Photovoltaic roof covering
10277161 ยท 2019-04-30
Assignee
Inventors
Cpc classification
F24S20/67
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S80/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E10/44
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S25/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S2025/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/47
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S25/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B10/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F16B2005/0678
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24S20/67
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S80/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
There is provided a bracket, comprising: a first portion configured to hold a first solar panel connector of a first solar panel module; a second portion configured to provide a guide along the length of the second portion for a second solar panel connector of a second solar panel module, the first and second portions being configured so that, when first and second solar panel connectors are connected to the bracket, the first and second solar panel modules protrude away from the bracket in different directions; and a third portion connected to said first and second portions and configured for attachment to a roof structure.
Claims
1. A system comprising: a sheet of flashing; a first solar panel connector comprising: a first portion extending along one or more sides of the first solar panel connector for receiving an edge section of the flashing to provide a weather-proof connection between the flashing and the first solar panel connector; and a second portion extending along one or more sides of the first solar panel connector for receiving an edge section of a bracket and configured to receive said bracket either slidably in the second portion along a length of the second portion and/or to receive said bracket rotatably so that the solar panel connector and the bracket may move laterally relative to each other only along the length of the second portion; a first solar panel joined to the first solar panel connector; a second solar panel connector comprising: a third portion extending along one or more sides of the second solar panel connector for receiving an edge section of the flashing to provide a weather-proof connection between the flashing and the second solar panel connector; and a fourth portion extending along one or more sides of the second solar panel connector for receiving an edge section of said bracket and configured to receive said bracket either slidably in the fourth portion along the length of the fourth portion and/or to receive said bracket rotatably so that the solar panel connector and the bracket may move laterally relative to each other only along the length of the fourth portion; a second solar panel joined to the second solar panel connector; and said bracket comprising: a fifth portion configured to hold the first solar panel connector, wherein the fifth portion is configured to retain the first solar panel connector with respect to the bracket after the fifth portion has been rotated onto the first solar panel connector so that the first solar panel connector and the bracket may move laterally relative to each other only along the length of the portion; a sixth portion configured to provide a slideable guide along a length of the sixth portion for the second solar panel connector, the fifth and sixth portions being configured so that, when the first and second solar panel connectors are connected to the bracket, the first and second solar panels protrude away from the bracket in different directions; and a seventh portion connected to said fifth and sixth portions and configured for attachment to a roof structure, wherein the flashing is separate from the bracket and is configured such that, on being inserted into the first portion of the first solar panel connector, the flashing extends into the third portion of the second solar panel connector as the second solar panel is slid along the bracket, producing a weather tight seal between the first and second solar panel connectors; and wherein the first portion of the first solar panel connector comprises one or more resilient members such that, in use, the insertion of the flashing into the first portion automatically forces at least one of said resilient members into a configuration in which they are biased against the flashing.
2. The system as claimed in claim 1, wherein the fifth portion of the bracket is configured to hold the first solar panel connector slidably, so that the first solar panel connector may be guided along the length of the fifth portion of the bracket.
3. The system as claimed in claim 1, wherein the bracket is substantially U-shaped, the first portion being located along one of the legs of the U-shape, the second portion being located along the other of the legs of the U-shape and the third portion being located along the base of the U-shape, further comprising: U-shaped guttering located within the bracket, the height of the U-shaped guttering being below the height of the first portion of the first solar panel connector and the first portion of the second solar panel connector to prevent sliding movement between the gutter and the bracket when the gutter is inserted into the bracket.
4. The system as claimed in claim 3, wherein the U-shaped guttering is located within the bracket so as to have an interference fit therebetween.
5. The system as claimed in claim 1, wherein the first portion of the first solar panel connector and the third portion of the second solar panel connector are configured to align in the same plane when in use.
6. The system as claimed in claim 1, wherein the bracket is shaped such that the fifth and sixth portions are located at one end of the bracket and the seventh portion is located at an opposite end of the bracket.
7. The system as claimed in claim 1, wherein the fifth and sixth portions of the bracket are separated from the seventh portion of the bracket via a single connection.
8. The system as claimed in claim 1, the first solar panel connector having a first side configured to receive a solar panel and a second side, opposite to the first side, via which the first and second portions are accessible by the flashing and the bracket.
9. The system as claimed in claim 1, wherein the first portion is arranged to be above the second portion when the first solar panel connector is being used to fix a solar panel to a roof.
10. The system as claimed in claim 1, wherein the first portion is formed as a continuous gasket around the periphery of the first solar panel connector.
11. The system as claimed in claim 1, wherein the third portion of the second solar panel connector comprises one or more resilient members such that, in use, the insertion of flashing into the third portion automatically forces at least one of said resilient members into a configuration in which they are biased against said flashing.
Description
FIGURES
(1) Hereunder follows a detailed description of embodiments, by way of example only, with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(15) In the present application, a design of a solar panel connector and roof fixing bracket is disclosed that enables the close-coupling of solar panels/solar modules with a simple push-fit action. In its most general form, the term solar panel connector is used herein to denote a connection on the solar panel module configured for connecting the solar panel module to other components (e.g. to a roof fixing bracket). The solar panel connector may be continuous (so that it completely surrounds a perimeter of the solar panel module) or it may be discrete (so that it does not surround a perimeter of the solar panel module). Where the solar panel connector is continuous, it may simply be a frame surrounding at least part of a photovoltaic glass sheet of the solar panel module.
(16) In the following, there is described a system for connecting together two solar panel modules using their respective solar panel connectors and a bracket configured for both attaching the two solar panel modules in a particular configuration with respect to each other and for attaching the two solar panel modules to at least a part of a roofing structure (for example, to a roof beam or a tile batten). In particular, the bracket is configured so that it is connected to each of the solar panel connectors at respective first and second portions of the bracket. The profiles of the first and second portions of the bracket are asymmetric as they are configured differently. In particular, the first and second portions of the bracket are configured to be suitable for different respective connection mechanism. The bracket is slidably connected to (at least) the second solar panel connector along a first axis. By this, it is meant that the bracket is configured to provide a guide along the length of the second portion of the bracket. The guide is for locating and/or orientating the second solar panel connector/module with respect to the first solar panel connector/module. This is one mechanism for connecting the bracket to a solar panel connector. The first portion of the bracket is configured to connect to a (different) solar panel connector via a second mechanism. In particular, the first portion may be configured to retain the first solar panel connector with respect to the bracket after the first portion has been rotated onto the first solar panel connector so that the first solar panel connector and the bracket may move laterally relative to each other only along the length of the first potion. In other words, the first portion may be configured to retain the first solar panel connector with respect to the bracket after the first portion has been rotated onto the first solar panel connector so that the first solar panel connector and the bracket may move laterally relative to each other only along the length of the solar panel connector. An additional retaining mechanism may be provided to this effect, or this retention may be effected through the shape of the first portion that interlocks with a complementary shape of the solar panel connector.
(17) In the described embodiments, the bracket is further shown such that it is slidably connected to the second solar panel connector along the first axis. It is understood that, whilst this is an aspect of the described embodiments, other mechanisms for attaching a solar panel and the bracket are also possible. Some of these are mentioned below. When a solar panel module is connected to respective brackets along opposing sides of the module, the solar panel connectors and the bracket are configured to be locked together in use so that each component may only move laterally with respect to each other along a single axis, parallel to the bounded opposing sides.
(18) To illustrate the system, two embodiments are described below with respect to the Figures. The first embodiment is described below with particular reference to
First Embodiment
(19) As mentioned above, the first embodiment is directed to an arrangement in which there is no gutter between two solar panel modules 1. In a particular aspect of this arrangement, there is a minimum gap between the two solar panel modules 1.
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(21) The solar panel connector is provided with at least one further slot 6 on an opposite face/side to the first side of the solar panel connector 2. This further slot 6 is configured to accept a fixing bracket 7. Fixing bracket 7 is shown in an isometric orientation in
(22) The fixing bracket is configured to have at least three portions. A first portion of the bracket is configured to be inserted into the further slot 6 (as shown in
(23) The fixing bracket 7 further comprises a second portion 9. This second portion protrudes away from (i.e. in an opposite direction to) the first portion and presents a face for providing a guide to a second solar panel connector 2 (see
(24) Preferably, a face of the first portion and a face of the second portion of the bracket 7 are configured to respectively contact faces on the first and second solar panel connectors for holding the first and second solar panels in configurations in which the solar panel connectors 2, 2 may be slid along the same plane, as well as along the same axis (although it is understood that this is not essential). The bracket 7 may be said to cause the respective connection points between the bracket and the first and second portions to align vertically.
(25) The fixing bracket further comprises a third portion, separated from the first and second portions of the bracket by a leg. The third portion is a base portion and is configured for attachment to a part of a roofing structure, such as a roof beam or a tile batten. The leg is perpendicular to the third portion. The third portion of the bracket is shown as being substantially parallel to the first and second portions of the bracket. In use, the bracket can be fixed (using, for example, fixing means such as screws) to the roof structure below.
(26) In one embodiment, the first portion of the bracket 7 comprises a protruding element, shaped to have a leading edge that angles upwards (perpendicularly to the third portion) to ensure a smooth interface as the first solar panel connector is slid into location.
(27) In another (non-exclusive) embodiment, the second portion of the bracket 7 comprises a protruding element 9, shaped to have a leading edge that angles upwards (perpendicularly to the third portion) to ensure a smooth interface as the second solar panel is slid into location.
(28) The solar panel connector 2 further comprises a second slot/recess 5 on the same side as of the solar panel connector as the further slot/recess 6. When the structure is orientated with the base 7 of the fixing bracket 7 nearest to the ground, the second slot/recess 5 is located above the further slot/recess 6. The second slot/recess 5 is shaped to receive retaining means, such as a flexible gasket, for retaining a sheet of flashing 10.
(29) The retaining means in the second slot/recess 5 may be a generally U-shaped section formed with a series of lips extending into the centre, such that when a thin sheet of material is pushed into it, they are deflected to form a series of seals against the upper and lower faces of the sheet of flashing 10.
(30) As mentioned above, the roofing system also comprises flashing 10 for creating a weather-tight seal between the two close-coupled solar panels. In its simplest form this is a thin rectangular strip of a length that exceeds the length of the side of the panel that is to be close coupled and a width sufficient to push into the retaining means in the second slot/recess 5 on both solar panel connectors. The flashing 10 can be pushed into the retaining means of the second slot/recess 5 of the solar panel connector 2 along one side of the first solar panel connector (as shown in
(31) One advantageous embodiment of the flashing can include a formed ridge 17 that extends along at least part of the length of the flashing to provide stiffness in handling and to reduce the depth between the top surface of the panel and the flashing, thus encouraging water (e.g. rain water) to be shed onto the panels and away from the gasket/solar panel connector-flashing interface. This is shown in
(32) It can be seen that by fixing the first panel with a roof fixing bracket 7 as described and then pushing the flashing 10 into the retaining means of the second slot/recess 5 on the first solar panel connector, the second solar panel connector can be joined to the first solar panel connector to create a weather-tight seal between the two edges and to fix both solar panels modules to the roof structure below by the simple method of pushing the two together.
(33) A method of fixing together the components of the first embodiment may therefore be considered to be as follows.
(34) In a first step, a first portion 8 of bracket 7 is fixed to a second portion of a solar panel connector 2 (that is part of a solar module). One way of fixing the first portion of the bracket 7 to the second portion of the solar panel connector 2 is by simply fixing the two components together using screws, or some other fixing means. In a preferred embodiment, the first portion of the bracket 7 is configured to be fixed to the further slot 6 by being rotatably inserted into the further slot 6. In this case, at least one of the first portion 8 of the bracket 7 and the solar panel connector 2 are configured such that, after a minimum amount of rotation, the first portion 8 of the bracket 7 and the second portion of the solar panel connector 2 are rotatably locked onto each other. Instead, the only relative motion between the bracket 7 and the solar panel connector 2 is laterally and along a single axis.
(35) In a second step, a third portion of the bracket 7 is used to attach the bracket 7 and the solar panel connector 2 to at least part of a roofing structure.
(36) In a third step, flashing is inserted into the first portion on the first solar panel connector 2, for creating a weatherproof seal therebetween.
(37) In a fourth step, a second portion 9 of the bracket 7 is used as a guide to slide the second solar panel connector 2 of another solar module into position, adjacent to the first solar panel connector. The second portion 9 of the bracket 7 is such that the second solar panel connector is constrained (once slid onto the bracket) to move laterally along the first axis and to move laterally out of the second portion of the bracket. The second solar panel connector cannot, however, move up or down (relative) to the roof to which the system is being attached. In other words, the second solar panel module is constrained to be unable to move in a direction perpendicular to the face of its photovoltaic glass once slid onto the second portion of the bracket.
(38) In a fifth step, flashing is inserted into the first portion on the second solar panel connector 2, for creating a weatherproof seal therebetween. The fourth and the fifth step may be combined in a single operation.
Second Embodiment
(39) The presently described second embodiment provides for the attaching bracket to provide support for, and allow definition of, a gutter extending between adjacent solar panel connectors. The gutter is used to direct water to shed downwards at the corners where four panels meet.
(40) As in the first embodiment, there is provided a photovoltaic glass sheet 3 of a solar panel that may provide an attachment point to the solar panel connector 2 in a recess/slot on a first side of the solar panel connector 2. The attachment point may comprise a sealant compound 4 with the aim of contributing to providing a weather tight seal for the solar panel module 1.
(41) The bracket 11 that is the focus of second embodiment is illustrated with respect to
(42) The bracket 11 of the second embodiment differs from the first embodiment in that the bracket is substantially U-shaped, with the base of the U-shape providing the third portion, and respective legs 12, 13 of the U-shape corresponding to the first and second portions. The distance between the legs 12, 13 of the U-shape defines a maximum size of a gutter area spanning between the legs of the U-shape of the bracket 11. This is better illustrated with respect to
(43) In
(44) Subsequent to this step, a third portion (the base portion) of the bracket 11 may be used to attach the bracket 11 and the first solar panel connector/module to a roofing structure.
(45) The second solar panel connector may then be slid onto and along the second portion of the bracket 11 by means of using the second portion 9 of the bracket 11 as a guide (in particular, using a lower surface of the second portion 9 of the bracket 11 (lower is defined in use relative to a roof structure, as described in the general section below)). This operation results in the second solar panel connector being slidably attached to the bracket such that the second solar panels lateral movement (with respect to the bracket 11) is constrained along and to move out of the bracket. The second solar panel connector cannot, however, move up or down relative to the roof to which the system is being attached. In other words, by locating the second solar panel connector in the second portion 9 of the bracket 11, the second solar panel module is constrained to be unable to move in a direction perpendicular to the face of its photovoltaic glass. In other words, the second solar panel connector 2 is configured to use a face of the bracket 11 as a guide along the length of the bracket to locate and/or orientate the second solar panel connector 2 with respect to the first solar panel connector 2. In particular, to set any displacement/offset of the outermost face of the photovoltaic glass 3 of the second solar panel connector 2 with respect to the outermost face of the photovoltaic glass 3 of the first solar panel connector 2. Preferably, the offset is zero.
(46) As in the case of the first embodiment, the first portion of the bracket 11 may comprise a protruding element, shaped to have a leading edge that angles upwards (perpendicularly to the third portion) to ensure a smooth interface as the first solar panel connector is slid into location.
(47) Further, the second portion of the bracket 11 may comprise a protruding element 9, shaped to have a leading edge that angles upwards (perpendicularly to the third portion 7) to ensure a smooth interface as the second solar panel is slid into location.
(48) The solar panel connector 2 further comprises a second slot/recess 5 on the same side as of the solar panel connector as the further slot/recess 6. When the structure is orientated with the base 7 of the fixing bracket 7 nearest to the ground, the second slot/recess 5 is located above the further slot/recess 6. The second slot/recess 5 is shaped to receive retaining means, such as a flexible gasket, for retaining a sheet of flashing 15.
(49) The retaining means in the second slot/recess 5 may be a generally U-shaped section formed with a series of lips extending into the centre, such that when a thin sheet of material is pushed into it, they are deflected to form a series of seals against the upper and lower faces of the sheet of flashing 15.
(50) Once both the first and second solar panel connectors are set a fixed distance apart through use of the bracket 11, a gutter for the washing away of rainwater is thereby provided therebetween.
(51) To improve the provided gutters, a waterproof seal may be provided. This may be provided by use of two distinct components. One component is a U-shaped gutter element 14, configured so as to fit into the gap between the two sides of the bracket 11 as shown in
(52) The other component is flashing 15. In the present example, the flashing component 15 is provided by two separate L shaped covers 15. The flashing is configured to have at least one portion that protrudes into retaining located in a respective second slot/recess 5 in a respective solar panel connector. The connection between the flashing 15 and the second slot/recess of the solar panel connector is as described above with respect to the flashing 10 of the first embodiment. The remaining end 16 of the L-shaped flashing 15 is configured to bend into the U-shaped recess defined by the U-shaped guttering element 14. This arrangement is illustrated with respect to
(53) A method of fixing together the components of the second embodiment may therefore be considered to be as follows.
(54) In a first step, a first portion of bracket 11 is rotated onto a second portion of a solar panel connector (that is part of a solar module). At least one of the first portion of the bracket 11 and the solar panel connector 2 are configured such that, after a minimum amount of rotation, the first portion of the bracket 11 and the second portion of the solar panel connector 2 are rotatably locked onto each other. Instead, the only relative motion between the bracket 11 and the solar panel connector 2 is laterally and along a single axis.
(55) In a second step, a third portion of the bracket 11 is used to attach to at least part of a roofing structure.
(56) In a third step, a second portion 9 of the bracket 11 is used as a guide to slide the second solar panel connector 2 of another solar module into position, adjacent to the first solar panel connector. The second portion 9 of the bracket 11 is such that the second solar panel connector is constrained (once slid onto the bracket) to move laterally along the first axis and to move laterally out of the second portion of the bracket. The second solar panel connector cannot, however, move up or down (relative) to the roof to which the system is being attached. In other words, the second solar panel module is constrained to be unable to move in a direction perpendicular to the face of its photovoltaic glass once slid onto the second portion of the bracket.
(57) In a fourth step, a U-shaped gutter component is inserted in the bracket 11, between the first and second solar panel connectors. The U-shaped gutter component defines a channel for receiving water and for draining the water towards the edges of the roof to which the components are attached.
(58) In a fifth step, respective L-shaped flashing components 15 are inserted into respective first portions on the first and second solar panel connectors, for establishing a weatherproof seal therebetween.
General Comments Applicable to all Embodiment
(59) It is understood that the above two described embodiments may be implemented into the same roofing architecture. An example of this is shown in
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(61) The solar panel connector 2 may be of extruded aluminium that is cut and joined at four corners to hold a photovoltaic glass cover sheet 3.
(62) The sealant compound may be silicone 4.
(63) Examples of suitable materials for the gasket are rubber and EPDM. It can be formed by extrusion, and joined with moulded mitred corners to form a continuous loop.
(64) Throughout the above embodiments, reference is made to relative directions, such as above and below. These are terms are used relative to the orientation in which the system/components assume when being used to attach to a roofing structure, with the fixing brackets 7, 11 being configured to connect to a roofing structure towards the bottom of the solar panel connector/bracket/flashing system.
(65) Throughout the above, reference is made to the term length of a component. In this sense, the length of a component is the magnitude of its largest dimension.
(66) The above detailed description of embodiments of the present invention is provided by way of example only, and various modifications can be made to these embodiments without departing from the scope of the invention.
(67) The applicant draws attention to the fact that the present invention may include any feature or combination of features disclosed herein either implicitly or explicitly or any generalisation thereof, without limitation to the scope of any definitions set out above.