Metal roofing light transmitting panel

Abstract

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 linear coefficient buffer therebetween to allow the respective panels to expand and contract with respect to the other without loss of containment or seal. The light transmitting panel is formed so as to substantially match the configuration and the strength characteristics of the roofing system into which it is installed.

Description

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 natural lighting systems for roofs, and more particularly, to a light transmitting panel connectable within a metal roofing system.

[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 of 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 curbless skylights do provide benefits over curbed skylights they 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 square or metal grate is required to be placed over the skylight. This so called OSHA 252 bag test is instituted to prevent people, in particular, workers from falling through the skylight when it is stepped or sat on. 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] It would be a benefit therefor, to have a light transmitting panel adapted for connection in a metal roofing system that did not comprise the use of clips, fasteners and the like to secure the light transmitting panel to the metal panel while at the same time meeting OSHA 252 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 OSHA 252 bag test specifications 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] 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 linear coefficient buffer therebetween.

[0019] The linear coefficient buffer is adapted to connect the translucent panel and the metal panel in such a was 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.

[0020] 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 a SIKA 452 adhesive, manufactured by SIKA Industries. 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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. A neutral cure 100 percent silicon adhesive is desired because of its ability to bond many combinations of material with 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. In particular, 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.

[0025] 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.

[0026] 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

[0027] FIG. 1 is a perspective view of a light transmitting panel of the present invention.

[0028] FIG. 2 is a front, planar view of the light transmitting panel of the present invention in connection with adjacent panels.

[0029] FIG. 3 is a front, planar view of an alternative connection of the light transmitting panel of the present invention and an adjacent panel.

[0030] FIG. 4 is a perspective view of another configuration of the light transmitting panel of the present invention.

[0031] FIG. 5 is a perspective view of another embodiment of a light transmitting panel of the present invention.

[0032] FIG. 6 is a perspective view of an embodiment of the light transmitting panel.

[0033] FIG. 7 is a perspective view of an embodiment of the light transmitting panel.

[0034] FIG. 8 is a perspective view of an embodiment of the light transmitting panel.

DETAILED DESCRIPTION OF THE INVENTION

[0035] 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.

[0036] 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.

[0037] 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 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.

[0038] 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, 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.

[0039] 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.

[0040] 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.

[0041] Side rails 14 and 16 are connected to translucent section 12 by an adhesive or bonding agent to form light transmitting panel 10. Examples of adhesives or bonding agents are UNI-WELD, a two-part epoxy from Kent Industries, and adhesives from Dynatron Bondo Adhesives. In particular, it is desired to utilize a neutral 100 percent silicone adhesive.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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 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.

[0048] 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, 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.

[0049] 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.

[0050] 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. It should also realized that the embodiment as disclosed applies to all forms of

[0051] 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 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.

[0052] 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.

[0053] 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

[0054] A light transmitting panel assembly according to the present invention was constructed for testing under UL 90 test requirements. A five (5) panel assemble 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./ft2 (˜0.045″ thick) was overlaid onto the metal panel so as to cover the cut-outs. A SIKA 252 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. A neutral cure silicone (Silpruf manufactured by Bayer Corporation) was used as an addition 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 SIKA adhesive. The five (5) panel assembly including the light transmitting panel assembly was testing according to ASTM specification UL 90. After the testing, the light transmitting panel assembly was inspected and no break down or fatigue of the component parts was observed.

[0055] The foregoing disclosure and description of the preferred embodiment are illustrative and explanatory thereof, and various changes in the components, circuit elements, circuit configurations, and signal connections, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit and scope of the invention.

Claims

1. A light transmitting panel for use in a metal roof system, said light transmitting panel comprising: a translucent section; and a metal panel having at least one opening therein, wherein a linear coefficient buffer is disposed between said translucent section and said metal panel.

2. The light transmitting panel of claim 1, wherein: said linear coefficient buffer is selected from the group consisting of adhesives, adhesive gaskets, and adhesive rubber, and adhesive foam.

3. The light transmitting panel of claim 2, wherein: said linear coefficient buffer is a chemical adhesive.

4. The light transmitting panel of claim 2, wherein: said linear coefficient buffer is an adhesive gasket.

4. The light transmitting panel of claim 2, wherein: said linear coefficient buffer is in the range of 0.5 mil-20 mil. in thickness.

5. The light transmitting panel of claim 2, wherein: said linear coefficient buffer is in the range of 2 mil -10 mil. in thickness.

6. The light transmitting panel of claim 1, wherein: the metal panel comprises a planar lateral section, and a side rail extending from each side of said planar lateral section, and the translucent section comprises a planar lateral section, wherein a side rail extends from each side of said lateral.

8. The light transmitting panel of claim 7, wherein: said linear coefficient buffer is selected from the group consisting of adhesives, adhesive gaskets, and adhesive rubber, and adhesive foam.

9. The light transmitting panel of claim 8, wherein: said linear coefficient buffer is a chemical adhesive.

10. The light transmitting panel of claim 9, wherein: said linear coefficient buffer is an adhesive gasket.

11. The light transmitting panel of claim 10, wherein: said linear coefficient buffer is in the range of 0.5 mil-20 mil. in thickness.

12. The light transmitting panel of claim 11, wherein: said linear coefficient buffer is in the range of 2 mil-10 mil. in thickness.

13. A light transmitting panel for use in a metal roof system, said light transmitting panel comprising: a translucent section having a lateral planar portion and an angled portion extending from said lateral planar portion; and a metal side rail having a first horizontal portion and a first angled portion, said side rail being adapted for connection to an adjacent side rail; wherein said side rail is connected by a linear coefficient buffer between at least said lateral planar portion and said angled portion of said translucent section said first horizontal portion and said first angled portion of said side rail.

14. The light transmitting panel of claim 13, wherein: said side rails are adapted for rolling connection to said adjacent side rails.

15. The light transmitting panel of claim 14, wherein: said linear coefficient buffer is selected from the group consisting of adhesives, adhesive gaskets, and adhesive rubber, and adhesive foam.

16. The light transmitting panel of claim 15, wherein: said linear coefficient buffer is a chemical adhesive.

17. The light transmitting panel of claim 15, wherein: said linear coefficient buffer is an adhesive gasket.

18. The light transmitting panel of claim 13, wherein: said linear coefficient buffer is in the range of 0.5 mil-20 mil. in thickness.

19. The light transmitting panel of claim 13, wherein: said linear coefficient buffer is in the range of 2 mil-10 mil. in thickness.

20. The light transmitting panel of claim 16, wherein: said linear coefficient buffer is in the range of 2 mil-10 mil. in thickness.