GB2521860A

GB2521860A - Roof panel assembly

Info

Publication number: GB2521860A
Application number: GB1400150.7A
Authority: GB
Inventors: Gregory Flynn; Thomas Martin; Gareth Mcdonald
Original assignee: Kingspan Holdings IRL Ltd
Current assignee: Kingspan Holdings IRL Ltd
Priority date: 2014-01-06
Filing date: 2014-01-06
Publication date: 2015-07-08
Also published as: GB201400150D0

Abstract

A roofing panel for assembly in an array of roofing panels to form a roof structure, the roofing panel comprising a weather proof sheet having inner and outer sides and has a sheet profile that comprises a raised ridge and with a channel formed in a side of the raised ridge. The panel may be an insulated double skinned panel. The ridge may form an overlap portion for engaging an adjacent panel. The channel acts as a part of a securing arrangement for securing a further structure on the outer side of the sheet. For example an energy panel such as photovoltaic (PV) panel may be inserted into the channel so as to create a gap between the solar panel and the roofing panel.

Description

Roof Panel Assembly

Field of the Invention

[0001] The present invention relates to a roof panel that can be assembled in an array to form a roof structure.

Background to the Invention

[0002] It is increasingly desirable to provide roofing panels that are easy to assemble.

Furthermore there is a desire to provide panels which are insulative and thus have a low thermal conductivity value. Also it is desirable to provide upon roofs other structures such as energy modules.

[0003] In the past energy modules such as solar or photovoltaic ("PV") panels have been affixed to roofs. In one arrangement a support structure is first affixed to the roof, the panels are then supported by the support structure and secured to the support structure using one or more retention brackets. Typically this involves a grid of rails or bars that are attached to the roof and then holding brackets which attach to a rail or bar.

[0004] Such arrangements are time consuming and costly to erect and add substantially to the cost of adding energy panels. Furthermore as they are erected on the roof this allows for errors in fitting.

[0005] On the other hand arrangements where an energy panel is integrated into a roofing structure are also known.

[0006] The issue then arises as to how to provide a panel that is easy to assemble for example in a side-by-side array to form a roof, to which a further structure such as an energy module, for example an energy panel may be attached with ease.

Summary of the Invention

[0007] In one aspect, the present invention provides a roofing panel for assembly in an array of roofing panels to form a roof structure, the roofing panel comprising a weather proof sheet having inner and outer sides and characterised in that the sheet has a sheet profile that comprises a raised ridge and with a channel formed in a side of the raised ridge, the channel acting as a part of a securing arrangement for securing a further structure on the outer side of the sheet.

[0008] This is a very simple arrangement yet is a highly efficient way of providing the required securing arrangement for supporting something like an energy module or panel. For example one pad of, such as one side of, the further structure can simply be engaged within the channel for example by pushing it into the channel. This means that pad of a securing arrangement is provided by the panel itself without the need for additional securing means to be provided, for example additional fixings such as screws or brackets. The additional structure is thus mount directly to the sheet and there is no requirement for a mounting structure intermediate the panel and whatever is being mounted upon it. For example the support bars mentioned above can be eliminated.

[0009] Furthermore this can be done even after the panel has been assembled into a roof structure. It is thus allows a minimum amount of further assembly on site yet is highly cost effective [0010] As the channel is in the outer side of the sheet it will hold the further structure in a position where it is entirely on the outer side of the roofing panel. Typically it is held above (spaced apart) from the outer side of the panel.

[0011] The outer side of the sheet forms the exterior of the roofing panel and thus will be a weatherproof material. The outer sheet will typically be profiled. For example the panel profile may be roll-formed from a planar sheet.

[0012] The channel will face inwardly on the panel. This allows for the further structure to be held in position above the remainder of the panel. Typically the channel will be continuous along the entire length of the panel. It will be appreciated however that the channel may run for only a portion of the panel. However it is desirable that the channel is at least long enough to accommodate at least one entire side of an energy module such as an energy panel. For example the channel on a panel may accommodate more than one additional structure. The channel may be provided in separated portions, for example a channel portion for each additional structure.

[0013] Suitably the raised ridge is for overlapping with pad of an adjacent panel, on assembly. This means that the raised ridge fulfils two functions, providing a support for an additional structure and also allowing for overlapping with an adjacent panel for the purpose of weatherproofing. Again this is a highly efficient construction that allows for ease of assembly of an array of panels to form a roof structure.

[0014] It is desirable that the raised ridge is provided toward one side of the panel. This allows for accommodation of an additional structure that occupies a substantial portion of the width of the panel.

[0015] The raised ridge typically runs parallel to a longitudinal axis of the panel.

[0016] Desirably the sheet has a corrugated profile with alternating ridges and grooves and the raised ridge may then be raised with respect to other ridges. Suitably the channel is located at a position on the raised ridge and faces out a position where it is above the remainder of the panel. To the extent that an additional structure accommodated within the channel extends laterally across the panel it can pass across (and above) the remainder of the panel such as other across (and above) ridges.

[0017] Desirably the further structure is an energy module or panel which is adapted to capture solar energy. It may be one or more photovoltaic and/or thermal modules. For example it may be a photovoltaic panel. It may be a solar thermal tube module.

[0018] A side of the energy panel may be insertable into the channel as a part of a securing arrangement for securing the energy panel to the exterior of the roofing panel.

[0019] The further structure may be a photovoltaic panel. Optionally a side of the photovoltaic panel is insertable into the channel as a part of a securing arrangement for securing the photovoltaic panel to the exterior of the panel.

[0020] The further structure may be held in an arrangement where there is a gap between it and the sheet other than whele the further structure is attached to the panel.

This can allow for air circulation and cooling which is important where the additional structure such as an energy module that generates heat. Overheating can thus be prevented.

[0021] The further structure may be a photovoltaic panel which has on the underside thereof a downwardly projecting enclosure for components of the photovoltaic panel and wherein the sheet has defined therein a depression that corresponds to the position of the downwardly projecting enclosure. This avoids contact between the sheet and the downwardly projecting enclosure. Some energy modules have a junction box or similar protrusion on their underside and desirably the panel is shaped to avoid any contact between it and the energy panel, when assembled.

[0022] Where the sheet is corrugated with alternating ridges and grooves the depression may be formed between corrugations and/or by utilising lower ridges.

[0023] One or more additional fixtures may be provided on an opposing side of the additional structure for securing a further structure to the exterior of the panel.

[0024] In this way an additional structure to be held by the panel needs only to be fixed on one side during assembly.

[0025] Desirably the roofing panel is a manufactured composite insulating panel comprising:-an external weather-proof sheet having an outer face and an inner face; an internal sheet having an outer face and an inner face; an insulating body between the inner face of the external sheet and the inner face of the internal sheet, the external sheet having a portion that extends beyond the internal sheet and the insulating body to define an overlap part for overlapping with part of an adjacent panel, on assembly.

[0026] This means that a panel of the invention is thermally insulating, yet provides for ease of attachment of a further structure.

[0027] The invention also provides a method of attaching a further structure to a roof panel comprising the steps of providing a roofing panel according to the present invention; providing a further structure having a side; inserting the side of the further structure into the channel of the panel; and using a securing means to secure the further structure to the panel.

[0028] The securing means is any suitable securing means such as a bracket, trim, fastener for example a screw etc. [0029] Desirably the securing means is provided on an opposite side of the further structure.

[0030] The present invention also relates to a roof comprising an array of roofing panels according to the invention that are assembled to form a roof structure.

Optionally the roof has one or more additional structures mounted thereon wherein at least one additional structure has a side which is inserted into a channel of a panel.

[0031] The invention extends to a panel; or roof structure; or assembly comprising a panel and an additional structure; as described herein and/or as illustrated in the accompanying drawings.

Brief Description of the Drawings

[0032] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings in which: [0033] Figure 1 is a perspective view of a roofing panel of the invention; [0034] Figure 2 is a sectional view (along A-A) of the roofing panel of Figure 1; [0035] Figure 3 is perspective view of an additional structure in the form of a photovoltaic panel; [0036] Figure 4 is a sectional view (along B-B) of the photovoltaic panel of Figure 1, and wherein enlarged partial views A and B are provided; [0037] Figure 5 is a view showing the photovoltaic panel (as per the cross-sectional view of Figure 4) being inserted into the roofing panel (as per the cross-sectional view of Figure 2); [0038] Figure 6 is a view showing an assembly comprising the photovoltaic panel (as per the cross-sectional view of Figure 4) and the roofing panel (as per the cross-sectional view of Figure 2) secured together; [0039] Figure 7A is a perspective view showing an array of (four) roofing panels of Figure 1 assembled in an array to form a roofing structure and each with (three) photovoltaic panels of Figure 3 secured to it; [0040] Figure 7B is an enlarged partial perspective view of the assembly formed between two adjacent panels; and [0041] Figure 7C is an enlarged partial sectional view of the assembly formed between two adjacent panels.

Detailed Description of the Drawings

[0042] The present invention will be described with reference to Figures Ito 6.

[0043] A roofing panel 1 is provided. It can be assembled with like panels in an array that will form a roofing structure as will be described in more detail below.

[0044] The panel 1 has an external weather proof sheet 2 that can be formed of any suitable material. For example it may be a metal sheet such as an aluminium sheet.

This external sheet 2 forms the exterior face of a roof structure. The sheet 2 has an outer face 3 and an inner face 4.

[0045] The panel 1 has an internal sheet 5 that can be formed of any suitable material.

For example it may be a metal sheet such as an aluminium sheet. This internal sheetS forms the interior face of a roof structure. The sheet 5 has an outer face 6 and an inner face 7.

[0046] A body of insulating material 15 is provided between the sheets 2 and 5 so that the panel 1 takes the form of a composite insulating panel.

[0047] The external sheet 2 has a portion 10 that is in the form of a ridge that is for overlapping with an adjacent panel when assembled in use. The portion 10 extends beyond the internal sheet (best seen in Figure 2).

[0048] The panel 1 further comprises a raised ridge 12 on one side thereof The ridge 12 is located to one side of the panel 1 and runs longitudinally along the panel 1. The ridge 12 is formed as part of the profile of the external sheet 2.

[0049] The sheet 2 has a generally corrugated profile and comprises a number of ridges 18 that alternate with grooves 19. It will be noted that raised ridge 12 is raised with respect to all other ridges (other that the ridge forming overlap portion 10).

[0050] It will be appreciated that overlap portion 10 of one panel 1 will overlap over ridge 12 of an adjacent panel for weather proof mating of adjacent panels. The panels can then be fixed together by any suitable means.

[0051] The sheet 2 has defined therein a depression in the form of a longitudinal groove 20 that is depressed relative to the remainder of the sheet 2.

[0052] The raised ridge 12 has an outer wall or side 13 and inner wall or side 14 and a top end or crown 16.

[0053] Defined in a sidewall of raised ridge 12, and in particular the inner side 14 is a channel 22 which acts as a receiving slot for a further structure. It will be noted that the channel 14 opens out at a position that is elevated relative to the remainder of the panel (other than overlap portion 10).

[0054] In the embodiment the further structure to be attached to the roof is an energy panel, of the type that captures solar energy and in the form of a photovoltaic panel 30 as shown in perspective view in Figure 3 and cross-section in Figure 4. It can be seen that the PV panel 30 comprises an array of PV cells 31.

[0055] The PV panel 30 is a substantially flat and a substantially rigid panel.

[0056] On the underside of the PV panel 30 is a downwardly projecting enclosure or housing in the form of a junction box 32. The junction box 32 typically would obstruct the fitting of the PV panel 30 to the panel 1.

[0057] However, as mentioned above the sheet 2 is profiled to accommodate the junction box 2, in this case by provision of the depression 20.

[0058] As can be seen from the sequence shown in Figures 5 and 6 a first side 35 of the PV panel 30 is inserted into the channel 22 and then the panel 30 is moved into position as indicated by arrows C and D in Figure 5. The opposite side 36 of PV panel 30 is then attached to the top of a ridge 18 as shown in Figure 6.

[0059] This means that the PV panel 30 or indeed any other additional structure to be attached to a roof only needs to be secured on one side during assembly because the channel 22 forms the other part (opposite side) of the securing arrangement.

[0060] It is appreciated that the PV panel 30 is held entirely to the outside of sheet 2.

This means that the integrity of sheet 2 is maintained and this is advantageous as it retains its weather-proof properties.

[0061] Furthermore in the arrangement there is a gap between a substantial part of the PV panel 30, and the roofing panel 1, and so there is maintained the possibility of ambient air cooling of the PV panel 30.

[0062] As shown in Figure 7A an assembly comprising an array of adjacent panels 1, in this case four panels, are mated side-by-side. On each panel 1 are three PV panels so there is a 3x4 array of PV panels 30. This assembly forms a roof structure.

[0063] In order to secure the PV panel(s) in place upon a panel 1 any suitable securing means can be utilised as best seen from the enlarged partial view B of Figure 4. In the example a c-shaped bracket 40 is provided on side 36 of the PV panel 30. It can in turn be fixed to the panel 1, for example to a ridge 18 of the exterior sheet 3 using suitable fasteners such as one or more screws 43 which may be inserted through apertures 44 in a flange 45 thereof. When assembled, for example as shown in Figure 6 it then acts to hold the PV panel 30 in place and in particular in a position in which it is held in a position where it is inserted in the channel 14.

[0064] While it is not necessary to do so it may be desirable to provide a gasket or profile, such as the c-shaped profile 41 shown in Figures 3 to 6 though as best seen from the enlarged partial view A of Figure 4, for the side 35 of the PV panel 30 that is inserted in the channel 22. This may provide some protection from damage and/or better allow for variation in sizes of additional structures being inserted into channel 22.

[0065] Typically then roofing panels 1 would be laid in an overlapping array and fixed to a suitable roof structure. Then the additional structures such as energy panels would have one side inserted into the channel 22 and then the other side would be fixed to a roofing panel to retain it within the channel.

[0066] Figure 7B is an enlarged partial perspective view of the assembly formed between two adjacent panels where the assembly of the roofing panels is clearly shown with the panel 30 accommodated within channel 22. An additional screw 43 has been utilised to fasten the overlapping panels together through the ovelpa portion 10 into a ridge 12 of a neighbouring panel.

[0067] Figure 7C is an enlarged partial sectional view of the assembly formed between two adjacent panels also clearly showing the mating of adjacent panels 1.

[0068] As shown in Figure 5 and is desirable for all arrangements that the mating can first occur at an angle and allow movement in the direction in the Arrow D as a fitter is likely to insert an energy module from the raised position as shown in Figure 5 and then lower the energy module to the position shown in Figure 6.

[0069] 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.

[0070] 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.

S

Claims

Claims 1. A roofing panel for assembly in an array of roofing panels to form a roof structure, the roofing panel comprising a weather proof sheet having inner and outer sides and characterised in that the sheet has a sheet profile that comprises a raised ridge and with a channel formed in a side of the raised ridge, the channel acting as a part of a securing arrangement for securing a further structure on the outer side of the sheet.
2. A roofing panel according to claim 1 wherein the raised ridge is for overlapping with part of an adjacent panel, on assembly.
3. A roofing panel according to any preceding claim wherein the sheet has a corrugated profile with alternating ridges and grooves and the raised ridge is raised with respect to other ridges.
4. A roofing panel according to any preceding claim wherein the further structure is an energy module which is adapted to capture solar energy.
5. A roofing panel according to Claim 4 wherein a side of the energy panel is insertable into the channel as a part of a securing arrangement for securing the energy panel to the exterior of the roofing panel.
6. A roofing panel according to any preceding claim wherein the further structure is a photovoltaic panel.
7. A roofing panel according to Claim 6 wherein a side of the photovoltaic panel is insertable into the channel as a part of a securing arrangement for securing the photovoltaic panel to the exterior of the panel.
8. A roofing panel according to any preceding claim wherein the further structure is to be held in an arrangement where there is a gap between it and the sheet.
9. A roofing panel according to any preceding claim wherein the further structure is a photovoltaic panel which has on the underside thereof a downwardly projecting enclosure for components of the photovoltaic panel and wherein the sheet has defined therein a depression that corresponds to the position of the downwardly projecting enclosure avoids contact between the sheet and the downwardly projecting enclosure.
10. A roofing panel according to Claim 9 wherein the sheet is corrugated with alternating ridges and grooves and the depression is formed between corrugations and/or by utilising lower ridges.
11. A roofing panel according to any preceding claim where one or more additional fixtures are provided on an opposing side of the additional structure for securing a further structure to the exterior of the panel.
12. A roofing panel according to any preceding claim which is a manufactured composite insulating panel comprising:-an external weather-proof sheet having an outer face and an inner face; an internal sheet having an outer face and an inner face; an insulating body between the inner face of the external sheet and the inner face of the internal sheet, the external sheet having a portion that extends beyond the internal sheet and the insulating body to define an overlap part for overlapping with part of an adjacent panel, on assembly.
13. A method of attaching a further structure to a roof panel comprising the steps of providing a roofing panel as set out in any preceding claim; providing a further structure having a side; inserting the side of the further structure into the channel of the panel and using a securing means to secure the further structure to the panel.
14. A method according to Claim 13 wherein the securing means is provided on an opposite side of the further structure.
15. A roof comprising an array of roofing panels as claimed in any of claims 1 to 12 assembled to form a roof structure and optionally having one or more additional structures mounted thereon wherein at least one additional structure has a side which is inserted into a channel of a panel.