Roofing, cladding or siding module or apparatus

Abstract

A roofing, cladding or siding module is described. The module comprises an underlapping region adapted to be substantially covered by an exposed region of an adjacent overlapping module when installed on a building surface. A plurality of projections are formed on an underside of the underlapping region. The projections are feet to support the module on the building surface to provide a gap between the module and the building surface, and/or provide a profile on the underside of the underlapping region to define a pathway for air flow between the module and the building surface. Each projection is formed by a downwardly projecting portion of the underlapping region with a corresponding cavity in an upper side of the underlapping region, and the cavity is shaped to prevent or minimize water pooling in the cavity.

Claims

1. A roofing, cladding or siding module comprising: an underlapping region adapted to be substantially covered by an exposed region of an adjacent overlapping module when installed on an inclined building surface, a plurality of projections formed on an underside of the underlapping region, wherein the projections: (i) are feet to support the module on the inclined building surface to provide a gap between the module and the inclined building surface, and/or (ii) provide a profile on the underside of the underlapping region to define a pathway for air flow between the module and the inclined building surface, each projection formed by a downwardly projecting portion of the underlapping region with a corresponding cavity in an upper side of the underlapping region, wherein the cavity is shaped to prevent or minimize water pooling in the cavity, wherein a surface of the cavity extending between a base of the cavity and a front of the cavity is inclined to allow water to flow from the cavity when the module is located on the inclined building surface, and wherein with the module located on the inclined building surface, an angle between the surface of the cavity extending between the base of the cavity and the front of the cavity and the inclined building surface is less than an angle of incline of the inclined building surface.

2. A module as claimed in claim 1, wherein each projection is a foot and an angle between the surface of the cavity extending between the base of the cavity and the front of the cavity and a base of the foot is less than the angle of incline of the inclined building surface.

3. A module as claimed in claim 1, wherein each projection is a foot and an angle between the surface of the cavity extending between the base of the cavity and the front of the cavity and a plane coterminous with bases of the feet is less than the angle of incline of the inclined building surface.

4. A module as claimed in claim 1, wherein the angle between the surface of the cavity extending between the base of the cavity and the front of the cavity and the inclined building surface is less than 30 degrees, or less than 25 degrees, or less than 20 degrees, or less than 15 degrees, or is 10 degrees to 15 degrees.

5. A module as claimed in claim 1, wherein an angle of a surface of the cavity extending between the base of the cavity and a rear of the cavity is greater than the angle of the surface of the cavity extending between the base of the cavity and the front of the cavity.

6. A module as claimed in claim 5, wherein an angle between the surface of the cavity extending between the base of the cavity and the rear of the cavity and the surface extending between the base of the cavity and the front of the cavity is less than 120 degrees.

7. A module as claimed in claim 6, wherein the angle between the surface of the cavity extending between the base of the cavity and the front of the cavity and the inclined building surface is relative to a front-to-rear centerline of the cavity, the angle of the surface of the cavity extending between the base of the cavity and the rear of the cavity is relative to the front-to-rear centerline of the cavity, and the angle between the surface of the cavity extending between the base of the cavity and the rear of the cavity and the surface extending between the base of the cavity and the front of the cavity is relative to the front-to-rear centerline of the cavity.

8. A module as claimed in claim 1, wherein the cavity reduces in width towards the front of the cavity to funnel water towards the front of the cavity.

9. A module as claimed in claim 8, wherein the cavity reduces in width between the base of the cavity and the front of the cavity.

10. A module as claimed in claim 1, wherein in plan-view the cavity is approximately teardrop shaped, a top of the teardrop shape forming the front of the cavity.

11. A module as claimed in claim 1, wherein each projection is a foot and a base of the foot comprises a flat portion to bear against the inclined building surface.

12. A module as claimed in claim 11, wherein a corresponding base of the cavity comprises a flat portion.

13. A module as claimed in claim 1, wherein the module comprises at least two rows of said projections, and wherein the rows are off-set or staggered between a front and rear of the underlapping region.

14. The module as claimed in claim 1, wherein the projections create a tortuous pathway for air flow between the inclined building surface and the module.

15. A module as claimed in claim 1, wherein the module is a starter module for use at a lower edge of the inclined building surface, the module to be substantially completely overlapped by an exposed region of an adjacent roofing, cladding or siding module.

16. A module as claimed in claim 1, wherein the module comprises an exposed region adapted to cover the underlapping region of an adjacent module when installed on the inclined building surface.

17. A module as claimed in claim 16, wherein the upper surface of the exposed region comprises a photovoltaic cell or device.

18. A module as claimed in claim 16, comprising: a projection extending from the exposed region to provide a bearing surface facing the under surface of the exposed region, and one or more location details in the underlapping region each for receiving a clip comprising a tongue adapted to be received between the bearing surface and the under surface of the exposed region of an adjacent overlapping module when installed on the inclined building surface.

19. A module as claimed in claim 1, wherein the module is adapted for use as part of a thermal energy recovery system.

20. A roofing, cladding, or siding apparatus comprising a roofing, cladding, or siding module as claimed in claim 1, the apparatus comprising: one or more clips attachable to the underlapping region to provide a tongue adapted to be received between a bearing surface and the under surface of an exposed region of an adjacent overlapping module when installed on the inclined building surface.

21. A system for removing or recovering thermal energy from a building surface, the system comprising: a roofing, cladding, or siding assembly comprising a plurality of partially-overlapping modules that substantially covers the building surface, wherein each module is a module as claimed in claim 1.

22. A roofing, cladding or siding module comprising: an underlapping region adapted to be substantially covered by an exposed region of an adjacent overlapping module when installed on a building surface, and feet projecting from an underside of the underlapping region to provide a gap between the module and the building surface, each foot formed by a downwardly projecting portion of the underlapping region forming a corresponding cavity in an upper side of the underlapping region, wherein a surface of the cavity extending between a base of the cavity and a front of the cavity is inclined to allow water to flow from the cavity when the module is located on the building surface, to prevent or minimize water pooling in the cavity, and wherein with the module located on the building surface, an angle between the surface of the cavity and the building surface is less than an angle of incline of the building surface.

23. A module as claimed in claim 22, wherein an angle between the surface of the cavity and a base of each of the feet is less than the angle of incline of the building surface.

24. A module as claimed in claim 22, wherein an angle between the surface of the cavity and a plane coterminous with bases of the feet is less than the angle of incline of the building surface.

25. A module as claimed in claim 22, wherein the angle between the surface of the cavity and the building surface is less than 30 degrees, or less than 25 degrees, or less than 20 degrees, or less than 15 degrees, or is 10 degrees to 15 degrees.

26. A module as claimed in claim 22, wherein an angle of a surface of the cavity extending between the base of the cavity and a rear of the cavity is greater than the angle of the surface of the cavity extending between the base of the cavity and the front of the cavity.

27. A module as claimed in claim 26, wherein an angle between the surface of the cavity extending between the base of the cavity and the rear of the cavity and the surface extending between the base of the cavity and the front of the cavity is less than 120 degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which:

(2) FIG. 1 is a schematic illustration of a solar thermal system.

(3) FIGS. 2A to 2E show a roofing apparatus comprising a roofing module with clips for securing a front edge of an overlapping module. FIG. 2A shows a top perspective view, FIG. 2B bottom perspective view, FIG. 2C top view, FIG. 2D bottom view, and FIG. 2E a rear view.

(4) FIG. 3 is a side view of a number of overlapping roofing modules to form a roof or roofing membrane.

(5) FIG. 4 is a cross sectional side view of the roofing module and clip of FIGS. 2A to 2C.

(6) FIG. 5 shows various views of a starter module with clips, for securing an overlapping module at a lower edge of a building surface.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(7) A solar thermal system is shown in FIG. 1 as a roof installation. However, solar thermal system comprising a cladding or external membrane may be mounted or coupled to any underlying support material (e.g., a wall, a roof, etc.) of a building or structure in order to collect solar energy at the structure.

(8) The solar thermal system may include a solar collector consisting of an outside cladding or external membrane (e.g., one or more roofing modules) forming a cavity with the underlying support material of the building structure. The system is configured to collect heat from solar energy by extracting air from the cavity. The solar thermal system also includes a thermal collection unit (e.g., a thermal box) that may be mounted underneath the external membrane and connected to the cavity to collect and direct air flow from the cavity. The system may also include ducts (i.e., a ducting system) to direct the flow of air within the solar thermal system. The system described herein offers an additional benefit of providing building efficiency (e.g., energy efficiency) by way of reducing thermal load into the building or other associated structure during warm seasons and reducing the escape of thermal energy produced within the building or other structure during cold seasons.

(9) Referring to FIG. 1, a solar thermal control system 100 is shown. The system 100 may be configured to form an outermost (e.g., topmost) surface of a building or other structure. The system 100 includes a roofing membrane 102 configured to cover underlying support material 112 (e.g., building paper, plywood, dry wall, etc.) of an associated building. The roofing membrane 102 may be at least partially made from a weatherproofing material in order to protect the structure from the elements, including the underlying material 112. The outermost surface of the roofing membrane 102 may be made from a material configured to absorb sunlight, such as a solar panel. In an exemplary embodiment, the roofing membrane 102 is made from a plurality of overlapping sections (e.g., roofing modules, tiles, shingles, etc.), as shown in FIG. 3.

(10) The roofing membrane 102 is configured to form a cavity 108 for air to flow between the membrane 102 and the underlying material 112. In an exemplary embodiment, the air within the cavity 108 is heated by the sunlight (i.e., the solar energy) captured by the roofing membrane 102. The hot air is drawn from the cavity 108 into a thermal collection unit shown as a box 104. An exemplary path for the hot air is illustrated by the arrows of FIG. 1. The box 104 is fluidly connected to the cavity 108 and configured to receive the hot air from the cavity 108.

(11) From the thermal collection unit 104, the air is either routed into the building (down according to FIG. 1) to be used to heat water or the environment within the building or the air is exhausted into the outside air via a vented ridge 106 of the system 100. Air may also be otherwise vented from the building in this or other embodiments (e.g., via a duct to an exterior wall such as a gable end). The vented ridge 106 is configured to cover a portion of the roofing membrane 102 and provides at least one extraction point shown as opening 114 for excess hot air to be exhausted from the system 100 (e.g., from the box 104). The system 100 may include any number of extraction points (e.g., openings, exhaust areas, etc.) in other embodiments. The number of extraction points may depend on the size and/or shape of the roof or the associated building and/or a particular application of the thermal control system 100. A fan may be provided to draw or push air up the cavity, and/or from the box 104.

(12) Referring now to FIGS. 2A to 2E, a roofing, cladding or siding apparatus 20 is shown. In this embodiment, two or more roofing apparatuses 20 may be combined (e.g., coupled, stacked, overlapped, etc.) to form the roofing membrane 102 or another similar outside cladding or covering for the system 100, as shown in FIG. 3. Each roofing, cladding or siding apparatus comprises a roofing, cladding or siding module 200. Each module 200 includes an underlapping section 202 (e.g., bottom section, under section, etc.) and an overlapping section 204 (e.g., top section, over section, etc.). The sections 202 and 204 may be made from similar material, and preferably are integrally formed as a single unitary member. In an exemplary embodiment, the sections 202 and 204 have similar dimensions, including a similar area, such that the sections 202 and 204 overlap to form the membrane 102.

(13) Each module may be fixed to a building surface such as a roof surface by fasteners (nail or screw for example) applied through the module in the underlapping region or fixing region of the module. Preferably the fasteners are applied through the underlapping region so that the fasteners do not penetrate the exposed overlapping region of the module, thereby making the roofing, cladding or siding apparatus less likely to leak. In some embodiments the underlapping region may be pre-formed with fastener holes or may include markings for locating or supporting fasteners for penetrating the module.

(14) Preferably the exposed region of the module is also secured to the building surface to ensure the module is properly secured to the building. Preferably a front edge or front edge portion of the exposed region is secured to the building surface to prevent damage to the module caused by wind lifting a front edge of the module off or away from an underlying module.

(15) To secure the exposed region of the module to a building surface, the roofing, cladding or siding apparatus according to some embodiments comprises one or more clips 208. Each clip 208 secures the exposed region 204 of an adjacent overlapping module 200 to the underlapping module 200. Each clip may be located within a location detail on the underlapping region 202. As the underlapping module is secured to the building surface, the exposed region 204 of the overlapping module is secured to the building surface via the underlapping module. In some embodiments, the clip is secured to the building surface by a fastener (e.g. a nail or screw, not shown) extending through the underlapping section 202 of an underlapping module, the exposed region 204 of an overlapping module secured to the building surface by the clip 208 and fastener extending through the underlapping module. Thus the fastener and clip secure an underlapping module and an overlapping module to the building surface at a single location of the building surface.

(16) As best shown in FIG. 4, each clip 208 provides a tongue 209 to be received in a corresponding groove 210 of the exposed region 204 of an adjacent overlapping module 200. In some embodiments the module comprises a projection or lip 211 extending rearward from the under surface of the exposed region 202. The lip 211 provides a groove or channel 210 between the lip 211 and the under surface 212 of the exposed region 204. In some embodiments the groove or channel 210 is open towards the rear of the module for receiving the forwardly extending tongue 209 of a clip 208.

(17) For securing a module 200 to a building surface, a starter module may be provided that has an underlapping region 202 and no overlapping region. A starter module 300 is illustrated in FIG. 5. The starter module 300 may be fixed to a building surface 112, for example a roofing surface, at a lower edge of the surface 112. A module 200 in a next row of modules up the building surface is applied with its overlapping section 204 overlapping the starter module 300, and with its front edge 215 secured to the starter module via clips 208.

(18) The underlapping section 202 of the module 200, 300 includes projections 206. Some of the projections may form feet 206 configured to rest on the underlying material 112 (or another outer surface) of the associated building, raising the remainder of the underlapping section 202 a distance above the underlying material 112. When the feet 206 rest on the underlying material 112, the cavity 108 is formed between the underlapping section 202 and the underlying material 112 (i.e., around or between the feet 206).

(19) The height of the projections 206 may be related to an intended air flow through the cavity 108, with a greater height leading to a greater air flow. In an exemplary embodiment, the projections 206 are sized and shaped to provide an approximately 20 millimetre air gap between the roofing module 200 and the underlying material 112 (e.g., wherein the feet 206 and/or the cavity have a height of approximately twenty millimetres). The air gap (e.g., the cavity 108) is intended to allow air to be drawn from either a section (e.g., a roofing module 200) or the whole roof (e.g., the membrane 102) to a centrally located thermal collection unit (e.g., box 104). However, the roof of a building structure may contain a plurality of collection units to optimize thermal energy harvest. For example, solar thermal energy may be collected from a first roof surface and directed (e.g., via a system of ducts and dampers) to a second roof surface to melt snow on the second roof surface. In another embodiment, a first roof surface or section of roof surfaces may be utilized for water heating and a second roof surfaces or section of roof surfaces may be utilized for space heating.

(20) In some embodiments, some of the projections 206 may not act as feet, but may be provided to disrupt or direct air flow through the cavity. For example, some projections 206 may act as feet and also as projections for directing air flow, and some projections 206 may provide for directing air flow only, without supporting the module 200 from the building surface. In some embodiments, as best illustrated in FIGS. 2C and 2D the projections 206 may be provided in rows that are staggered, to provide a tortuous pathway for the air flow up the cavity between the building surface and membrane.

(21) The underlapping section 202 may include any number of projections 206 as is suitable for the particular application of the system 100. For instance, the underlapping section 202 may include less projections 206 if a greater air flow is required through the cavity 108 (i.e., to create more air space within the cavity 108). The underlapping section 202 may also include more projections 206 if the roofing modules 200 are made from a particularly heavy material (i.e., to support the weight of the projections 200) or are to be positioned in a relatively high foot-traffic area of the roof (e.g., to support the weight of any service personnel or other persons on the roof). The projections 206 may be approximately equally spaced across the underlapping section 202 in order to raise the underlapping section 202 an appropriate distance above the underlying material 112 and create the cavity 108.

(22) Each projection 206 is formed by a downwardly projecting portion of the underlapping region 202 with a corresponding cavity 214 in an upper side 213 of the underlapping region 202. If there were to be any water reaching between the exposed region 204 of an overlapping region and the under lapping region of an underlapping module, for example in extreme weather conditions whereby water may be directed upwards up a roofing surface, the water may collect or pool in the cavities in the upper surface of the module. Therefore, according to the present invention, each cavity is shaped to prevent or minimize water pooling in the cavity. As shown in FIG. 3, the roofing membrane 102 is particularly configured for a slanted or angled roof (relative to the horizon). Each cavity is preferably shaped to prevent or minimum water pooling in the cavity for a particular angle of inclination of the building surface. Where the module is positioned at an angle with the front 215 of the module below the rear 220 of the module, the cavity is shaped so that water drains or runs from the cavity towards the front of the module.

(23) With reference to FIG. 4, the cavity 214 has a base or bottom 218. The depth of the cavity is greatest at the base or bottom of the cavity. According to some embodiments, a surface 219 of the cavity that extends between the base 218 of the cavity and a front of the cavity is inclined to allow water to flow from the cavity when the module is located on an inclined building surface. A projection 206 that forms a foot for supporting the module 200 from a building surface 112 comprises a bottom or a base 217 that contacts the building surface. The base 217 of the foot 206 preferably comprises a flat portion to bear against the building surface 112. The base 218 of the cavity may be correspondingly flat. In some embodiments, an angle A.sub.s between the surface 219 of the cavity 214 and the base 217 of the foot is less than an angle of incline A.sub.i of the inclined building surface 112 (with respect to the horizon), so that water drains from the cavity 214 towards a front 215 of the module. The bases 217 of the plurality of feet 206 are coterminous on a plane, so that they all contact the building surface 112 to support the module. An angle A.sub.s between the surface 219 of the cavity 214 and the plane coterminous with the bases 217 of the feet is less than the angle of incline A.sub.i of the inclined building surface. With the module 200 located on the inclined building surface 112, an angle A.sub.s between the surface 219 of the cavity and the building surface 112 is less than the angle of incline A.sub.i of the inclined building surface. In some embodiments the angle A.sub.s described above is less than 30 degrees, or less than 25 degrees, or less than 20 degrees, or less than 15 degrees, or is 10 degrees to 15 degrees. For example, an angle A.sub.s of less than 15 degrees allows for a minimum roof angle of incline A.sub.i of 15 degrees to allow water to drain from the cavity. In one embodiment the angle A.sub.s is about 11 degrees.

(24) In some embodiments, an angle A.sub.r of a surface 223 of the cavity 214 extending between the base 218 of the cavity 214 and a rear 222 (FIG. 2C) of the cavity is greater than the angle A.sub.S of the surface 219 of the cavity extending between the base 218 of the cavity and the front 221 (FIG. 2C) of the cavity. In some embodiments, an angle between the surface 223 of the cavity extending between the base 218 of the cavity and the rear 222 of the cavity and the surface 219 extending between the base 218 of the cavity and the front 221 of the cavity is less than 120 degrees.

(25) The cross section of FIG. 4 is taken on a centreline of one of the cavities 214. The angles A.sub.s and A.sub.r described above may therefore be relative to a front-to-rear centreline of the cavity.

(26) As best shown in the plan view of FIG. 2C, in some embodiments the cavity 214 reduces in width towards a front of the cavity, so that the cavity funnels water towards the front 221 of the cavity. The cavity reduces in width between the base 218 of the cavity 214 and the front 221 of the cavity. As shown, in some embodiments the cavity is approximately teardrop shaped in plan view, a top 221 of the teardrop shape forming the front 221 of the cavity 214.

(27) In some embodiments, the module 200 may be adapted for use in a system to generate electrical energy from solar power. Such products are generally referred to as building integrated photovoltaic products (BIPV). A series or array of photovoltaic cells may be carried on the exposed region 204 of the module 200 so that they capture photons when installed on a building surface 112. For example, an energy generating module may comprise one or more moulded material layers, a solar array layer of connected photovoltaic cells, and an optional transparent surface laminate layer. The energy generating module may also comprise bonding/encapsulation/tie layers to the front and/or back of the PV layer and may also contain layers to stop the corrosion of the PV layer e.g. polyethylene, EFTE, etc. The photovoltaic cells installed on a module may be arranged in a row and connected via two bus strips extending the entire length of the module; one running across the upper edges of the cells and one running across the lower edges so that only a single electrical junction for each module need be connected to a main power take-off on installation. A further option is to have a bus strip material integrally moulded into the module during the forming process. The modules may be molded to accommodate various components of the photovoltaic system. For example, as shown in FIG. 2A, the upper surface of the underlapping region may include channels 224 configured to receive cables or wires of the photovoltaic array. Moreover, the upper surface of the underlapping region may also include formed cavities configured to receive junction boxes, printed circuit boards (PCB), communication devices, cables, wires, buses, components, cells, or diodes, and the like of the photovoltaic array. Thus, the modules may contain all of the hardware and software required to connect and regulate the PV cells. Example thermal energy recovery modules and modules comprising an array of solar cells for electrical energy generation, and methods for the continuous forming process for manufacturing such modules are described in WO2013/081477, the contents of which is hereby incorporated by reference.

(28) The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention.