Solar-collector roofing assembly

Abstract

A solar-collector roofing assembly (10) comprises a plurality of elongate spaced-apart primary support members (12) aligned in a horizontal plane and extending in a first direction A; a plurality of elongate spaced-apart secondary support members (14) having first and second end portions (38, 40) connected to corresponding said primary support members (12), first and second end portions (38, 40) on a respective primary support member (12) being vertically offset relative to each other; and at least one solar-energy collector panel (16) directly or indirectly supported by the secondary support members (14) so as to have a predetermined fall towards an associated primary support member (12).

Claims

1. A car-park solar-collector roofing assembly comprising: a plurality of elongate spaced-apart primary support members aligned in a plane and extending in a first direction, the plurality of primary support members with a plurality of vertical support members forming a plurality of portal frames; a plurality of elongate spaced-apart secondary support members, each secondary support member being supported by more than two portal frames and each portal frame supporting a plurality of secondary support members, the secondary support members being aligned in a plane extending in a second direction perpendicular to the first direction; and at least one solar-energy collector panel supported by the secondary support members, so as to have a predetermined fall; and the secondary support members including an integrally formed cable guide to hold one or more cables associated with the or each solar-energy collector panel; wherein the secondary support members comprise Z-purlins and a bottom flange of each Z-purlin acts as the integrally formed cable-guide, the bottom flange having an upward extending portion at an outside edge thereof so that a cable-receiving channel is defined between the upward extending portion and a web of each Z-purlin, the or each solar-collector panel supported directly on an upper flange of each Z-purlin.

2. The car-park solar-collector roofing assembly as claimed in claim 1, wherein the or each solar-energy collector panel is inclined at between 2 and 3 degrees.

3. The car-park solar-collector roofing assembly as claimed in claim 1, wherein the fall of the or each solar-energy collector panel is sloped from a north to south direction, such that the or each solar-energy collector panel faces in a southward direction, or is sloped from a south to north direction, such that the or each solar-energy collector panel faces in a northward direction.

4. The car-park solar-collector roofing assembly as claimed in claim 1, further comprising a drainage system which removes excess water collected on an upper surface of the roofing assembly.

5. The car-park solar-collector roofing assembly as claimed in claim 1, further comprising a heating apparatus which inhibits the formation of snow or ice on the or each solar-energy collector panel.

6. A vehicle parking system comprising: a surface for defining an access road in a first direction and a plurality of parking bays extending from the access road in a second direction transversely to the first direction; a solar-collector roofing assembly as claimed in claim 1; and a plurality of vertical support members to support the solar-collector roofing assembly above said surface.

7. The vehicle parking system as claimed in claim 6, wherein the primary support members are equally spaced-apart, and aligned perpendicularly to the access road.

8. The vehicle parking system as claimed in claim 6, wherein the separation between the primary support members above the access road is greater than the separation between the primary support members above the parking bays.

9. The car-park solar-collector roofing assembly as claimed in claim 1, wherein each portal frame further comprises corner struts conjoining the primary support members and vertical support members.

10. The car-park solar-collector roofing assembly as claimed in claim 1, wherein each primary support member comprises a beam or a truss.

11. The car-park solar-collector roofing assembly as claimed in claim 10, wherein each primary support member comprises an I-beam.

12. The car-park solar-collector roofing assembly as claimed in claim 1, wherein each portal frame supports more than two secondary support members.

Description

(1) The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 shows a diagrammatic perspective representation of one embodiment of a solar collector roofing assembly in accordance with the second aspect of the invention;

(3) FIG. 2 shows the roofing assembly of FIG. 1 as viewed from direction B;

(4) FIG. 3 shows the roofing assembly of FIG. 1 as viewed from direction A;

(5) FIG. 4 shows the connection point between the first and second support members of the roofing assembly of FIG. 1;

(6) FIG. 5 shows a cross-sectional perspective view through centre of the roofing assembly of FIG. 1 along direction A;

(7) FIG. 6 shows a cross-sectional view through a connection point along direction B as shown in FIG. 4;

(8) FIG. 7 shows a diagrammatic representation of a first embodiment of a vehicle parking system in accordance with the third aspect of the invention;

(9) FIG. 8 shows a diagrammatic representation of a second embodiment of a vehicle parking system in accordance with the third aspect of the invention;

(10) FIG. 9 shows an alternative embodiment of a primary support member for use with a roofing assembly in accordance with the second aspect of the invention;

(11) FIG. 10A shows a side-on view of a second embodiment of a solar collector roofing assembly in accordance with the first aspect of the invention;

(12) FIG. 10B shows a diagrammatic representation of the roofing assembly of FIG. 10A when viewed from direction A and simplified for clarity;

(13) FIG. 10C is an enlarged view of part of the roofing assembly shown in FIG. 10A;

(14) FIG. 11A shows a side-on view of a third embodiment of a solar collector roofing assembly in accordance with the first aspect of the invention;

(15) FIG. 11B diagrammatically shows the roofing assembly of FIG. 11A when viewed from direction A and simplified for clarity; and

(16) FIG. 11C is an enlarged view of part of the roofing assembly shown in FIG. 11A.

(17) Referring firstly to FIGS. 1 to 6, there is shown one embodiment of a solar-collector roofing assembly, indicated globally at 10, suitable for an outdoor structure. The roofing assembly 10 comprises a plurality of elongate primary support members 12, a plurality of elongate secondary support members 14 and one or more solar-energy collector panels 16.

(18) The primary support members 12 are preferably Universal Beams, also known as I-beams, having top and bottom flanges 18, 20 joined by a web 22. At a plurality of intervals along the length of the web 22 are connection points 24 to which the secondary support members 14 are connectable. Each connection point 24 comprises an upper and a lower portion 26, 28, each having one or more bolt-holes 30, which are slotted so as to allow for some tolerance when installing the secondary support members 14.

(19) The secondary support members 14 are also Universal Beams, having top and bottom flanges 32, 34 joined by a web 36. However, unlike the primary support web 22, the secondary support web 36 preferably has a parallelogram rather than a rectangular profile, as best seen in FIG. 3. At each of the first and second end portions 38, 40 of the secondary support members 14 is a connection plate 42 which is capable of attaching to the connection points 24 of the primary support members 12, typically utilising bolts or rivets.

(20) The top flange 32 of each secondary support member 14 includes a plurality of panel connecting elements, which are the means by which the or each solar-energy collector panel 16 is connected to the roofing assembly 10. To form the solar-collector roofing assembly 10, the primary support members 12 are arranged in a parallel spaced-apart configuration, and are interconnected by a plurality of secondary support members 14. Since each secondary support member 14 has a parallelogram-shaped web 36, the secondary support members 14 do not lie in a horizontal plane, but will have a predetermined fall from one primary support member 12 to the next.

(21) As shown in FIG. 4, the first end portion 38 of a secondary support member 14 is connected to the upper portion 26 of a connection point 24 of a primary support member 12. As a result of the parallelogram-shape of the secondary support member 14, the web 36 slopes along a predetermined fall towards the second end portion 40. This fall is typically between 2 and 3 degrees.

(22) Depending upon the length of the secondary support member 14, the second end portion 40 will have a lower vertical position relative to the first end portion 38, and can therefore be connected to the lower portion 28 of a connection point 24 on another primary support beam 12.

(23) The fall over the secondary support member 14 is therefore sufficiently shallow to allow for the connection of a first and second end portion 38, 40 of two secondary support members 14 within the depth of a single primary support member 12, the two secondary support members 14 being connected on opposing faces of the web 22 of the primary support member 12.

(24) A framework can therefore be constructed to a given size, comprising primary support members 12 arranged in a parallel spaced-apart manner along a first direction A which are interconnected by a plurality of secondary support members 14 ananged in a parallel spaced-apart manner substantially along a second direction B. The secondary support members 14 are oriented such that their falls are aligned in parallel.

(25) The resulting framework, when viewed from the first direction A, has a zig-zagged or serration-like profile, as shown in FIG. 3. However, since the fall of the secondary support members 14 is contained fully within the depth of the primary support members 12, the framework appears fully planar when viewed from the second direction B, as shown in FIG. 2.

(26) Whilst the framework can be utilised as assembled in the solar-collector roofing assembly 10, it may be desirable to provide a more rigid structure. This can be achieved by installing further elongate primary support members 12 in the horizontal plane as defined by the primary support members 12, but aligned in a parallel spaced-apart manner along the second direction B. A framework including such further primary support members 12 is shown in FIG. 8.

(27) The installation of further primary support members 12 increases the strength and rigidity of the roofing assembly 10, but also the weight. Therefore, the decision to include further primary support members 12 will be determined by the relative importance of these factors to the structure for which the roofing assembly 10 is created.

(28) To complete the roofing assembly 10, at least one solar-energy collector panel 16 is attached to the secondary support members 14. Solar-energy collector panels 16 will typically be photovoltaic panels, having an upper surface 46 with a plurality of solar cells 48 thereto affixed, and a lower surface 50 comprising a supporting substrate 52 for the solar cells 48.

(29) Each solar-energy collector panel 16 has a connecting means 54 affixed to the lateral extremities 56 of the supporting substrate 52, by which the panel 16 can be attached to the connecting elements 44 of the secondary support members 14. Each solar-energy collector panel 16 straddles two adjacent secondary support members 14, as seen in FIG. 5, and a plurality of solar-energy collector panels 16 are provided between each pair of secondary support members 14. Such modularisation allows for smaller solar-energy collector panels 16 to be utilised, reducing the effort required when replacing individual panels 16.

(30) Once the solar-energy collector panels 16 have been installed, the solar-collector roofing assembly 10 is complete, and the assembly 10 can be installed as the roof of a structure. Typically, a roofing assembly 10 will be installed as part of an outdoor structure which may not necessarily have retaining walls.

(31) In particular, the roofing assembly 10 of the present invention is designed for use with a vehicle parking system, such as a substantially open-air car park 58. See FIGS. 7 and 8. Such a car park 58 would be provided on a substantially level surface 60, upon with is demarcated at least one access road 62, from which laterally extend a plurality of marked parking bays 64. A solar-collector roofing assembly 10 can then be installed thereover. The roofing assembly 10 is supported by a plurality of vertical support members 66, providing sufficient clearance to permit passage of vehicles along the access road 62.

(32) Said vertical support members 66 are again Universal Beams, connected to the primary support members 12 of the roofing assembly 10. The vertical support members 66 are positioned so as to project upwardly from the level surface 60, between parking bays 64, thereby maximising the parking area of the car park 58. To ensure the stability of the vertical support members 66, they will typically have solid concrete foundations 68, preferably positioned at or adjacent to distal corners of the parking bays 64 relative to the access road 62.

(33) The vertical support members 66 may be clad at least at vehicle level in an impact resistant substance such as a foam-based padding. This will limit the damage to the structure should a vehicle impact or collide with any of the vertical support members 66 whilst navigating the car park 58.

(34) The design of the car park 58 will therefore determine the form of the roofing assembly 10. A preferred car park design 10 is to have equally spaced-apart primary support members 12, being aligned perpendicularly to the access road 62. Vertical support members 66 are arranged in convenient positions to maximise the parking area, typically at an intersection between four back-to-back parking bays 66. Such a vehicle parking system is shown in FIG. 7.

(35) The roofing assembly 10 could alternatively be aligned in the opposite direction, with the primary support members 12 being in alignment with the access road 62. Typically, the access road 62 will be wider than the length of the parking bays 64, and in order to suitably accommodate the vertical support members 66, the separation between primary support members 12 may be unequal.

(36) By way of example, there may be a primary support member 12 extending substantially along the extent of each side of the access road 62. This would require a separation between the primary support members 12 of approximately six meters, with accordingly sized secondary support members 14 therebetween. Such a car park is shown in FIG. 8, in this case including further or supplementary primary support members 12. Either side of these primary support members 12, there will be another gap of approximately four meters, corresponding to the length of a parking bay 64, before the next primary support member 12. Again, there will be accordingly sized secondary support members 14 extending therebetween.

(37) The approximately fourteen meter wide unit defined by the four primary support members 12 can be repeated at will, with parking bays 64 arranged back-to-back. It will be appreciated that this is merely the standard arrangement of a car park 58, and any arrangement could be considered. Furthermore, there will likely be interconnecting access roads between the main access roads 62 to permit navigation of the car park 58 by vehicles.

(38) By combination of the repeating unit, a roofing assembly 10 can be created to cover any size of level surface 60 to create the car park 58. It is therefore possible to provide a roof for the car park 58 which is capable of harnessing solar energy. To utilise the energy, it is therefore necessary to provide the relevant infrastmcture to transmit or use the generated electricity. If the electricity is being sold to a national grid, this may be as simple as providing cables, but if the electricity is being used in situ, further infrastructure may be required, for instance, a substation.

(39) To maximise the solar-energy collected by the solar-collector roofing assembly 10, it is optimal to align the primary support members 12 along a substantially east-to-west direction, with the fall of the secondary support members 14 being from north-to-south. By doing so, the solar-energy collector panels 16 will be oriented in a southward direction, which, in the northern hemisphere, will result in maximum incident solar radiation. Evidently, were the roofing assembly 10 to be provided in the southern hemisphere, the reverse would be applicable.

(40) Since the car park 58 is likely to have at least partially open walls, there will be wind-loading on the roofing assembly 10. In existing solar collector roofing assemblies, a substantial portion of the roof as a whole is aligned along a predetermined fall. As such, the wind-load is relatively large, as the wind catches underneath the solar panels.

(41) By providing the roofing assembly 10 of the present invention within a horizontal plane, to the depth of the primary support members 12, the lateral force experienced by the roofing assembly 10 in high winds is greatly reduced. As such, the roofing assembly 10 can be formed from considerably fewer supporting members than existing assemblies, since fewer reinforcing beams are needed.

(42) In addition, the construction of the present roofing assembly 10 is considerably simpler than that of existing assemblies, since there is no requirement to apply a fall to the primary support members. This typically has to be achieved by installing struts to raise one end portion of a primary support member vertically.

(43) This vertical raising of the primary support members also creates gaps in the roofing assembly, which either must be sealed, or the roofing assembly will allow ingress of rainwater or similar, which defeats the purpose of a car park to a large extent. Since the secondary support members 14 are wholly contained within the depth of the primary support members 12, the roofing assembly 10 is automatically sealed against the elements, following the installation of the solar-energy collector panels 16.

(44) Given that the roofing assembly 10 is sealed, it may be preferable to install various extra components to accommodate inclement weather conditions. For instance, a drainage system for the removal of rainwater is a logical addition to the assembly, as might be a heating apparatus to melt any snow or ice which might form on top of the solar-energy collection panels 16. Any such heating apparatus could be powered by the electricity generated by the solar collector roofing assembly.

(45) It will be appreciated that whilst the primary support members are described above as being Universal Beams, there is no requirement for them to be so. One possible alternative embodiment of a primary support member 112 is shown in FIG. 9.

(46) The primary support member 112 is a truss, comprising top and bottom flanges 170, 172, interconnected by a plurality of struts 174 arranged in a triangulated fashion along the length of the flanges 170, 172. At periodic intervals along the length of the primary support member 112, there will be upright buttresses 176, on which are located connection points 124 for interconnecting with secondary support members 14. This is merely one possible alternative embodiment of the primary support member, and several arrangements could be envisaged.

(47) The main advantage of using trusses instead of Universal Beams is that less steel is used in its construction for the same length of support member. However, this benefit must be weighed against the increased cost of fabrication of a truss compared with a Universal Beam, and therefore the type of beam used will be dependent upon the cost trade-off between these competing factors.

(48) Referring now to FIGS. 10A to 10C, there is shown a second embodiment of a solar collector roofing system. Similar references refer to identical or similar parts, and further detailed description is omitted. This roofing system comprises primary support members 212, aligned in a plane, which form part of two portal frames 278. The portal frames 278 additionally comprise vertical support members 266 and also preferably corner struts 280 conjoining the primary support members 212 and vertical support members 266 of each portal frame 278. The arrangement of the portal frame 278 is advantageous as lateral loads, such as those caused by wind, are advantageously transferred by the corner struts 280 to the vertical support members 266, which transmit the then vertical loads to the foundations.

(49) This transfer of the lateral loads is in addition to the transmission of vertical loads, such as structural weight, snow, wind uplift, and other forces, ensuring that the foundations supporting the portal frames 278 are not subjected to bending moments. This is a significant advantage over standard cantilevered solar collector roofing systems. Additionally, the portal frames 278 reduce the maximum bending stresses in the primary support members 212 by up to 75% compared to if they were simply supported.

(50) Secondary support members 214 are then connected by at least their first and second end portions 238, 240 perpendicularly to respective primary support members 212. In this embodiment, the secondary support members 214 are preferably Z-purlins 282. These Z-purlins 282 support the solar-energy collector panels 216 and their bottom flanges 282a can act as cable trays for power cabling and the like.

(51) The solar-energy collector panels 216 are sloped at approximately 2.5 degrees from horizontal in a north-to-south direction. This provides a higher intensity of light per unit area of the panel 216 due to the angle of the Sun in the sky. However, where two portal frames 278 meet, there may be shadowing. Therefore, the solar-energy collector panels 216 preferably do not extend the entire length of the primary support members 212. Advantageously, this allows drainage means or a drainage system, which in this embodiment is a gutter 284, to be situated at the lowermost end of each army of solar-energy collector panels 216, in order to capture any water run-off, which can then be channelled away and disposed of

(52) FIG. 10B shows how each portal frame 278 is interlinked by the secondary support members 214, with each portal frame 278 being parallel to one another. More or fewer portal frames 278 could be utilised in the same or similar arrangement, extending either in a parallel manner in one direction or in a series manner in the other direction as shown in FIG. 10A, creating a repeating sawtooth pattern. This allows the system to be readily and modularly expandable. As the secondary support members 214 span continuously over a number of primary support members 212, the maximum bending stresses in said secondary support members 214 are reduced by up to 75% compared to if they were simply supported. This ensures better structural integrity, and is advantageous over prior known solar collector roofing systems.

(53) As can be seen in FIG. 10A, first ends of the primary support members 212 are aligned in a first horizontal plane P1, whilst second ends are aligned in a second horizontal plane P2. The end portions 238, 240 of the secondary support members 214 are vertically offset relative to one another on each respective primary support member 212.

(54) The width of the portal frames 278 allows cars to drive through the centre of portal frames and park without having to include vertical support members 266 at the intersection between access roads and parking spaces, in a similar manner to the previously described embodiments. This is suitable for car parks with access roads in an east-to-west orientation. Therefore, in order to allow orientation of the system in a perpendicular direction, whilst maintaining the advantageous inclination of the solar-energy collector panels 216, a third embodiment is required, as shown in FIGS. 11A and 11B.

(55) The third embodiment is similar to the second embodiment, but portal frames 378 themselves have horizontal primary support members 312. In order to incorporate the slope of the solar-energy collector panels 316, adjacent portal frames 378 are preferably different heights. This results in primary support members 312 which are aligned in an inclined plane.

(56) Perpendicular to the primary support members 312 and inclined so as to have at least first and second end portions 338, 340 attached to respective primary support members 312 are the secondary support members 314, which again are preferably Z-purlins 382. At the lowermost end of the Z-purlins 382 may be located gutters 384, for channelling water run-off.

(57) This third embodiment has all of the advantages of the second embodiment, but is more suited to providing a roofing system for parking in the perpendicular direction. This is due to the portal frames 378 of FIG. 11A being aligned at 90 degrees to those of FIG. 10A, allowing access roads and car parking spaces also to be aligned differently, without having to place vertical support members 362 in proximity to access roads, similarly to the above described embodiments. The embodiment of FIGS. 11A and 11B is therefore particularly suited to those car parks with access roads in a north-to-south configuration. It is also suitable for expansion of scale, in the same way as the second embodiment described with reference to FIGS. 10A and 10B.

(58) FIG. 11A shows how the primary support members 312, which are present at the top of each of the portal frames 378 are aligned in horizontal planes with the longitudinal extent of each primary support member 312 extending in a direction into the page, as shown. In the particular embodiment shown, planes P3, P4, and P5 show the alignment in horizontal planes of every third portal flame 378. The end portal frames are horizontally-aligned with plane P3, whilst the two central portal frames of each group of three are horizontally-aligned with planes P4 and P5 respectively. Clearly, there may be a greater or lesser number of portal frames per group, and therefore there will be a greater or lesser number of horizontally-aligned planes. Equally, the ends of each primary support member 312 are aligned horizontally with each other, such as plane P6 as shown on FIG. 11B.

(59) In the embodiments of FIGS. 10 and 11, the bottom flanges 282a, 382a of the Z-purlins 282 are utilised as cable trays or cable guides. This is shown in detail in FIG. 10C which is an enlarged perspective view of box X of FIG. 10A. The arrangement shown thus allows the cabling 286 and other items associated with the solar-energy collector panels 216, positioned on top of the Z-purlins 282, to be supported and channelled along the structure. The cabling 286 is additionally bundled together by ties 288, keeping the cabling 286 tidy and ordered. The bottom flange 282a additionally has an upward extending portion 282b which prevents or limits the cabling 286 becoming displaced from the bottom flange 282a. Other methods of bundling the cabling, including but not limited to tape or strapping, may be utilised in place of ties in order to bundle the cabling and/or ensure that the cabling is not displaced from the Z-purlins.

(60) FIG. 11C, which is an enlarged perspective view of the contents of box Y of FIG. 11A, shows more particularly how the primary and secondary support members 312, 314 are positioned relative to one another. It is therefore clear that the first end portion 338 of one secondary support member 314 and the second end portion 340 of another secondary support member 314 are each connected to a primary support member 312. These connections are therefore vertically-offset. This primary support member 314 then forms a part of a portal frame, which is not shown.

(61) Whilst the present embodiments have been described separately, it will be apparent to the skilled person that any feature described in one embodiment may be utilised in conjunction with another embodiment, or omitted, without departing from the scope of the present invention.

(62) It will also be appreciated that the car park arrangements described above are merely examples of possible car park designs which could be covered by the present invention. It will also be apparent that the roofing assembly is not only applicable to the field of vehicle parking systems, but to any outdoor structure which may require a solar collector, where wind-load may be an issue. By way of example, a children's outdoor play area could be covered.

(63) It is therefore possible to provide a solar-collector roofing assembly for an outdoor structure which experiences a reduced wind-load, by providing the primary support members of the assembly in a plane, preferably being a horizontal plane. The secondary support members which support the solar-energy collector panels are aligned in a different plane and are perpendicular to the primary support members. Preferably, the secondary support members are aligned out of the horizontal plane, but are vertically subsumed within the depth of the primary support member. Such assemblies may be formed in a sawtooth-profile arrangement. As such, the optimum alignment of solar-energy collector panels is achieved without increasing the lateral forces on the structure which result from an assembly having an overall predetermined fall.

(64) Resultantly, the overall weight and amount of material required for construction of said roofing assembly can be greatly reduced. The primary use for the present invention is for large outdoor structures, in particular car parks, enabling a further revenue and/or energy generation means to an otherwise unutilised area having incident solar radiation.

(65) The words comprises/comprising and the words having/including when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

(66) It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

(67) The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined by the appended claims.