AU2004260808B2 - A corner seal cover and an edge seal for solar panels - Google Patents

Description

WO 2005/012667 PCT/AU2004/000649 A Corner Seal Cover and an Edge seal for Solar Panels Field of the invention The present invention relates generally to the weather sealing of solar panel framing systems used in building claddings against water ingress and more particularly to a corner seal cover and an edge seal for solar panels as a cladding.

The invention has been developed for use in mounting solar panel members or laminates in an array on a supporting structure and will be described with reference to mounting solar electric panels, also known as photovoltaic (PV) panels, to a suitable angle to the horizontal and with respect to the sun, typically for the dual use as solar energy generator and roofing material.

However, the invention is not restricted to this particular use and is also suitable for analogous applications, for example the vertical mounting of an external PV wall cladding system.

Background of the invention Laminate solar PV panels having the general characteristics of a roofing tile are known. Such panels are able to be integrated into a roof, commonly but not exclusively a tile roof, and serve as the roofing material as well as a solar power generator. Solar PV panels mounted over a roof are also known.

An important consideration of the design and development of PV panels is the ability of the panels to be effectively integrated architecturally into a roof design. Further, where the panels take the place of conventional roofing elements such as tiles or metal sheets, reliable and convenient mounting within the roof and effective weather sealing is very important.

One known installation system relies on each solar panel having a framework for mounting the PV laminate with a seal around the periphery of the laminate and the framework having structural features to facilitate its mounting on, for example, conventional roof battens. However, such framework are of fixed proportions and therefore are not necessarily desirable for some installations and will not conform with, for example, standard batten spacings. Further, the fixed proportions also severely limit the number of commercially and commonly available PV panels that can be incorporated into the framework. Custom size PV panels are more expensive, which makes any system using them less competitive in the market.

Another known installation system requires additional structures below the PV panel to ensure weather sealing, or use extruded or longitudinal frame sections that need additional components to attach to the roof structure, which in some cases lack a smooth WO 2005/012667 PCT/AU2004/1000649 -2external finish appearance important for both aesthetic and external environmental conditions.

Another known installation system uses PV panels that are assembled, prior to transportation to site or installation, with external sealing strips that are suited to easy mounting on conventional roof battens. This system advantageously avoids any on-site component assembly, which can be complex and time consuming, and also lowers the risk of transportation/installation damage by providing edge protection to the glass PV laminate panels.

This system also improves the weather sealing of PV panels by using longitudinal edge sealing elements joined at the corners of each panel, either by direct mitre joints or in combination with corner sealing elements, to make a frame that surrounds and is weather sealed to the PV panel. The advantage of longitudinal edge sealing elements in such a panel framing system is that they may be cut to length to suit the glass panel dimensions. This makes such a system adaptable to variations in panel dimensions, such as occurs in panels from different manufacturers. The framed panel is then used as a roofing element that can be laid on conventional roofing structures such as roof battens and, when laid and joined together, forms a weather proof roofing system. Such a framing system is often referred to by the generic name of solar roof tiles.

However, a problem with using such longitudinal edge sealing elements to frame glass PV panels is that poor sealing often occurs between the longitudinal elements and the glass panel, in particular the sealing of the longitudinal elements at comer joints. This can lead to leaks into the supporting building.

It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages.

Summary of the invention Accordingly, in a first aspect, the present invention provides a corner seal cover adapted to be installed between adjacent overlapping corners of upper and lower, inclined solar panels, the upper panel overlapping the lower panel, the panels each having an upper surface bounded along their side and top edges by sealing strips raised with respect to the upper surface, the top edge sealing strip meeting each of the side edge sealing strips at a junction, the comer seal cover including: a first portion extending over the lower panel's top edge raised sealing strip; and a second portion extending over the panel's adjacent side edge raised sealing strip, WO 2005/012667 PCT/AU2004/000649 -3wherein the first and second portions are integrally formed from a water impervious material and cover the junction between the lower panel's adjacent top edge and side edge sealing strips.

The term "sealing strip" as used herein is intended to include resilient sealing strips applied to the panel edges and also to a combination of resilient sealing strips and adjacent rigid supporting or mounting structures, the latter commonly being in the form of Aluminium extrusions.

The first portion preferably has a substantially central planar portion, a rear lip extending and depending from the central portion and a front stepped flange depending from the central portion.

The second portion preferably has a substantially planar portion adjacent the front stepped flange and a relatively raised curved side portion. The relatively raised curved side portion preferably has a distal part adapted to overlap a relatively raised curved side portion distal part of a like mirrored corner seal.

The corer seal cover preferably further includes a third portion adapted to engage a corresponding portion of a like mirrored comer seal.

The corer seal cover is preferably produced from a plastic material. The corer seal corer seal is preferably produced from a polymer. The polymer is preferably SEBLEX (Trade Mark) or a type ofpolyolefin elastomer which has similar physical properties to neoprenes, In a second aspect, the present invention provides an edge seal for solar panels, the solar panels having an upper surface, a lower surface and an edge surface therebetween, the edge seal including: a longitudinally extending, generally U-shaped, channel having two distal edges, the channel being adapted to snugly receive the edge surface of the panel therein; and a longitudinally extending, flexible lip extending at an angle outwardly from one of the channel's distal edges and in a direction towards the other of the channel's distal edges, the lip being resiliently biased towards the channel's other distal edges, wherein the lip, in use, abuts the panel's lower surface and forms a longitudinal drainage void between the lip, the channel and the panel's lower surface.

The lip preferably has a proximal part and a distal part, the distal part being angled with respect to the proximal part.

The exterior of the channel preferably includes a plurality of longitudinal grooves, WO 2005/012667 PCT/AU2004/1000649 -4- The edge seal is a preferably produced from a plastic material. The edge seal is preferably produced from a polymer. The polymer preferably has the physical properties and long service life of neoprene.

In further aspects, the present inventions provide three elements or components to improve the weather sealing of longitudinal element framed glass panels with corner joins and these elements or components may be applied separately or work in unison to form an improved sealing system for weather sealing and for providing safe water drainage of the framed panel. The inventions apply in particular for systems for PV panels in roofs or facades that use an overlapping roof-tile like PV panel elements made up of elongate frame elements surrounding PV glass panels.

In commonly found glazing systems, a weather/water seal between an elongate element retaining channel and the edge of a glass panels can be achieved using an elongate polymeric glazing element or gasket, typically of a U shape profile. However corner joints at the end of elongate frame elements are commonly found as areas difficult to effect a durable weather seal due to the joints and satisfactory methods for sealing of these.

The first component is preferably a weather sealing component of thin, nonporous material with a shape to form a water sealing interfacial gasket fitted closely between overlapping corner joints of a tile-like or tessellated glazing system wherein a superior tile lower frame elongate element overlaps an inferior tile upper frame elongate element and each of the overlapping elongate elements has joints at either end to respective side frame elongate elements at comer joints made by mitre- or partial mitrecuts of the elongate elements or by using corner insert joining elements.

The frame comer weather sealing components are preferably a system of a lefthand and right-hand pair of thin, generally flat shaped polymeric elements forming interface gaskets or 'flashings' used in between the overlap of the corner joints of the framing system forming a weather/water seal on the upper surface of the upper left-hand and right-hand upper comers of each inferior frame, that in turn are overlapped by the lower corners of the superior frame.

The second component preferably includes a V groove water catching and drainage channel feature added to outer lip of the bottom wall of a generally U shaped elongate polymeric gasket used to seal elongate elements of framed panels to the glass panel of a framing system.

The third component is preferably an improvement of the weather seal of an overlap join between the superior lower frame elongate element and inferior upper frame elongate element at the outer most, weather exposed overlap join between these elements using a polymeric 'bulb' shaped seal to make a compression seal between the lower edge of the superior frame onto the surface of an inferior glass panel of the inferior frame.

WO 2005/012667 PCT/AU20041000649 The first part of the invention, being the polymeric corner flashings will now be described. Preferably the corner flashing is a thin interposed polymeric gasket-type element forming a water flashing located between the upper and lower surfaces of upper and lower comer elements and or adjoining elongate frame elements that make the comer joint of a frame.

Preferably, the shape of the polymeric corner flashing is generally that of a thin overlaying element that conforms closely to the surface shape of the framing system leftor right-hand upper comer joints, if comer insert elements are used, and/or to the adjoining surfaces of upper frame and side frame elongate elements.

Preferably, the shape of the comer flashings also closely conforms to the outer surface of the elongate capping element described as "the cover strip" that joins two side by side adjacent tiles, the cover strip being inserted into voids provided in the lower frame comer elements when the lower comer elements lie on top of the upper frame corner elements when installed.

Preferably, the comer flashing is made of left- and right-hand parts that mate together when assembled in the installation of the panel framing system by inserting together, and overlapping intimately such that their interlocking also defines the spacing distance side-to-side between the adjacent framed panels, the shape of this interlocked area between flashings has features of; a vertical wall portion that rises to a height so as to fit closely beneath a superior elongate capping element or 'cover strip' fitted to seal and secure between adjacent superior framed panels, the vertical wall portion ends with a flat horizontal wall on one -hand of the flashing, this flat area is of a rectangular size and shape and stiffness so as to fit underneath, into a pocket formed by the equivalent vertical and horizontal wall portions of the other -hand flashing, this flashing having a similar rectangular horizontal wall which is slightly higher than the other, and in addition has a V groove feature that is for taking the tip of a penetrating self-drilling roofing screw that is driven through the superior capping element or 'cover strip' and penetrates through both the flashing rectangular horizontal wall portions for the purpose of securing the framing system to the supporting structure of the building.

Preferably, the comer flashing/s have an upper extension lip area that extends beyond the upper frame elongate upper edge and upper edge of the comer insert if present, to form a surface for capture of drainage water from the overlapping end of the glazing polymeric elongate gasket V shaped drainage channel, the upper lip extension of the comer flashing also ending with a depending vertical wall portion which stiffens the overhanging portion of the lip area, the depending vertical wall also having perpendicular abutment walls that bear onto the vertical walls of the upper frame elongate and comer insert if present, to add further support and stiffening to the overhanging lip area.

Preferably, each left- and right-hand comer flashing has a portion to closely overlap the capping elongate element or 'cover strip' that inserts into the overlap comer joints of two adjacent side-by-side framed panels; this overlap portion of one -hand corner flashing is extended further than the other -hand to form a further overlap join WO 2005/012667 PCT/AU20041000649 -6between the flashing overlap portions, preferably the thickness of the overlapped portions of each flashing is reduced to maintain consistent overall thickness of the two overlapped parts to the thickness of the flashing generally.

Preferably, each flashing has a portion that closely follows the contour of the overlapped inferior frame elongate side frame section and a further portion that drops down onto the glass area of the inferior panel in the upper comer area of the panel to form a further barrier to water impinging from the glass surface onto the upper comer joint of the inferior framed panel.

The second components of the present invention, being the elongate polymeric gasket component will now be described. Preferably the elongate glazing gasket is made of a polymeric material usually with an asymmetric U shape profile, with the addition of an extended lip portion that forms the outer side wall of a shaped channel extending from the lower edge, outermost face of a lower wall portion of the U shaped gasket.

The V channel shape formed by the lip extension creates a drainage channel to collect, retain and channel water that may penetrate between the glazing polymeric seal and the glass panel to an external surface where it is expelled to the outside of the panel system.

Preferably, the outermost edge of the V channel lip feature forms a mild compression seal to the underside of the panel or laminate by virtue of its pre-formed, pre-tensile shape such that it deflects on installation and the elastic resilience of the polymeric material holds the inclined plane shape of the tip of the V outer wall to seal flat onto the glass panel rear surface at installation, the V wall extends to leave a void within the V groove in which water can be retained and drained.

Gravity and surface tension drains the water to a lower position in the framing system where it can be put to the external weather surface of the panel framing system.

Preferably, the lowermost end of the V shaped drainage channel of the elongate polymeric gasket used in the side frame elongate elements of the panel framing system overlaps onto an upper surface feature of the polymeric comer flashing located at the panel frame lower comer overlap joint.

The third component of the present invention being the overlapping bulb seal will now be described. Preferably, the lower frame elongate element has a lower horizontal lip extension of frame material that includes a mushroom shaped undercut groove on the lower under side surface of the extension for taking the flange of an elongate polymeric seal that has a bulb shaped profile.

Preferably, the polymeric bulb seal has a hollow or easily deformable circular form with a mushroom shaped flange to insert into a retaining groove, the bulb being a deformable shape that affects a seal when compressed between the two surfaces of the lower frame lip extension and the glass of the inferior panel.

WO 2005/012667 PCT/AU20041000649 -7- Brief description of the drawings Preferred embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a roof with solar tiles attached thereto using the covers and seals according to embodiments of the invention; Figure 2A is a perspective view of two solar tiles using the covers and seals according to embodiments of the invention; Figure 2B is an enlarged partial detailed view of the tiles/ covers and seals shown in Figure 2 and a third tile; Figure 3 is perspective views of a left hand comer seal cover according to an embodiment of the invention; Figure 4 is perspective views of a right hand comer seal cover according to an embodiment of the invention; Figure 5 is a partial perspective view of three tiles installed using covers and seals according to embodiments of the invention; Figure 6 is a partial perspective view of two tiles installed using covers and seals according to embodiments of the invention; Figure 7 is a cross sectional view of two tiles installed using covers and seals according to embodiments of the invention; and Figure 8 is a cross sectional view of three tiles installed with some elements removed to better show the use of covers and seals according to embodiments of the invention.

Detailed description of the preferred embodiments Referring to Figure 1, there is shown a segment of an inclined roofing structure comprising rafters 12, battens 14, roof tiles 16 and solar PV panels 18. The airflow path behind the panels 18 is indicated by arrows 20 (inclined solar panels).

Figure 2A shows two of the panels 18 in isolation, namely an upper panel 18a and a lower panel 18b. The bottom edge of the upper panel 18a overlaps the top edge of the lower panel 18b. An embodiment of a comer seal cover 22 is shown on the top comers WO 2005/012667 PCT/AU20041000649 -8of the upper panel 18a and between the top corners of the lower panel 18b and the bottom comers of the upper panel 18a.

The comer seal covers 22 are best shown in the Figures 3 and 4 and are produced as a left hand corner seal cover 22a (Figure 3) and a right-hand comer seal cover 22b (Figure The left and right hand corner seal covers 22a and 22b are effectively a mirror of one another except for some male/female interlocking components which will be described in more detail below.

The comer seal covers 22 are comprised of a first portion that includes a central planar portion 24, a rear lip 26 depending from the extended central portion 24 and a front stepped flange 28, also depending from the central portion 24. The seal covers 22 also have a second portion with a substantially planar portion 30 adjacent the flange 28 and a relatively raised curved side portion 32. The left hand corner seal cover 22a also includes a male boss 34a which can be received in an interlocking fashion within a corresponding female recessed part 34b provided in the right-hand side comer seal cover 34b. The corner seal covers 22 also include walls 36 between the central planar portion 24 and rear lip 26.

The various parts of the corner seal covers 22 described above are integrally formed from a water impervious material, preferably the polymer marketed under the trade mark SEBLEX.

The installation and purpose of the comer seal covers 22 will now be described with reference to Figures 5 to 8.

Turning firstly to Figure 6, there is shown two side-by-side lower panels 18b and 18b'. The panels 18b and 18b' have a top sealing strip 38 along their top edges and an edge sealing strip 40 along their adjacent side edges. The sealing strips 38 and 40 are comprised of a rigid aluminium extrusion and a flexible polymeric seal, as will be described in more detail below.

The sealing strips 38 and 40 meet adjacent the comer of the panels 18b and 18b' and it is this join or junction that presents a potential leaking point for the panels 18 and the sealing strips 38 and Figure 6 shows a left hand comer seal cover 22a being positioned at the junction of the top and side sealing strips 38 and 40 with its first portion (comprising the central portion 24, the lip 26 and the flange 28) extending over the panel's top edge sealing strip 38. The second portion of the comer seal cover 22a (comprising the planar portion and the raised curved side portion 32) extends over the panel's side edge sealing strip The seal 22a is positioned with the walls 36 abutting the outer edge of the top edge sealing strip 38.

As the comer seal covers 22 are water impervious then, by covering the junction or join of the top and side sealing strips 38 and 40, any water that is incident on the WO 2005/012667 WO 2005012667PCTIAU200t10006-t9 -9junction or join region is directed over and away from the join therefore avoiding any leakage at the join.

A similar process occurs in relation to the right hand corner seal cover 22b which is positioned over the junction of the top and side edge sealing strips for the panel 18b'.

The corner seal cover 22b is installed with the recessed part 34b being placed over and into engagement with the boss 34a of the corner seal cover 22a.

Further, and referring now to Figure 5, there is shown an upper panel 18a overlapping the lower panell 8b. The bottom edge of the upper panel 18a has a substantially flush sealing strip 42 (as best seen in Figure Accordingly, any water incident on the upper panel 1 8a, particularly that is travelling adjacent the side sealing strip 40 of the upper panel 18a, is directed onto the corner seal cover 22a and over the potential leak point discussed above.

An edge seal 50 for solar PV panels will also now be described with reference to Figures 7 and 8. The seal 50 is produced from a polymer with characteristics of neoprene and can be used for sealing the top, bottom and side edges of the panels 18.

Figures 7, 7A and 8 show the edge seals 50 which have a longitudinally extending generally U-shaped channel 52 which is adapted to snugly receive the panel 1 Sa therein in a substantially water-tight sealing connection. The channel 52 includes two distal edges 54 and 56. A longitudinally extending, flexible lip 58 extends at an angle outwardly from the distal edge 54 and in a direction towards the distal edge 56, towards which it is also resiliently biased. After installation, this also biases the lip 58 towards the adjacent lower surface of the panel 1 8b. More particularly, the lip 58 has a proximal part 58' and a distal part 58", with the latter being resiliently biased, after installation, into contact with the adjacent lower surface of the panel 18.

The upper inner surface of the channel 52 includes a number of fine longitudinal grooves 55 to assist in sealing the edge seal to the upper surface of the panel glass.

The upper and lower exterior surfaces of the channel 52 include a number of longitudinal grooves 60 to assist in interlocking the seal 50 within a correspondingly grooved recess provided in a recess 64 in the aluminiumn mounting extrusion.

In use, the distal part 62 of the lip 58 abuts the panel's lower surface and forms longitudinal drainage void 57 between the lip 58, the channel 50 and the panel's lower surface. As a result, any water that leaks past the interface between the exterior surfaces of the panel and the interior surfaces of the U-shaped channel 50 is caught in the void 56 and can thereafter be safely drained away by the downward sloping inclination of the panels side edges and the mitre joining of the upper frame edge horizontal drainage channel portion at the panel's upper corners where it is possible to have the mitre join of the U shaped channel and drainage portion fusion -welded so that the drainage channel is fully sealed at the mitre joins.

Although the invention has been described with reference to preferred embodiments, it will be appreciated by those silled in the art that the invention may be embodied in many other forms.

Claims (9)

1. 2. An comner seal cover adapted to be installed interfacial between the Overlapping, unsealed cornters of upper and lower, ilnclined framed panels, the ffame surrouind for each panel characterized by longitudinal side, top and bottom frame elements each being in a weather sealed relationship to their respective panel edges, and being joilied at coniors characterized in that the junctions between adjacent frame parts are not sealed or waftr tight. the overlapping relationship of the upper framed panel to the lower framed panel characterized in that the upper panel! s bottom frame corner junctions directly overlap the lower panel's top frame corner junctions., the improvement is that the corner seal cover is in the majority interfacial only to the overlap region of the panel cmrer junctions and of a shape that seals over the lower panel's unsealed comner junctions, the comner seal including: a firs( portion extending over the lower panel's top frame, and a second portion extending over the lower paniel's adjacent side frame, wherein the first and second portions are integrally formed from a water impervious material arnd cover the junction between the lower panel's adjacent top frame and side frame; 2. A corner seal cover as claimed in claim 1 wherein; the forst portion has a substantially central planar portion, a rear lip depending from the Lipper edge of the central portion and a front stepped flalige depending from the central portion.
2. 3. A comner seal cover as claimed in claim 2 wherein an upper cdge portion of the central plantar portion extend,- beyond the lower panel top frame upper edge to create an extended ,surface to capture drainage from an edge seal drainage capture feature associated with the overlapping upper panel's side frame element.
3. 4. A corner seal cover as claimed in claim 2 wherein the extended upper edge portion and the depending roar lip are supported by batiress walls that4 bear onto the upper depending wall of the top frame. The corner seal cover as claimed in claim 1, wherein the second portion has a substantially planar portion adjacent the front stepped flange and a relatively raised curved side portion,
4. 6. The comner seal cover as claimed in claim 5, wherein the relatively raised curved side portion has a distal part adapted to overlap a relatively raised curved side portion distal part of a like mnirrored corner seal.
5. 7- rhe comner seal cover as claimed in any one of claims I to 5, further including a third portion adapted to engage a corresponding portion of a like mairrored corner seal.
6. 8. The corner seal cover as claimed in any one of the preceding claims, wherein the corner seal is a produced from a plastic material.
7. 9. The corner seal 1cover as claimed in claim 8. wherein the corner seal is a produced from a polymer, AMENDED SHEET (ARTICLE 19) WO 2005/012667 WO 205102667PC11AU2004/000649 The comner seal cover as claimed in claim 8, wherein the polymer is SEBLEX (Trade Mark) or a Polymer With Polyolefin elatomer modified polypropylene or neoprene like characteristics, IL. An edge seal for solar panels as claimed in claim 3, wherein, the solar panels having an upper surface, a lower surface and an edge surface there between, the edge seal including- a longitudinally extending, generally U-shaped, channel having two distal edges, the channel being adapted to sntigly receive the edge surface of the panel therein, and a longitudinally extending, flexible lip extending at ani angle outwardly from one of the channel's distal edges and io a direction towards the other of the chavinel's distal edges, the lip being resiliently biased towards the channel's other distal edges, wherein the lip, in use, abuts the panel's lower surface and forms a longitudinal drainage void between the lip, the channel and the panel's lower surface, the drainage void lower open end being Wt an overlying relationship to an extended upper edge portion of the adjacent underlying corner seal cover.
8. 12. The edge seal as claimed in claim 11,* wherein the edge seal is a produced fRom a plastic material.
9. 13. The edge seal as claimed in claim 12. wherein the edge seal is a produced from a polymer. 14, The edge seal as claimed in claim 12, wherein the polymer is a neoprene like material. AMENDED SHEET (ARTICLE 19)