GB2548983A

GB2548983A - Solar panel mounting

Info

Publication number: GB2548983A
Application number: GB1703614.6A
Authority: GB
Inventors: Estill Ewen
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-03-25
Filing date: 2017-03-07
Publication date: 2017-10-04
Also published as: GB201703614D0; GB201812035D0; WO2017162433A1; GB2561326A; GB201605135D0

Abstract

A frame for mounting a panel 30, 31 of sheet material, such as a photovoltaic solar panel. The frame is made of elements of profiled edge section with a groove, slot or recess 28, 29 for receiving and edge of the panel. There is an inset profiled groove or channel at another outward edge for mutual mechanical interfit and sealing engagement with other framed panels or a flashing strip. There may be plural frame elements which may form a rectangular frame. The frame elements may have mitred corners which may be connected by corner joints. The edges of a plurality of panels may be attached to a plurality of flashing strips. The frame may be part of a PV solar panel installation for a roof, consisting of one or more solar panels, which may have flashing strips shared between peripheral panels. A top-down installation of a solar panel array upon an inclined surface is also disclosed, wherein the edges of the array all have flashing elements for connection with the mounting surface. A roof and a building containing the framed panels are also discussed.

Description

Solar Panel Mounting

This invention relates to panel framing and mounting and in particular photovoltaic (PV) solar panel mounting upon the roofs of buildings. Variants might also be used for mounting other thin plates than solar cells, including plain glass sheet, such as for a glazed roof. The term ‘panel’ is used herein to embrace these. The term frame embraces any panel edge carrier or support leaving the panel surface largely unobstructed. Peripheral boundary edge capture and support leaves the panel area free and unobstructed for optimised panel power output

The Applicant seeks a so-called 'roof integrated' solar PV frame and mounting installation using minimal parts and which could be assembled by automated robots on a production line and installed from the top of the roof to the bottom of the roof to increase speed and safety of installation; one that is fast and easy to install and does not require multiple clips and clamps; that can be sold to various different PV panel manufacturers enabling them to offer a roof integrated solution. Solar collectors might also be mounted.

In a known SOLRIF in-roof system panel frames for PV laminate modules are held by clamps to roof battens; with a shingled overlap from top to bottom and interlocking left to right; the installation sequence is from right to left and from bottom to top; clamps are fitted to battens first, spaced using a mounting gauge; reliance is placed upon silicone sealant, ridge and edge flashing, eaves side skirting and sealing tape. Expandable foam tape is used to seal from flashing to roof tiles overlaid in a next step; which serves as a 'just in case' final barrier to prevent any windblown rain getting under the tiles.

Overall, the Applicant's system (designated as the Solfit Top Lop loader system) is a roof integrated solar PV frame and flashing system that encapsulates solar PV laminates forming an integral watertight roof that sits flush with the surrounding roof covering, without the need for slates or tiles under the array. The subject framing system features interlocking aluminium extruded profiles that enable each panel to interconnect with other panels or the peripheral flashings that surround it, thus creating a more aesthetic, easy to install and durable in-roof solar PV solution.

The envisaged panel frame section itself is intricate of convoluted profile internally, to serve a combined mechanical interfit, location and support role between frames, along with weather sealing between frames; and frame to panel capture, bracing and sealing, without the need for costly and time-consuming additional sealing gaskets or mastic compound. The seal and inter-seal path is convoluted to counter water flow and through-draughts. Both a mechanical interfit and water seal are provided at peripheral bounding edge of a panel array and between panels, through (respective) bespoke co-operatively inter-fittting strip profile(s).

Preparatory additional installation tasks of local stripping of existing roof slates or tiles over a panel array area and subsequent fitment of edge sealing are offset and justified by easier (top down) panel installation direct upon tile battens or underpinning roof structure; and more aesthetic appearance.

For either retro-fit or new build, a distinguishing feature of the present invention is that it is, or can be, installed from the top down; which is easier and safer than from the bottom up of conventional known roof integrated PV panel systems. In particular, the peripheral edge and between panel framing and flashing profile is more readily fitted and installed and effective than hitherto. Bespoke profile(s) afford secure mechanical (panel frame) interfit and weather seal (edge flashing), yet are readily fitted without the need for additional mastic sealant.

Framing contributes somewhat to panel array mechanical rigidity and integrity. A weather resistant flashing profile inhibits panel flex, for a more permanent seal accommodating any roof load deflection; yet is compatible for conjoin and interface with existing roof slates or tiles. Existing slate or tile battens can be retained and utilised supplemented with additional battens for edge flashing mounting. Stacked or doubled-up depth battens can present mounted panels edges at a consistent level with the line of the original roof slates or tiles. A bespoke peripheral edge and between panel framing and flashing profile is more readily installed and fitted and effective than hitherto and affords secure mechanical (panel frame) interfit and weather seal (edge flashing), yet are readily fitted, without additional mastic sealant. Panel framing can contribute panel array mechanical rigidity and integrity; and a weather resistant flashing profile contributes support and to inhibit panel flex for a more permanent seal; yet is compatible for water barrier conjoin and interface with existing roof slates or tiles. Stacked underlying double tile battens present mounted panels at a consistent level with the original roof slates or tiles; and raise the panel by some 25mm, so there is no contact between a panel (or panel connection junction box) and existing slate or tile battens.

Prior Art

For ready installation and access, PV panels are commonly surface mounted as a superficial overlay upon an existing roof covering, such as slates or tiles, but as an additional surface layer can be visually dominant and intrusive as a marked departure from the former conventional roof appearance. For such surface mounting, rail mounting systems of extruded aluminium sections are known, to sit upon discrete roof anchors and clips, using spacer leg upstands with retaining clamps, which fit in a dog-leg profile under and between overlapping tile edges and are secured to underlying roof timbers. Panels themselves do not locate directly into the rails. An example is Renusol (Trade Mark) per web link <http://www.renusol.com/en/pv-mounting-solutions.htmb*. The rails and the distance from the roof makes the panels even more prominent and differentiated and unsightly.

In contrast, the present invention is concerned with so-called 'integrated roofing' systems, where the panels are inset or embedded and surface aligned with a roof tile or slate covering. Rails are not intended for so-called 'in roof' or 'integrated mounting' within a covering roof depth.

Individual panel framing for PV panels, with an outer edge profile for mutual interfit, is known from the SOLRIF (Trade Mark) product of Ernst Schweizer AG and the subject of EP1060520. An inner frame side edge profile has a recess or groove to receive and locate a panel edge between opposed side flanges. That system relies upon elaborate additional fitments.

The Applicant seeks a simpler and more cost-effective integrated (PV) panel mounting configuration; which will appeal to installers and so in turn to panel providers.

Statement of Invention A frame for mounting a panel of sheet material, such as a PV (photovoltaic) solar panel, comprises a plurality of conjoined individual frame elements of sectional profile for interfit with other panels, or bounding peripheral edge flashing. One frame section has a groove, slot or recess on one side edge to receive and locate a corresponding edge of an inserted panel; an inset upward or downward facing profiled groove, slot or channel at an opposite outward side edge; for co-operative such as drop-over or drop-in interfit and location of a complementary outboard edge of an overlaid or underlaid frame with a complementary edge profile, such as of another framed panel, or an edge sealing or flashing strip. Panel frame edges nestle mutually comfortably together for ease of installation without special clips or other fitments.

Panel mounting frames can be factory fitted by a panel manufacturer or retrospectively by an installer or other end user. Pre-cut lengths could be provided along with jointing pieces such as at corners.

An example edge profile interfit includes mutual orthogonal and inclined limbs with multiple local contact points, such as limb end abutments, and a convoluted gap or pathway between frame elements to inhibit water ingress and through passage. The abutment or contact point can form a weather resistant barrier or seal. An edge profile 'drop-in' or 'drop-over' snug nestling interfit can also serve as a set up reference bar, for initial installation of a panel in relation to a top flashing strip with a bottom edge profile. An extruded slender or thin-wall frame section is convenient for economic production of a complex profile in uniform profile long lengths of consistent form.

The panel mounting or framing system can be used to bound individual panels and collectively hold together a plurality of panels in a collective, co-operative coherent layout and array. Within a boundary, intervening frame elements form a grid or matrix, with pairs of frame elements from juxtaposed panels, to the side, above or below, in mutually supportive location. The frame elements overlap somewhat at their respective outer margins. The frame mounting is adaptable to a variety of rectangular or even polygonal panels. A panel with some edges pre-fitted with the mounting frame is ready for installation using the frame for fastening with only minimal fasteners. This for a panel level flush or even with a roof line. Panel surfaces are level in the same row and stepped or staggered between rows as with a roof tile edge overlay. Flashing is fitted at the overall peripheral bounding edges of a framed panel array. Panel frames are mounted upon battens and secured by screw fasteners; battens are set vertically and horizontally at spacings to suit panels. Panel frame outward sectional detail for edge interfit differs between left-hand, right-hand side, top and bottom. This edge asymmetry or 'handedness' helps in orientating panels for installation. The frame is separate from the panel, so not restricted to any particular panel type, supplier or manufacture. Panels are commonly produced without mounting provision. Rather, frame and panel are conjoined for mounting. A stiffer assembly results. A PV solar panel (mounting) frame elongate edge capture element has an inward continuous groove, slot, recess or throat to receive an inserted panel edge, such as of a PV solar panel. The inner and inward or panel facing slot walls have bounding contact noses to bear upon opposite panel sides. A snug, secure fit is achieved with the section edges in contact with and bearing upon opposite sides of the panel. Collectively, assembled frames provide a continuous reception and location channel for a panel around the entire inner frame periphery. A panel side frame outboard edge features a groove, channel or recess facing downward on one side and upward on the opposite side for 'drop-over' or 'drop-in' interfit respectively with underlaid or overlaid panel frames on those sides, or with a profiled edge flashing strip. A mutually staggered or offset panel disposition allows one panel to overly another at the respective top and bottom panel edges. Mutually inter-fitting edge capture elements can be inter-nested for edge-to-edge panel mounting in a common mounting plane, so adjoining panels can form an effectively continuous array.

In a particular configuration, outward edges of the frame elements present different profiles, respectively for upper, lower, right-hand or left-hand sides. A left-hand side profile has a downward facing outward edge slot with side stands, limbs or ledges to overlie a corresponding upward slot of a juxtaposed frame in the same row, but another column, of a panel array. A right-hand side profile has an upward facing outward edge slot with upstands to underlie a corresponding downward slot of a juxtaposed frame in the same row, but another column, of a panel array. An upper or top frame element has an outer nose edge for insertion in a slot in a juxtaposed lower frame element of a frame element in a row above or a top flashing strip. A lower or bottom frame element has an up-stand with an outward slot to receive a panel edge and an underlying slot to receive the upper edge of a panel in a lower row in a panel array or a bottom flashing strip. The outward slot sits below the inward panel groove, so an inserted frame also sits below the panel in the frame above to achieve a stepped or staggered relative panel disposition and transition between rows, as with a conventional tiled roof. A frame profile serves for mutual interfit to interconnect with complementary other frame profiles, to weather seal, not just between frame elements, but between frame and a mounted panel and between frame and peripheral flashing bearing upon an underlying or adjacent roof. Frame interfit also contributes to overall frame and panel alignment, stiffness, rigidity and a cohesive framed panel array. When fitted with a frame, each panel presents a similar frame profile to that of an adjacent framed panel at a boundary of an assembled panel array, although the upper, lower, right-hand and left-hand side profiles differ; for interaction with a tile edge line on the rest of the roof, either directly or through an intermediate flashing strip, whose profile is adapted to suit a vertical or horizontal orientation. A lower frame edge profile has a pronounced depending step flange alongside a deep recess or slot to receive an inserted upper frame edge of the next panel in a row below, after fastening to an underlying roof batten. The flange has a series of apertures for screw fasteners to secure to an underlying panel batten. A depending or overhanging flange or gutter on one frame element serves as a pelmet or gutter flange to sit alongside the top edge of an inset frame of an underlying framed panel. The gutter flange also sets the relative tile disposition, for a stepped transition between panels, with an upper or higher panel surmounting a lower edge underlying panel. The lower edge of a gutter itself can feature a lip or drip cill. A drip cill profile can also be incorporated on the upper face outward top edge. Edge profile features of the frame can be replicated in flashing strips for bounding the edges of an array. The flashing can be continuous along the individual array sides. A frame section serving as a jointing or transition element between juxtaposed otherwise abutting panels can incorporate a step or level change so inserted at one side cans site at an offset disposition from a panel inserted at the opposite side. Thus mounted panels can replicate the layered marginal edge overlap effect of overlapping roof slates or tiles, preserving visual uniformity and harmony. A corner transition between orthogonal frame elements around a panel can feature a pre-cut 45 degree corner edge mitre. For frame corner jointing, a demountable corner joint piece, with orthogonal limbs, each with an end tongue, locates in a recess, groove or channel, such as in a hollow closed cross-section, in respective juxtaposed frame elements. The ends of the tongues have a chamfered nose with undercuts to impart a resilient spring action for a snug or tight tolerance interfit. Corner joint pieces locate in frame grooves, slots or channels toward either the inside or outside faces of the frame section.

Venting of an under panel roof void between opposite top and bottom sides helps keep the ambient panel temperature down, to counter the risk of PV cell over-heating and damage to which it the semiconductor material is otherwise susceptible and vulnerable with deterioration in panel output performance. A silicone seal is used between panel and frame groove. The panel installation laying procedure is from right to left, and from bottom to top, with panels usually orientated in landscape mode. This is an advantage for an installer, who can work head up and facing a roof, rather than head down, unbalanced and risking tipping over and falling forward. For maintenance, repair or upgrade, the panels are locally demountable by temporarily disengaging the frame edge interfit, without dismantling or otherwise disturbing the overall panel array or the integrity, weather resistance or water-tightness of the roof.

Embodiments

There now follows a description of some particular embodiments of PV solar panel mounting frame, and frame array inter-couple, interfit and peripheral edge sealing system of the invention, for use with diverse individual panels, sheets, or glazing, by way of example only, with reference to the accompanying schematic and diagrammatic drawings of individual component elements, in which:

Figure 1 shows a sectional view of mutually inter-fitting or inter-nesting mounting frame profiles, for interposition between and to border around, individual panels and an array of side-by-side juxtaposed panels and to interfit with continuous peripheral sealing or flashing boundary frame strips (not shown) bordering each side of a panel array; effectively, left and right hand side edge frame profiles, such as shown in Figures 3A-3C are mutually inter-coupled for panel jointing in the same plane;

Figure 2 shows a sectional view of a stepped, staggered or offset profile mounting frame variant of Figure 1, in which opposite longitudinal side edges are mutually staggered or offset at different levels to present inserted panels in mutual marginal edge juxtaposition; this for a tiered or layered panel disposition, as with say a traditional roof slate or tile layout; a frame variant such as shown in Figure 6 allows marginal panel edge overlap;

Figures 3A through 6D show variants of the inter-fitting mounting frame elements of Figures 1 and 2; with different frame profiles at the opposite (horizontal) top and bottom edges and opposite (vertical or upright) right-hand and left-hand sides;

Figures 3A through 3D show a frame element for one (vertical or upright) left-hand side edge of a solar panel; More specifically: Figure 3A shows a plan view with a chamfered, bevelled or waisted sloping side face at an inward edge with a continuous slot or groove bounded by opposed flanges to receive an inserted PV solar panel (not shown); Figure 3B shows a three-quarter 3D view from a bottom left-hand end corner; Figure 3C shows a three-quarter 3D view from a top left-hand end corner; Figure 3D shows an end on left-hand edge view; a downward facing outer edge marginal slot with protruding upstands or limbs inter-fits with a corresponding upward facing slot also with upstands or limbs of the right hand frame element of another panel frame when assembled in a framed panel array;

The top end corner features a dog leg or inset between a 45 degree angle mitred inward face and the top end compared with the bottom end corner. The top end thus has a modest, in this case 5 mm step in which sits a frame top bar shown in Figures 4A through 4D. A corresponding feature of the right-hand frame bar of Figures 5A through 5D, is an upward open-faced outward edge of convoluted groove profile with upstands or limbs for interfit abutment and local sealing contact;

Figures 4A through 4D show another frame element from Figures 3A through 3D to service as a top frame bar, for a panel mounting frame assembly. More specifically: Figure 4A shows a plan view, with chamfered or bevelled downward edge to a reception groove or throat for a panel; Figure 4B shows a three-quarter 3D view from a bottom left-hand end corner; Figure 4C shows a three-quarter 3D view from a bottom right-hand end corner; Figure 4D shows a bottom edge end-on view of a longitudinal slot or groove to receive a panel; the top edge is closed as a nose to locate in a slot or groove in the underside of a bottom frame element of another frame, or in corresponding profiled flashing strips;

Figures 5A through 5D show yet another frame element from Figures 3A-D and 4A-D to serve as a right-hand side frame of a panel mounting frame assembly. More specifically, Figure 5A shows a plan view with a chamfered or bevelled inward edge to a side groove, slot or recess to receive and locate an inserted panel (not shown); Figure 5B shows a three-quarter 3D view from a bottom left-hand end corner; Figure 5C shows a three-quarter 3D view from a bottom right-hand end corner; Figure 5D shows a bottom edge end-on view; an outward edge margin has an upward facing slot of convoluted profile with upright and inclined upstands to interfit with a downward facing slot of a left hand frame element of another framed panel in an array;

Figures 6A through 6D show a further frame element from Figures 3A-D, 4A-D, 5A-D and which can serve as a frame bottom bar; it is similar to the stepped profile of Figure 2 with a pronounced upstand with a re-entrant outward turned throat to receive and locate a panel (not shown) to be mounted and an underlying generous slot to receive a closed profile nose edge of an upper frame element of another framed panel in an array; More specifically, Figure 6A shows a plan view with fastener mounting apertures in the bottom edge; Figure 6B shows a three-quarter 3D view from a bottom left-hand end corner; Figure 6C shows a three-quarter 3D view from a bottom right-hand end corner; Figure 6D shows a bottom edge end-on view;

Figures 7A through 7D show a set-out reference bar for framed panel installation and panel array layout, with an upper raised throat to locate an upper flashing strip and an underside throat to receive the upper edge of a top panel frame in an initial row; it is similar to the profile of the bottom bar of Figures 6A-D and its top edge can fit within a profiled upper flashing strip whilst is bottom edge can accommodate the nose of a top frame element of an underlying framed panel;

The set up bar has a series of three apertures to receive screw fasteners to secure the bar to a top batten and/or underlying roof timbers; more specifically, Figure 7A shows a fragmentary plan view of a set-out reference bar; Figure 7B shows a longitudinal side elevation of the bar of Figure 7A; Figure 7C shows a three-quarter 3D view of a right hand of the bar of Figures 7A through 7B; Figure 7D shows a three-quarter 3D view of a left hand of the bar of Figures 7A through 7C; overall the set out bar section is similar to the frame bottom bar profile of Figures 6A through 6D,

Figures 8A and 8B show an 'L'-shaped frame corner joint element for insertion in the open ends of juxtaposed abutting frame elements, such as top, bottom, right-hand and left-hand side frame elements.

More specifically, Figure 8A shows a plan view; Figure 8B shows a three-quarter 3D view;

Figure 9 shows a three quarter perspective view of an assembled panel and frame using the frame side elements of Figures 4A through 6D; the upward and downward facing edge slots respectively in right and left hand frame elements are apparent, as is the depending bottom flange and slot of a bottom frame element and the edge nose of the upper frame element;

Figures 10A through 10C show panel frame and peripheral flashing interaction, with an in-turned flashing edge interfit with an open face slot profile in a panel frame outward edge. More specifically: Figure 10A shows a sectional view of a right-hand side panel frame and side flashing with an upstand from a side flange against which roof tiles can overlaid and an overturned top edge to fit over and within the upward facing slot of a right hand panel frame edge; Figure 10B shows a sectional view of a left-hand side panel frame and side flashing with an upstand and turned back top edge for interfit with a downward facing slot in a left hand side of a panel frame; and Figure 10C shows a sectional view of a bottom panel frame and bottom flashing with a reverse turned top edge for reception in a slot in a base frame and a reverse in-turned lower edge bearing upon roof tiles; a rectangular framed panel shown, but other polygonal forms might be used; the panel detail, such as PV cell shape and layout can vary;

Figures 11 - 21 show a series of respective installation steps 11-21 for a framed panel installation sequence upon a pitched roof, from initial top flashing and set-up reference bar fitment for a first row of panels bounded at opposite ends by side flashing strips, followed through to laying of further rows with respective end flashing until a final row with bottom flashing. More specifically, Figure 11 shows top left-hand corner detail of panel frame, set-up reference bar and flashing; Figure 12 shows screw fastening of a bottom panel frame to an underlying roof batten; Figure 13 shows fastening of an upper row of juxtaposed panels with respective side edges inter-fitted; Figure 14 shows side flashing fitted at opposite ends of an upper row of panels;

Figure 15 shows a second row fitted and screw fastened, with respective top frame edges inter-fitted with bottom frame edges of an initial row; Figure 16 shows side flashing fitted to opposite ends of the second row; Figure 17 shows local enlargement detail of a bottom left hand corner with local overlap of side and bottom flashing; Figure 18 shows an assembled panel array; Figure 19 shows local enlargement detail of fitment of a bottom flashing element; Figure 20 shows local enlargement detail of overlap and screw fastening of an adjoining flashing strip; Figure 21 shows an array with bottom flashing fully installed; at this stage expandable foam tape can be laid over side flashing to interact with overlaid roof tiles; roof tiles can be continued from Figure 18;

Referring to the drawings:

Successive rows of (PV) solar panels are laid in marginal side and top and bottom outward edge mutual overlap or interfit; along with top, bottom, right-hand and left-hand side flashing seal with a tiled roof. Panels sit upon dedicated panel battens, in this case vertical and/or horizontal panel battens laid upon rows of horizontal panel battens. One outward side edge of a panel frame has an upturned or upward facing or orientated recess, slot or groove of convoluted profile. An opposite outward side edge of a panel frame at an opposite side had a downturned or downward facing recess, slot or groove of different convoluted profile. A bottom panel frame outward edge has an offset or dog-leg depending flange forming a deep recess for an upper downturned edge of a bottom flashing strip whose opposite end is turned back to form a seal lip overlay with a roof tile. A top panel outward edge has a closed nose profile for insertion in an outward edge slot of the bottom frame of a panel in a next higher row, or the bottom edge margin of a bottom flashing strip. With frame panels similarly orientated the peripheral edges of a frame panel array present correspondingly orientated continuous edge clots, whether upward, downward or inward facing.

Peripheral boundary edge flashing and sealing of multiple discrete profiled strip elements at the top, bottom, right-hand and left-hand sides is configured for interposition and interface between a PV (or other) panel array bounding edge and an adjacent tiled or other roof covering. Flashing strips have complementary profiled edges flashing to the respective frame edges for co-operative, underlay, overlay or interfit.

As reflected in Figures 10A-C, a side flashing strip on one (left-hand) side is profiled with an upstand and out-turned then reverse returned inward top lip for interfit with a downward facing recess in the outer edge of an edge overlaid left-hand frame element. An opposite (right-hand) side flashing also has an upstand and overlap top edge to locate in the upturned outer edge slot of a right-hand side frame element. A panel array can be vented from between opposite top and bottom ends. A lower flashing strip, with an in-turned depending flange at an upper inboard end sitting upon a vertical panel mounting batten (itself sitting upon underlying horizontal battens) and with venting provision at one outboard lower end, serving as a cold air inlet; the flashing being shaped to accommodate a panel frame edge element. The upper flashing strip also features a venting provision, serving as a warm air outlet; the flashing profile features a hood with an in-turned edge to receive a panel frame element and sitting upon a vertical panel mounting batten.

Additional venting might be provided in the panel frames themselves, or by fitting intermediate flashing or gullies with breathing apertures communication with flow passages under the panels between the vertical panel mounting battens. Vent action is by natural inflow, then diversion and re-circulation of prevailing wind upon the panel surfaces.

Panel mounting frame sections are conveniently metal, specifically aluminium or aluminium alloy, bespoke linear extrusions from dies which allow complexity in form. Frames can be generic to suit a diversity of panel formats or adapted for a particular frame style. The elaborate convoluted frame section of Figures 1 through 7 helps preserve stiffness and rigidity, whilst reducing weight through a hollow core, open-sided channels and gullies, as a weather barrier to inhibit rain water ingress and to provide a drain away path internally and externally for rainwater and internal condensation. Each left or right hand and top or bottom frame side of a panel mounting frame has its own particular profile. The corners are mitred from an outboard edge to an inboard panel reception and location channel, groove or throat. Panel location and retention is by a mechanical interference fit with a respective juxtaposed frame, along with an optional silicone seal bonding agent and securing opposed frame elements to an underlying mounting batten. The panel and fitted frame follow the roof pitch when installed, so the side frame edge channels serve as drainage gutters for any incident rainwater which may find its way through overlapping or inter-fitting frame edge slot profiles. These include limbs orthogonal to a fitted panel and limbs parallel to it along with inclined limbs. It is convenient to have a simple panel overlay installation which is weather resistant without overly tight panel fit.

Figure 1 shows a sectional view of mutually inter-fitting or inter-nesting frame profiles 15,16 each with an outer or out-turned edge with a continuous groove, slot or throat 18 to receive a panel edge 19. The mouth of each groove has a modest inward lip 27 to promote local sealing contact and to secure the panel. The respective inward or in-turned edges of the frames 15,16 have different, but complementary, inter-fitting profiles, so an internal ledge 23 on one frame 15 sits upon an upturned lip 24 on the other frame 16. This allows one frame 16 to overlay another frame 15 at the frame margins. Inset from the respective panel grooves 18 each frame has a hollow void 21 with opposed internal stiffener ribs 22. Figure 2 shows variant inter-nesting frame profiles 25, 26 with the entirety of one frame 25 being received within an underlying step recess 27 of the other frame 26. Again each frame has an outward or out-turned edge with a groove or recess 28, 29 to receive and locate a respective panel 30, 31. The frame 26 is depicted mounted upon an underlying vertical batten 41.

Collectively, the interfit of frames 25, 26 achieves a stepped, tiered, staggered or layered panel 30, 31 disposition as with marginally depending edge overlapping roof tiles. The inter-nest of frames 25, 26 also provide a weather-resistant interconnection. The panel mounting is configured for ease of installation with either a new roof construction, or a retro-fit or conversion of an existing roof to a solar array. Dedicated frame mounting battens are employed at spacings to suit a panel array and independent of tile battens. Both horizontal and overlaid vertical panel battens are used.

The frame section itself is intricate to serve a combined mechanical interfit, location and support role between frames, along with weather sealing between frames, and frame to panel capture, bracing and sealing, without the need for costly, messy and time-consuming elaborate additional sealing gaskets or mastic compound at every joint or interface. The seal and inter-seal path is convoluted to counter water flow and through-draughts from prevailing wind. Some inherent resilience in the flashing material can be used to a snap action fit with the panel frame edge profile.

The hollow frame sections could also serve as a convenient conduit for panel electrical wiring, such as to PV cells of a panel. The panel mounting frame hollow section with internal ribs contributes to overall stiffness and rigidity without undue weight penalty. The sectional detail admits of some variation consistent with this, along with a panel fitment and sealing. In practice, the frame sections are pre-fitted to respective panels to achieve a (pre-)framed panel ready for installation on site. The frames also provide some panel protection, bracing and support in production, storage and transit to site. Frames are also convenient for handling, such as manually or with robotic arms and grips. A certain amount of tolerance for panel bending, flex or twist, can be accommodated within the frame assembly, such as in the corner joint. This can be useful in panel installation and removal, such as by twisting or wriggling in situ. It can also help absorb operational loading such as incident wind. A so-called 'integrated' PV solar panel array for Ίη-roof mounting, is of panels closely aligned to a consistent level, with one another in stepped rows, and the remainder of a roof covering, such as tiles. A tailored mounting frame 15, 16 is provided for each individual panel 19 and is configured for interconnection with corresponding other panel frames in a collective and co-operatively, mechanically and electrically, interconnected rectangular assembly as a rectangular grid or matrix array. Panels 19 are juxtaposed in mutual edge-to-edge abutment, in sealing interfit, by overlapping abutment, without need for intervening weather sealing gaskets or mastic. The frames 15, 16 or frame mounted panels can be handled and manipulated for assembly in an automated factory build. For maintenance and repair, panels are removable and replaceable by disengaging their respective frames.

Panel frame sides are pre-cut to size, with pre-mitred ends for corner abutment, ready for factory assembly, such as with robotic handling arms. Similarly, flashing strips pre-cut to suit an array of panels, for installation on site. A snug sealing interfit between frames reduces or even obviates the need for gasket seals or mastic sealant, except optionally at the panel array and roof margin interface. A silicone sealant can also be applied between panel edges and frames. Right-angled arm corner joint pieces shown in Figures 9A through 9D with resilient noses are inserted into frame section open ends to secure the frame elements together. In a panel array, mutual panel frame location is by insertion along a longitudinal side edge and overlay upon an opposite side edge.

For panel array mounting and support, a grid of horizontal and vertical panel mounting battens is set out over a desired panel area and secured to roof timbers by screw fasteners through a barrier membrane. An upper flashing strip is fitted at the top boundary with other roof covering, such as roof tiles, using a horizontal set-out or reference bar of Figures 7A-D, whose upper end locates the flashing lower underside edge profile and whose lower side has a deep throat to locate the upper frame edge of an initial panel in a top row of a panel array. Pre-framed panels are laid, one at a time, in turn in rows, with marginal overlap between abutting juxtaposed side edges of adjoining panels. An initial upper row of panels in an array is inserted snugly into the downward throat of the reference bar or a series of end conjoined reference bars. A frame is optionally secured locally to an underlying panel mounting batten. A next underlying row can then be laid by respective upper and lower panel frame end edge overlap. The panel frame edges mutually interfit in an intervening weather-tight or resistant seal by the co-operative inter-nest of respective convoluted profiles of ridges and slots or recesses. These also serve as back-up drainage channels or gullies for any water ingress along paths generally downward along the plane of the roof pitch. A bottom collection gully, such as a profiled flashing strip (not shown), can be used as an outward drain for discharge of accumulated water from the roof. The snug interfit between framed panels is similar to that between panels and peripheral edge flashing. This helps preserve the overall mechanical integrity of the panel array, pending permanent fastening between panel frame or flashing and underlying mounting battens and in turn roof timbers such as rafters. Sufficient tolerance or slack is retained for ease of frame interconnection, by simple drop-over action, whist preserving a weather resistant interface. Horizontal or transverse panel battens could be regular tile battens, with additional battens at the margins and overlaid vertical battens spaced to suit the panels and frames.

Overall, the panel frame open edge profiles allow a straightforward mutual edge 'drop-over' or 'drop-in' panel laying action and sequence, with tolerance for some modest lateral shuffle to 'settle' the edge interfit, yet with a secure interfit once installed, along with a simple through fastening to an under batten. The framing for a panel array from top to bottom requires only some three screw fasteners in the set-up reference bar, and similarly for a panel bottom frame. This without awkward multiple fiddly hooks and clamps of the bottom to top SOLRIF system, so is more readily and rapidly fitted. Panels are captive within peripheral boundary flashing strips and the set up bar. Panels are screw fastened through apertures in a bottom frame bar into an underlying panel batten. An adjoining panel edge fits in a slot in a bar upstand, repeated as a tiered column of mutually staggered or edge offset panels. Panel top and bottom frame edges are tucked into one another; whereas side opposite side edges are overlaid, so depending ribs on one side frame fit into corresponding slots or grooves on another side frame. The outer margin of a top frame member is a nose element to abut the upstanding inner wall of the slot in the upstand of the bottom frame member, or a corresponding profile in a bottom edge of a set out bar, also with fastener apertures. This offers advantages to panel manufacturer or assembler and installer through a more readily implemented installation.

For installation, an upper flashing strip and reference set-up bar helps set the panel array alignment from the outset; which is continued consistently by the interaction of panel frame sides. Side flashing is fitted incrementally as each row is laid, culminating with bottom flashing. Each panel bottom frame in a row is secured by screw fasteners to an underlying batten, along with flashing strip, until the panel array is held captive within boundary flashing. The frames are conveniently pre-drilled with apertures for fasteners which also serve as a jig for pilot hole drilling, with say two or three fastening points per bottom frame.

The 'set out bar' serves as a (bottom) reference for a first (uppermost) laid row of panels; and is of an equivalent section to the frame bottom bar. It is the same as the bottom profile, but it holds the top flashing (where the glass normally goes) and it holds in place the top profile of the first row of panels. Flashings are set out in the order, of top flashing, top left, top right flashing, side left side flashing, side right side flashing, bottom flashing. Right angled limb corner joint pieces hold the frame elements held together; with tight interference and/or bonded fit. The panel can be bonded to the frame with a silicone product. The inclination angle or roof pitch can be varied to suit the location and the mounting situation.

Another aspect of the invention provides a method of installing a solar panel upon an inclined mounting surface, such as a roof, comprising the steps of fitting a peripheral frame to the panel, as a series of edge bounding recessed or slotted strip elements along each panel side edge; fitting a top flashing element of target width or span to the mounting surface; inserting an upper edge of the framed panel into the top flashing at one end; continuing across the flashing with additional framed panels, as a contiguous row to a target width or span; fitting an underlying row of framed panels, by inserting respective panel upper edges into lower edges of corresponding overlying panels; continuing across the underlying row to a target width or span; repeating the panel laying in successive rows to a target depth or height; fitting a bottom edge flashing to the mounting surface beneath edges of the last and lowest row of panels; fitting side flashing on the mounting surface to the respective side edges of the panel rows.

An array of framed panels is set within bounding edge flashing laid by the above method. A panel array is inset within a surrounding array of roof slates or tiles as an integrated assembly with a common roof surface. A building with a roof of integrated panels and slates or tiles as above serves has a combination roof.

Component List 15 panel frame 16 panel frame 18 groove / slot 19 panel 21 void 22 rib 23 rib 24 ledge 25 panel frame 26 panel frame 27 lip 28 groove / slot 29 groove / slot 30 panel 31 panel 32 groove / slot 34 corner joint 35 arm / limb 36 nose 41 panel batten

Claims

Claims 1. A frame for mounting a panel (19, 30) of sheet material, such as a photovoltaic (PV) solar panel, comprising a frame element (15, 16) of profiled opposite upstand edge section, with a groove, slot or recess (28, 29) on one side edge, to receive and locate a corresponding edge of an inserted sheet or panel, an inset profiled groove or channel at another outward edge, for co-operative drop-in or drop-over interfit and location of a complementary outboard edge of an overlaid or underlaid frame with a complementary edge, of another framed panel, or an edge sealing or flashing strip for mutual location, support and sealing.
2. A frame of Claim 1 comprising a plurality of frame elements collectively disposed to serve as a peripheral panel boundary frame, with a frame element for each side of a panel to be mounted and a mitred corner interface between abutting frame ends at each frame junction.
3. A frame of either preceding claim with a frame element for each side of a panel to be mounted and a corner joint connector element between abutting frame ends at each frame junction.
4. A frame of any preceding claim configured as a rectangular mounting frame for a rectangular panel, the frame comprising four sides in two opposite pairs, each with an inboard recess slot or groove, in which a corresponding panel edge is received, located and secured within the closed frame periphery
5. A frame of any preceding claim comprising a frame element configured for interfit at one side edge, with a discrete flashing or sealing strip, having an edge of complementary profile to a frame edge.
6. A panel array of framed panels with frame elements of any preceding claim, in which juxtaposed panels are interconnected by respective adjoining frame elements.
7. A panel array of framed panels with frame elements of any preceding claim, in which juxtaposed panels are interconnected by respective adjoining frame elements and a peripheral edge of a plurality of panels is conjoined by a plurality of flashing strip elements.
8. A PV solar panel installation for a roof configured for incorporation in, or integration with, the roof incorporating a frame of any preceding claim, about the periphery of one or more solar panels, with a respective mounting frame around each panel periphery, and frame edge profile co-operative interfit with a juxtaposed panel edge.
9. A PV solar panel assembly of conjoined co-operatively edge inter-fitting panel frames of any preceding claim, with flashing strips shared between panels around the periphery of the assembly, as a boundary interface with a mounting support.
10. A roof or roof covering, such as slates or tiles, fitted with a framed solar panel array of any preceding claim, mounted upon a plurality of respective mounting battens, and inset with a panel surface generally consistent with the roof covering, with flashing strips inter-fitted at the panel tile edge interfaces.
11. A method of installing a solar panel upon an inclined mounting surface, such as a roof, comprising the steps of: fitting a peripheral frame to the panel, as a series of edge bounding recessed or slotted strip elements along each panel side edge; fitting a top flashing element of target width or span to the mounting surface, inserting an upper edge of the framed panel into the top flashing at one end, continuing across the flashing with additional framed panels, as a contiguous row to a target width or span, fitting an underlying row of framed panels, by inserting respective panel upper edges into lower edges of corresponding overlying panels, continuing across the underlying row to a target width or span, repeating the panel laying in successive rows to a target depth or height, fitting a bottom edge flashing to the mounting surface beneath edges of the last and lowest row of panels, fitting side flashing on the mounting surface to the respective side edges of the panel rows.
12. An array of framed panels set within bounding edge flashing laid by the method of Claim 11.
13. A panel array of Claim 12 inset within a surrounding array of roof slates or tiles as an integrated assembly with a common surface.
14. A building with a roof of integrated panels and slates or tiles of Claims 12 or 13.