Patent Abstract:
A light transmitting panel that can connect within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and mechanical fastener or a linear coefficient buffer or mechanical fastener and a linear coefficient buffer therebetween to allow the respective panels to expand and contract with respect to the other without loss of containment or seal.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0003]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    The present invention relates to a light transmitting panel for metal roofing systems. Although other references teach away from the use of fasteners, it would be a benefit to have a light transmitting panel adapted for connection in a metal roofing system that would allow the use of fasteners and the like to secure the light transmitting panel to the metal panel. It is thus an object of this invention to provide a light transmitting panel for use in metal roofing systems for allowing ambient light to enter a structure and which meets UL 90 and ASTM E 1592 bag test specifications with and without the use of conventional fasteners or clips. One such assembly would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with or without linear coefficient barriers. 
         [0006]    2. Description of the Related Art 
         [0007]    For many years commercial buildings have utilized sheet metal roofs. Recently it has become more common and popular to utilize sheet metal roofs on residential homes, shops, patios and the like. Typically, the standing seam metal roof utilizes metal sheets having lateral upturned edges. The panels are laid side by side with the lateral edges of one panel contiguous with the upstanding edge of adjacent panels. The panels are joined together by a cap piece or by folding over the upstanding edge to tightly hold the panels together. The roofs are sloped so that water runs down the trough formed between the upstanding edges of each panel. 
         [0008]    The above referenced roofing systems may take many forms such as, but not limited to, trapezoidal, 90-degree modular, architectural, and industrial. Metal roofs may have minor ribs, stiffener ribs, or no ribs at all and may be a screw down roofing system. All of these roofing systems are similar in the requirement of attaching the panels at adjacent edges or side rails. 
         [0009]    It is very often desirable with metal roofing systems to have additional natural lighting whereby sunlight is permitted to enter the structure through the roof. Heretofore, this natural lighting was provided by installing domed skylights of either the curb or curbless variety. Unfortunately, skylights can be expensive and create water leakage. One of the causes of water leakage is due to the restricted flow path of water between the domed skylight and the standing seam, whereby the water level rises such as to penetrate the roof at the panel junctions. Additional problems arise with domed skylights when freezing temperatures are encountered. Ice and/or snow may collect between the skylight and the dome, and as the ice melts it is blocked by ice dams resulting in the level of water rising and penetrating the panel seam. 
         [0010]    Curbed skylights include a “curb” which is a raised structure formed around the opening in the roof upon which the transparent material is attached. The curb raises the seal between the curb and the transparent material above the point of water flowing down the roof. However, curbs are expensive to construct and to install. If not installed correctly leaks will develop around the curb and roof junction resulting in expensive repair. Additionally, installing curbed skylights requires cutting a hole in the existing roof which is performed at the job site increasing the cost of the skylight. 
         [0011]    Curbless skylights have been utilized and by definition do not require a raised frame. However, the prior art skylights typically utilize flashing, mechanical fasteners, and or sealing rings to install and to alleviate water leakage. Although curbed skylights do provide benefits over curbless skylights, curbed skylights often increase the weight of the panel with framing, increase the likelihood of water leakage and increase the cost of the metal roofing. 
         [0012]    In addition, OSHA requires that skylights be less than twelve inches in width or length, or a metal grate is required to be placed over the skylight. In order to meet these requirements the skylights and light transmitting panels in the prior art required a combination of fasteners, clips, clips, and fasteners, flanges, etc. in order to secure the transparent or semi-transparent material to the sheet metal surfaces. The differences in the respective linear coefficients of expansion of the various materials of construction resulted in systems that would inherently fail over time. The failures resulted from movement of the various materials in various directions due to the heating and cooling affect that occurs every day. With materials often moving in opposite directions fatigue occurs causing cracks, leaks and the inability to meet OSHA and UL testing requirements as discussed below. 
         [0013]    During the heating and cooling cycle of a typical day, the metal roof and its components expand and contract. For example, it is not an unusual occurrence in a normal pitched roof to expand and contract as much as 6″ over a 100 linear feet. As a result of this and other effects, UL 90 requires that a panel withstand a 90 mph wind created uplift without loss of containment. In order to achieve this, again the prior art systems employed very elaborate clip and/or conventional fasteners. However, due to the vastly different linear expansion coefficients of the fasteners, metal panels, clips, and metal panels and light transmitting panels, loss of containment or component failure would occur as noted above over time. 
         [0014]    Although other references teach away from the use of fasteners, it would be a benefit to have a light transmitting panel adapted for connection in a metal roofing system that would allow the use of fasteners or adhesives or a combination of both to secure the light transmitting panel to the metal panel while at the same time meeting ASTM E 1592 bag test and UL 90 requirements. It would be a further benefit to have a light transmitting panel which has side rails adapted for connecting with metal roofing panels. It would be a still further benefit to have a light transmitting panel prefabricated for installation on site in a metal roofing system in the same manner as standard metal roofing panels. It would be a still further benefit to have a light transmitting panel having substantially the same strength characteristics as adjacent metal panels. 
       BRIEF SUMMARY OF THE INVENTION 
       [0015]    It is thus an object of this invention to provide a light transmitting panel for use in metal roofing systems for allowing ambient light to enter a structure and which meets UL 90 and ASTM E 1592 bag test specifications with and without the use of conventional fasteners or clips. 
         [0016]    It is a further object of this invention to provide a light transmitting panel which is inexpensive and may be constructed off site. 
         [0017]    It is a still further object of this invention to provide a light transmitting panel which is readily connectable in a metal roofing system in the same manner as standard metal roofing panels. 
         [0018]    It is yet a further object of this invention to provide a light transmitting panel that will have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel. 
         [0019]    Accordingly, a light transmitting panel of the type for connecting within a metal roofing system is provided. The light transmitting panel includes a translucent panel, a metal panel and a mechanical fastener or a linear coefficient buffer or mechanical fastener and a linear coefficient buffer therebetween. Additionally, the panel may have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel. 
         [0020]    The linear coefficient buffer is adapted to connect the translucent panel and the metal panel in such a way as to allow the translucent panel and metal panel to expand and contract according to its individual linear coefficient relative to the other without loosing containment. Although, it should be noted that a mechanical fastener may be used in place of a linear coefficient buffer. This assembly can be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels would be simply lying against one another and can attach to the roof using mechanical fasteners for attachment. 
         [0021]    The linear coefficient buffer may comprise any material which allows the light transmitting panel to expand and contract along the metal panel and vice versa, without loss of containment or seal therebetween. In a preferred embodiment, the linear coefficient buffer comprises and may be selected from the group consisting of adhesives, adhesive gaskets, adhesive foam and adhesive rubber. In a most preferred embodiment the linear coefficient buffer is an adhesive. In order to allow for the expansion and contraction of the materials the linear coefficient buffer thickness will be generally in the range of about 0.1 mil.-20 mil., and more specifically in the range of 2 mil.-10 mil. in thickness. While we have disclosed that certain adhesives, gaskets, and other materials may comprise the buffer, one skilled in the art will understand that any material capable of adhering to the translucent panel and the metal panel so as to allow the respective panels to move according to their respective linear coefficients without resulting in a loss of containment so that if they can do that, then they fall within the scope of the linear coefficient buffers according to the present invention. And, although a linear coefficient buffer may be more desirable, a mechanical fastener will also be suitable for the present invention. 
         [0022]    The light transmitting panel may further comprise a pair of side rails on both the metal panel and light transmitting panel. The side rails may form a 90° angle, a trapezoid shape or any other shape. In this embodiment, the light transmitting panel side rails are disposed adjacent to the metal panel side rails in the metal roofing system. 
         [0023]    The light transmitting panel may comprise material such as, but not limited to, fiberglass, polycarbonates, and acrylic so as to allow ambient or exterior light to enter a structure through the light transmitting panel. It is not required for the translucent material to be transparent. The translucent section may be planar, substantially planar, or have a domed section formed therein. The translucent section has a planar section running approximate the lateral or longitudinal sides which may turn into an angled portion extending from the planar portion. The angle of departure between the angled portion and the planar portion is chosen so as to match the configuration of the side rail of the particular metal roofing system in which it is to be installed. 
         [0024]    The side rails are chosen to match the roofing system in which the light transmitting panel is to be installed. The side rails may be obtained from cutting the middle section out of an existing metal panel. The side rails may be individually turned to match particular roofing systems. Typically the side rails will have at least one horizontal portion and an angled portion extending therefrom. The adhesion surface of the horizontal portion, and the angled portion if desired, should be cleaned to remove foreign material, protective coatings and metal oxides before the adhesive is applied to join the side rails with the translucent material. 
         [0025]    Once the translucent material is formed to match the side rails chosen for the installation a chemical adhesive or bonding material is applied to either or both the translucent material and the adhesion surface of the side rails. An adhesive or a urethane compound adhesive is desired because of its ability to bond many combinations of material without a chemical degradation and its strength. The side rails and translucent material are then compressed at the contact point and the adhesive is allowed to cure. Once the adhesive has cured the light transmitting panel will have substantially the same configuration and strength characteristics of the metal roofing panels for a particular installation. If preferred, mechanical fasteners may be used in place of an adhesive. The light transmitting panel will have properties which allow it to be installed in a metal roofing system in a manner so as not to require metal grating to be installed in conjunction. The light transmitting panel may then be shipped to the site to be installed and will not require any additional equipment or additional expertise of the on-site personnel for installation. 
         [0026]    Once on site the light transmitting panel may be installed in the same manner as the metal roofing panels utilized in the construction. The adjacent side rails may be connected by rolling, folding, or caps and additionally may include screws or other types of mechanical fasteners. Light transmitting panels may be installed adjacent to other light transmitting panels and/or metal roofing panels. 
         [0027]    The light transmitting metal panels may have multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels can simply lie against one another and can attach to the roof using mechanical fasteners for attachment. In this case, the main strength of the assembly would be retained by the mechanical fasteners primarily, but the safety benefits of the perforated panel would still be available. 
         [0028]    The foregoing has outlined the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0029]      FIG. 1  is a perspective view of a light transmitting panel of the present invention. 
           [0030]      FIG. 2  is a front, planar view of the light transmitting panel of the present invention in connection with adjacent panels. 
           [0031]      FIG. 3  is a front, planar view of an alternative connection of the light transmitting panel of the present invention and an adjacent panel. 
           [0032]      FIG. 4  is a perspective view of another configuration of the light transmitting panel of the present invention. 
           [0033]      FIG. 5  is a perspective view of another embodiment of a light transmitting panel of the present invention. 
           [0034]      FIG. 6  is a plan view of another embodiment of the light transmitting panel. 
           [0035]      FIG. 7  is a front, planar view of the embodiment of the light transmitting panel of  FIG. 6 . 
           [0036]      FIG. 8  is a perspective view of the embodiment of the light transmitting panel of  FIG. 6 . 
           [0037]      FIG. 9A  is a plan view of another embodiment of the light transmitting panel. 
           [0038]      FIG. 9B  is a layered view of the embodiment of the light transmitting panel of  FIG. 9A . 
           [0039]      FIG. 9C  is another layered view of the embodiment of the light transmitting panel of  FIG. 9A . 
           [0040]      FIGS. 9D and 9E  are illustrative embodiments of the light transmitting panel. 
           [0041]      FIGS. 10A and 10B  are an end and a top view of a light transmitting panel of the present invention in the trapezoidal configuration. 
           [0042]      FIGS. 11A ,  11 B, and  11 C are two end views and a top view of a light transmitting panel of the present invention in the trapezoidal standing seam configuration with multiple perforations. Additionally  FIGS. 11A and 11B  show that the translucent material may be on the top or bottom of the metal panel. 
           [0043]      FIGS. 12A ,  12 B,  12 C are two end views and a top view of a light transmitting panel of the present invention in the “R” panel configuration with multiple perforations. Additionally  FIGS. 12A and 12B  show that the translucent material may be on the top or bottom of the metal panel. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0044]    Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views. 
         [0045]      FIG. 1  is a perspective view of a light transmitting panel of the present invention, generally designated by the numeral  10 . Light transmitting panel  10  includes a translucent section  12 , first side rail  14 , second side rail  16 , and a chemical adhesive  18 . 
         [0046]    Translucent section  12  in the embodiment shown is constructed of fiberglass and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section  12  may be constructed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section  12  is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section  12  have strength characteristics which alleviate requirements of metal grating. As shown, and in the present embodiment, light transmitting panel  12  is constructed so as to withstand at least 200 pounds per square foot of pressure so as not to require metal grating pursuant to OSHA regulations. 
         [0047]    Translucent section  12  includes a planar section  20 , and may have a first and second lateral, angled portion  22 ,  24 . As shown in  FIG. 1 , when present, lateral portions  22 ,  24  are angled approximately perpendicular to planar section  20  to form a 90-degree modular system. Translucent section  12  may be formed to fit and match any metal roofing design configuration. 
         [0048]    Side or locking rails  14 ,  16  are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails  14 ,  16  are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel. As shown in  FIG. 1 , side rails  14  and  16  are adapted for incorporation in metal roofing systems in which the roofing panels have male and female side rails  14 ,  16  which are interconnected by rolling or folding, and possibly caps or mechanical fasteners. However, the present invention is adaptable to many shapes, and forms of side rails  14 ,  16 , three examples of which are shown in  FIGS. 1 through 4 . 
         [0049]    As shown in  FIG. 1 , first side rail  14  is a female side rail having a first horizontal portion  26  and a first angled portion  28  which extends substantially perpendicular and upward from first horizontal portion  26 . Second side rail  16  is a male side rail also having a first portion  26  and first angled portion  28  which extends substantially perpendicular and upward from first horizontal portion  26 . Both side rails  14  and  16  have a top locking section  30 . In the female side rails, top locking section  30  of side rail  14  extends in the same direction as first horizontal portion  26  and is substantially parallel to first portion  26 . In the male side rails, top locking section  30  of side rail  16  extends in the opposite direction as first portion  26  and is substantially parallel to first portion  26 . As shown in  FIG. 1 , side rails  14  and  16  are adapted for connecting to adjacent light transmitting panels  10  or adjacent metal roofing panels  32  ( FIG. 2 ) by rolling or folding and therefor include tongues  34 . One or both tongues  14  may be deleted still allowing a rolled connection via locking section  30 . Additionally, at least first horizontal portion  26  and possibly first angled portion  28  have an adhesion surface  36  for connecting translucent section  12  such that section  12  is located below side rails  14  and  16 . However, as shown in  FIGS. 5 and 6 , translucent section  12  may be adhered atop side rails  14  and  16 . 
         [0050]    Side rails  14  and  16  are connected to translucent section  12  by an adhesive or bonding agent to form light transmitting panel  10 . It is desired to utilize a urethane based adhesive. Although, a mechanical fastener may be used in place of adhesives or bonding agents. 
         [0051]    To connect side rails  14  and  16  to translucent section  12  adhesion surface  36  and the surface of a portion of first planar section  20  adjacent to lateral angled portion  22  and lateral angled portion  22  should be cleaned to remove any foreign materials, protective coatings such as terne, and metal oxides. An adhesive or bonding agent  18  is applied to adhesion surface  36  and/or translucent section  12  and side rails  14  and  16  are placed in position whereby horizontal portions  26  are disposed upon a portion of planar section  20  and first angled portion  28  is disposed upon first lateral portion  22  of translucent section  12 . Side rails  14  and  16  and translucent section  12  are compressed together and adhesive  18  is allowed to cure to form light transmitting panel  10 . 
         [0052]      FIG. 2  is a front, planar view of light transmitting panel  10  of the present invention in connection with adjacent metal roofing panels  32 . As shown, adjacent side rails  14  and  16  are positioned so that a male side rail  16  overlaps a female side rail  14 . To connect panels  10  and panels  32  or panels  10  to adjacent panels  10  (not shown) by folding tongues  34  in the direction of the arrows. It should be recognized that tongue  34  is not necessary. 
         [0053]      FIG. 3  is a front, planar view of an alternative connection of light transmitting panel  10  of the present invention and an adjacent metal roofing panel  32 .  FIG. 3  demonstrates the connection of adjacent roofing panels  10  and  32  utilizing a cap  38 . Metal roofing panel  32  utilizes a female side rail  14  as does light transmitting panel  10 . Each panel  32  and  10  are placed side by side in a manner such that side rails  14  are adjacent and top locking sections  30  extend away from each other. A cap  38  is slid onto both side rails  14  along top locking sections  30  or cap  38  is placed atop locking sections  30  and crimped thereon. Although not shown this connection may be made between adjacent light transmitting panels  10  in the same manner. Note that the embodiment shown in  FIG. 3 , the lateral, angled portion  22  of the translucent section  12  is optional. 
         [0054]      FIG. 4  is a perspective view of another configuration of light transmitting panel  10  of the present invention shown in a trapezoidal configuration. In the trapezoidal configuration translucent section  12  has a first angled portion  22  which extends upwardly from planar portion  20  at an angle to match the angle that first angled portion  28  of side rails  14  and  16  extends from first horizontal portion  26  of side rails  14  and  16 . In this embodiment translucent material  12  is connected to side rails  14  and  16  in the same manner as described above. Additionally, light transmitting panel  10  as shown in  FIG. 4  may be connected to adjacent light transmitting panels  10  and/or metal roofing panels as shown in  FIG. 2 . 
         [0055]      FIG. 5  is a perspective view of another embodiment of light transmitting panel  10  of the present invention. Light transmitting panel  10  includes a translucent section  12 , first side rail  14 , second side rail  16 , and a chemical adhesive  18 . 
         [0056]    Translucent section  12  in the embodiment shown is constructed of a translucent or transparent material, such as fiberglass, and permits the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. Translucent section  12  may be constructed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic either singularly or in combination. Translucent section  12  is constructed of material so as to substantially match the characteristics of the metal panels utilized in the roofing system. It is desired that translucent section  12  have strength characteristics which alleviate requirements of metal grating. 
         [0057]    Translucent section  12  includes a planar section  20 , and may have a first and second lateral, angled portion  22 ,  24 . As shown in  FIG. 1 , when present, lateral portions  22 ,  24  are angled approximately perpendicular to planar section  20  to form a 90-degree modular system. Translucent section  12  may be formed to fit and match any metal roofing design configuration. 
         [0058]    Side or locking rails  14 ,  16  are constructed of metal of the same type as the roofing system in which the present invention is to be installed. Side rails  14 ,  16  are formed by taking a metal panel section of the design type chosen for a roof and cutting the side rails from the metal panel. 
         [0059]    Although not shown, it is contemplated to connect a cap or seal atop or about translucent section  12  so as to aid in the prevention of water entry through the connection between section  12  and side rails  14 ,  16 . 
         [0060]    Use of light transmitting panel  10  is now described with reference to  FIGS. 1 through 5 . A metal roofing panel (not shown) is taken and the panel is cut so as to provide two side rails  14  and  16 . Side rails  14  and  16  may be of any configuration so as to match the roofing system in which light transmitting panel  10  is to be installed. Additionally, side rails  14  and  16  may be turned individually to match the side rails of the roofing installation in which to be installed. A translucent section  12  formed of thermoset or thermoformed material such as, but not limited to, fiberglass, polycarbonates, and acrylic is formed so as to have a planar section  20  and may have an adjacent lateral angled section  22 . Translucent section  12  is formed so that lateral angled portions  22  are angled from planar section  20  to match the angle between first horizontal section  26  and first angled portion  28  of side rails  14 ,  16 . Adhesion surface  36  of side rails  14 ,  16  should be cleaned as well as the contacting surface of translucent material  12 . An adhesive or bonding agent  18  is applied to adhesion surface  36  and/or translucent section  12 . Side rails  14  and  16  are placed in contact with translucent material  12  such that horizontal portions  26  and planar sections  20  and angled portions  28  and lateral angled portions  22  are aligned. Compression is applied to side rails  14 ,  16  and translucent section  12  and adhesive  18  is allowed to cure. Once adhesive  12  is cured light transmitting panel  10  is completed and may be shipped for installation in a metal roof system. Light transmitting panel  10  may be installed in any system in which side rails  14 ,  16  are adapted, whether it be by rolling, folding, caps, and/or mechanical fasteners for connection with adjacent metal roofing panels. Also a mechanical fastener may be used in place of or in combination with an adhesive or bonding agent. 
         [0061]    With reference to  FIGS. 6-9 , further embodiments of the present invention are disclosed. The embodiment of  FIGS. 6-8  shows a bonded light transmitting panel  10 ′ comprising translucent panels  12 ′ a  and  12 ′ b , ( 12 ′ a  and  12 ′ b  can also be a single translucent panel) a roofing panel  32 ′. The utilization of a standard roofing panel  32 ′ in this embodiment provides compatibility with other roofing panels  32 ′ and/or light transmitting panels  10 ′. 
         [0062]    With reference to  FIG. 6 , a plan view of the bonded light transmitting panel  10 ′ is shown. In this embodiment, the roofing panel  32 ′ has a portion cut-out, allowing exposure of the planar sections  20 ′ a  and  20 ′ b , corresponding to translucent panels  12 ′ a  and  12 ′ b  ( FIG. 8 ). Thus, the light can be transmitted through translucent panels  12 ′ a  and  12 ′ b  ( FIG. 8 ) while the exterior portions of roofing panel  32 ′—as described below—allow connection with other roofing panels and/or light transmitting panels. 
         [0063]    With reference to  FIG. 7 , a front, planar view of the bonded light transmitting panel  10 ′ is shown. Translucent panels  12  (indicated  12 ′ a  and  12 ′ b  in  FIG. 8 ) includes a planar section  20 ′ (indicated  20 ′ a  and  20 ′ b  in  FIG. 6 ), and may have a first and second lateral, angled portion  22 ′,  24 ′. In this embodiment, when present, lateral portions  22 ′,  24 ′ are angled approximately perpendicular to planar section  20 ′ to form a 90-degree modular system. While these lateral portions  22 ′,  24 ′ are shown in this embodiment, other embodiments may not have them. In the embodiment shown in  FIG. 7 , lateral portions  22 ′,  24 ′ extend upward toward side rails  14 ′,  16 ′. By this illustration, it should become apparent to one of ordinary skilled in the art that translucent panels  12  (indicated  12 ′ a  and  12 ′ b  in  FIG. 8 ) may be formed to fit and match any roofing design configuration. 
         [0064]    With reference to  FIG. 8 , a perspective view of the bonded light transmitting panel  10 ′ is shown. The two translucent panels  12 ′ a  and  12 ′ b  in this embodiment permit the passage of light exterior of the structure, such as sun light, to be transmitted into a structure on which it is installed. The translucent panels  12 ′ a  and  12 ′ b  may be constructed of thermoset material such as, but not limited to fiberglass, polycarbonates, and acrylic either singularly or a combination of polycarbonates. Furthermore, the translucent panels  12 ′ a  and  12 ′ b  can be constructed so as to substantially match the characteristics of the roofing panels utilized in the roofing system. 
         [0065]    In the embodiment shown in  FIG. 8 , side rails  14 ′ and  16 ′ of roofing panel  32 ′—as briefly described above—are adapted for incorporation in roofing systems in which the roofing panels have male and female side rails  14 ′,  16 ′ which are generally interconnected by rolling or folding, or by utilizing caps or mechanical fasteners. As an illustrative example, roofing panel  32 ′ can be a standard roofing panel, adapted to connect with other standard roofing panels, which is removed and cut out in the manner describe with reference to  FIG. 6 . In other embodiments, the light transmitting panels  10 ′ can be adaptable to many shapes and forms of side rails  14 ,  16  (both from standard roofing panels and those adapted for connection with the metal roofs, in general). 
         [0066]    With reference once again to  FIG. 8 , first side rail  14 ′ is a female side rail and second side rail  16 ′ is a male side rail. Both side rails  14 ′ and  16 ′ have a top locking section  30 ′. As shown in  FIG. 8 , side rails  14 ′ and  16 ′ are adapted for connecting to adjacent light transmitting panels  10 ′ or adjacent roofing panels  32 ′. At least horizontal portion  26 ′ and possibly first angled portion  28 ′ are coupled to the roofing panels  32 ′. 
         [0067]    With reference to  FIGS. 9A-9C , another embodiment of the invention is shown with a translucent section  12 ′ coupled to a roofing panel  32 ′.  FIGS. 9A-9C  are similar to the embodiment of  FIGS. 6-8  in that a standard roofing panel  32 ′ can be utilized with a portion thereof cut-out, exposing the translucent section  12 ′.  FIG. 9A  shows a top plan view of a single translucent section  12 ′ being divided by a portion of the roofing panel  32 ′ into two separate light transmitting areas. As will be appreciated by those in the art, such a configuration can be used in some embodiments to facilitate structural integrity (e.g., desired force per surface area support) of each light transmitting area of the translucent section  12 ′. 
         [0068]      FIG. 9B  is a layered view showing the translucent section  12 ′ with the roofing panel  32 ′ shown in partial phantom view.  FIG. 9C  is another layered view showing an illustrative example of an area for the location of the linear coefficient buffer  18 ′, generally referenced in other embodiments. It will become apparent to one of ordinary skill in the art that such an area can change depending on the desired structural dynamics of light transmitting panel  10 ′ and linear coefficient buffer  18 ′ utilized. 
         [0069]    With reference to  FIGS. 9D-9E , an illustrative embodiment shows how the side rails  14 ′ and  16 ′ can be connected to translucent section  12 ′ by a linear coefficient buffer  18 ′, thereby absorbing the expansion and contraction between the roofing panel  32 ′ and the translucent section  12 ′. Additionally, this illustrative embodiment shows how the linear coefficient buffer  18 ′ may also serve as an adhesive or bonding agent to form the bonded light transmitting panel  10 ′. Examples of adhesives or bonding agents are UNI-WELD, a two-part epoxy from Kent Industries, adhesives from Dynatron Bondo Adhesives, and adhesives by SIKA or Michigan Adhesive Mfg. Inc, (other brands are also available). In addition, it may be desirable to utilize a neutral cure, or urethane, silicone adhesive on the edges of the translucent section  12 ′ as a secondary seal. If preferred, mechanical fasteners may be used in place of an adhesive. 
         [0070]    To connect side rails  14 ′ and  16 ′ to translucent section  12 ′ adhesion surface  36  and the surface of a portion of first planar section  20 ′ adjacent to lateral angled portion  22 ′ and lateral angled portion  22 ′ should be cleaned according to procedures known in the art to remove any foreign materials, protective coatings such as terne, and metal oxides. The linear coefficient buffer  18 ′ is applied to adhesion surface  36 ′ so that translucent section  12 ′ may be disposed upon a portion of planar section  20 ′ and first angled portion  28 ′. Side rails  14 ′ and  16 ′ and translucent section  12 ′ are compressed together and adhesive  18 ′ is allowed to cure to form light transmitting panel  10 ′. 
         [0071]    As can be seen with reference to embodiments of  FIGS. 9A-9E , the translucent section  12 ′ of the light transmitting panel  10 ′ can be connected to side rails  14 ′ and  16 ′ or directly to the roofing panel  32 ′. In addition, as discussed above, the side rails  14 ′ and  16 ′ may be adapted individually to match the side rails of the roofing installation in which they are to be installed. Therefore, the translucent section  12 ′ can be formed to fit and match any metal roofing design configuration. 
         [0072]    Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. For example, many configurations of metal roofing panels exist to which the light transmitting panel of the present invention may be adapted, many translucent materials are available for use in the light transmitting panel, and additionally it is contemplated that mechanical fasteners such as screws and nuts and bolts may be used for additional security between adjacent metal roofing panels and light transmitting panels, and adhesion of the light transmitting panels along a single portion or section of the side rails. 
         [0073]    The invention will be further described by the following example. This example is not intended to be limiting, in any way, the invention being defined by the appended claims. 
       Example 
       [0074]    A light transmitting panel assembly according to the present invention was constructed for testing under UL 90 test requirements. A five (5) panel assembly was created wherein one of the panels included a light transmitting panel. The panels were nominally ten feet ( 10 ′) in length and two feet ( 2 ′) wide. The panel which comprised the light transmitting panel assembly included a metal panel including one cut-out nominally 17″×53″ and two cut-outs that nominally 17″×24″. A translucent fiberglass panel nominally 8 oz./ft 2  (˜0.045″ thick) was overlaid onto the bottom of the metal panel so as to cover the cut-outs. An adhesive was used as the linear coefficient buffer and was disposed between the metal panel and translucent fiberglass panel to a thickness of 2.5 mil. The same material was used as an additional adhesive/buffer on the light transmitting panel edges as a secondary seal and to prevent the infusion of air or water under the panel in the event of a void in the adhesive. The five (5) panel assembly including the light transmitting panel assembly was testing according to ASTM E specification 1592 and UL 90. After the testing, the light transmitting panel assembly was inspected and no break down or fatigue of the component parts was observed. 
         [0075]    In the above example one could also take a standing seam metal panel, of the same configuration, with holes of varied design, and overlay it over a fiberglass or other polymer panel and mechanically fasten it to the perimeter of the metal roof or perimeter of the polymer panel assembly, using mechanical fasteners. This can also be done by applying it to the underside of the polymer panel. 
         [0076]    Turning to  FIGS. 10A and 10B , an end view and a top (or bottom) view, respectively, of the light transmitting panel of the present invention are illustrated. A panel  50  of the present invention for use in a metal roof system includes a metal panel  54  cut into any design. The metal panel  54  in  FIGS. 10A and 10B  is in the trapezoidal configuration similar to the light transmitting panel shown in  FIG. 4 . The panel  50  also includes a translucent material  52  substantially in the same shape as the metal panel  54  placed below the metal panel  54 . The translucent material  52  is sealed to the metal panel  54  with an appropriate linear coefficient buffer as described herein. In various embodiments, the translucent material  52  includes a planar section  20 ″ and may include first and second lateral angled portions  22 ″ and  24 ″. 
         [0077]    The composition of the translucent material  52  is preferably a plastic, which may be a laminate, such as used in melt-away domed skylights. Most of these materials are proprietary to the manufacturer, but are will known in the art. In various embodiments, the translucent material  52  is a meltable and/or shrinkable acrylic. In some embodiments, the translucent material  52  has a melting point of less than 200 degrees Fahrenheit. Note that in vent  50  embodiment of the present invention, structural support for weight by the translucent material  52  need not rise to the level of the structural support supplied by translucent material  12  in other embodiments of the light transmitting panels of the present invention. In the embodiment of  FIGS. 10A and 10B , the openings  56  are cut with a plasma cutting machine. Other manufacturing methods are contemplated. Note also that the translucent material  52  may be transparent or translucent. Additionally, as shown in  FIG. 11A , note that the translucent material  2  is below the metal panel  1  with linear coefficient barrier  3 . Another configuration is shown in  FIG. 11B  where the translucent material  2  is above the metal panel  1  with linear coefficient barrier  3 . Also, mechanical fasteners may be used in place of linear coefficient barrier  3 . 
         [0078]    In the top view shown in  FIG. 10B , a pattern may be seen in the metal panel  54  such that safety cross-over material  58  is present between openings  56  to protect from fall-through. The geometry of the pattern may of different designs in different embodiments. In one embodiment, the area of any one opening  56  is less than twelve square inches. In another embodiment, the cross-over material  58  is capable of supporting up to 200 pounds per square foot. 
         [0079]    While the panel  50  has been illustrated with respect to the trapezoidal configuration, other configurations are contemplated. Other contemplated configurations include architectural standing seam with or without minor ribs, architectural standing seam with or without geometric differences in the openings  56  to allow for the use of a protective grate, exposed fastener roof panels with or without minor ribs, exposed fastener roof panels with or without geometric differences in the openings  56  to allow for the use of a protective grate, including the well-known “R” panel and “U” panel. In particular, the panel  50  may be configured in various embodiments compatible with the embodiments of the light transmitting panels  10 ,  10 ′ shown in  FIGS. 1-3 ,  FIG. 5 ,  FIGS. 6-9   d , and  FIG. 9   e . Other configurations are contemplated based on aesthetic and/or safety considerations. 
         [0080]    In the presence of flame or high temperature, according to the material used for the translucent material  52 , the translucent material  52  will melt and fall out. The safety cross-over material  58  is configured to allow for workers or firemen to cross the panel  50  without falling through to the floor below. In a preferred embodiment, the safety cross-over material  58  provides fall protection that meets OSHA Regulation §1926.501 “Duty to have Fall Protection.” In some embodiments, the safety cross-over material  58  provides fall protection that meets local or state regulations. In some cases, a grate may become necessary. 
         [0081]    In addition to the standing seam systems, a corrugated or exposed fastener panel assembly must also be considered. This assembly would be of a type or similar to “R”, U, 2.67, 7.2 or the many other panel configurations used in the metal building industry. 
         [0082]    This “R” assembly shown in  FIGS. 12A ,  12 B, and  12 C would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with a linear coefficient barrier for attachment and then the assembly would be mechanically attached to the roof assembly.  FIG. 12C  shows that different sized perforations may be used in creating the ribbed panel.  FIG. 12A  shows that the translucent material  2  is below the metal panel  1  with linear coefficient barrier  3 . Another configuration is shown in  FIG. 12B  where the translucent material  2  is above the metal panel  1  with linear coefficient barrier  3 . Thus, the translucent material can either be on top or bottom of the metal panel. 
         [0083]    Another assembly would be built using a metal panel, with multiple holes or perforations on the top or bottom of a polymer translucent or transparent panel with no linear coefficient barrier. In this case the panels would be simply lying against one another and would be attached to the roof using mechanical fasteners for attachment. In this case the main strength of the assembly would be retained by the mechanical fasteners only, but the safety benefits of the perforated panel would still be available. 
         [0084]    The foregoing disclosure and description of the preferred embodiments are illustrative and explanatory thereof, and various changes in the components, elements, configurations, and connections, as well as in the details of the illustrated construction and method of operation may be made without departing from the spirit and scope of the invention

Technology Classification (CPC): 4