight assembly of  claim 1  wherein the peripheral frame is formed of a thermoplastic material. 
   
   
       13 . The skylight assembly of  claim 1  wherein the thermoplastic material is filled with reinforcing fibers. 
   
   
       14 . The skylight assembly of  claim 1  wherein the peripheral frame is generally rectangular in shape. 
   
   
       15 . The skylight assembly of  claim 1  wherein the outer peripheral flanges of the pair of plastic panels lie in a plane perpendicular to the central axis. 
   
   
       16 . A method of forming a glazing unit comprising:
 forming a pair of plastic panels from a sheet of plastic material which is at least semi-transparent to visible light, the pair of plastic panels having an outer peripheral flange and a central region, which, when stacked upon one another, define an enclosed cavity bounded by the spaced apart central regions of the plastic panels when overlying one another;   bonding an inner and outer pair of circumferentially oriented spacer frames between the outer peripheral flanges of the pair of plastic panels to form a central enclosed region which is filled with gas bounded by the inner spacer frame and the pair of plastic panels;   inserting the bonded pair of plastic panels into a skylight frame mold so that the mold entraps the peripheral flanges of the stacked pair of plastic panels;   injecting a moldable polymeric material into the mold forming a frame which is securely bonded to the peripheral flanges of the plastic panels and the outer spacer frame wherein the outer spacer frame prevents the a moldable polymeric material from entering into the central region formed between the plastic panels; and   removing the skylight assembly from the mold.   
   
   
       17 . The method of  claim 16  wherein the moldable polymeric material comprises RIM. 
   
   
       18 . The method of  claim 16  wherein the moldable polymeric material comprises a thermoplastic. 
   
   
       19 . The method of  claim 16  wherein the pair of plastic panels are formed of acrylic.