WO2024086890A1 - A solar roof tile - Google Patents

A solar roof tile Download PDF

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Publication number
WO2024086890A1
WO2024086890A1 PCT/AU2023/051075 AU2023051075W WO2024086890A1 WO 2024086890 A1 WO2024086890 A1 WO 2024086890A1 AU 2023051075 W AU2023051075 W AU 2023051075W WO 2024086890 A1 WO2024086890 A1 WO 2024086890A1
Authority
WO
WIPO (PCT)
Prior art keywords
frame
roof tile
solar
interlock
tile
Prior art date
Application number
PCT/AU2023/051075
Other languages
French (fr)
Inventor
Peter Leeson
Pierre Nicolas
Matthew LEESON
Original Assignee
Volt Solar Tile Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2022903164A external-priority patent/AU2022903164A0/en
Application filed by Volt Solar Tile Pty Ltd filed Critical Volt Solar Tile Pty Ltd
Publication of WO2024086890A1 publication Critical patent/WO2024086890A1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H02S20/25—Roof tile elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/02—Grooved or vaulted roofing elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S30/00—Structural details of PV modules other than those related to light conversion
    • H02S30/10—Frame structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/36—Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • E04D2001/308—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles for special purposes not otherwise provided for, e.g. turfing tiles, step tiles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]

Definitions

  • the disclosure herein generally relates to a solar roof tile.
  • the disclosure relates particularly, although by no means exclusively, to a frame for supporting a photovoltaic sheet to form a solar roof tile.
  • the disclosure also relates to a method of installing solar roof tiles on a roof.
  • Solar energy is the most abundant renewable energy source and has led to the development of solar panels which have been used to generate electricity for a range of industrial and domestic applications including heating and cooling.
  • solar tiles have a number of deficiencies. Firstly, solar tiles are not as efficient as solar panels. For example, solar panels can be mounted to a moveable support or frame to allow the panels to be tilted to maximise sun exposure throughout the day. This is not possible with solar tiles.
  • solar tiles are generally more expensive than solar panels because of their smaller surface area. As such, more solar tiles are required to produce the same electricity output as would be achieved using conventional solar panels. In addition, solar tiles frequently require specialist installers, equipment, and mounting arrangements. For this reason, it is also more expensive to install solar tiles than solar panels.
  • solar tiles may reduce the resistance of the roof to weather elements, particularly resistance to water ingress into the roof cavity, and lifting of tiles due to highspeed winds thanks to their different mechanical properties.
  • the present invention seeks to ameliorate one or more of the above disadvantages.
  • a frame for a solar roof tile the frame being configured to support a photovoltaic sheet to form the solar roof tile, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
  • a key feature of the present invention is an interlock that is configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form a network of interconnected tiles when mounted on a roof.
  • photovoltaic sheet encompasses any substrate that contains photovoltaic cells which convert solar radiation into electricity.
  • frame refers to a structure that is mechanically strong to support the photovoltaic sheet.
  • a water-resistant seal may be formed between a pair of connected tiles when the interlock of a frame is engaged with another interlock on the adjacent alike frame.
  • a water-proof seal is formed between a pair of connected tiles when the interlock of a frame is engaged with another interlock on the adjacent alike frame. This may reduce or prevent water ingress under the roof tiles.
  • the interlock may comprise a male or female element that is co-operable with a corresponding male or female element on an alike frame to connect the frames.
  • the co-operative elements may be an integral part of the frame.
  • the male element may be a projection and the female element may be a recess, wherein the projection is received within the recess.
  • the interlock may comprise a flange that is configured to engage a flange of an adjacent alike frame or roof tile.
  • the flange extends along the horizontal dimension of the frame.
  • the interlock may allow the tiles to engage in a non-permanent manner.
  • the flange may form a groove for receiving the flange of an adjacent alike frame or roof tile.
  • the flange may be L-shaped, U-shaped, Z-shaped, S-shaped, T-shaped, or V-shaped.
  • the interlock may be located along a side of the frame.
  • a frame comprises an interlock along a length-wise side of the frame. More suitably, a frame comprises an interlock along a length- wise side of the frame and another interlock along a width-wise side of the frame.
  • the interlock may be positioned to engage an interlock on an adjacent alike frame or non-solar roof tile when the tiles are in a side-by-side arrangement on a roof.
  • the interlock may be positioned to engage an interlock on an adjacent alike frame or non-solar roof tile when the tiles are in a top-to-bottom arrangement on a roof.
  • the interlock may provide a guide to align the solar tile with an adjacent solar tile or roof tile.
  • the interlock is shaped to permit unidirectional connection with an alike interlock of an adjacent solar tile or roof tile. More suitably, the engaged interlocks are immobile. This minimises the risk of the tiles being misaligned during installation.
  • the frame may further comprise a mounting arrangement for mounting the frame to a roof batten.
  • the mounting arrangement comprises a bracket configured to engage the roof batten.
  • bracket encompasses a protruding lip, flange, lug or shelf that includes a mounting face to enable the frame to rest on the batten.
  • the mounting face may include an opening to receive a fastener or a groove or notch to guide a fastener through the mounting face to secure the frame to the roof batten.
  • the mounting arrangement may comprise at least one mounting face configured to abut a surface of the roof batten to align the frame with the roof batten.
  • the mounting arrangement may comprise a first and second mounting faces that abut respective top and side surfaces of a roof batten to allow the frame to rest on the roof batten.
  • the mounting arrangement may comprise a third mounting face that abuts an opposing side surface of the roof batten.
  • the mounting faces may be orthogonal to each other.
  • the bracket may have an opening that is configured to receive a fastener to secure the frame to the roof batten.
  • the opening may be a circular opening, i.e., a hole, a non-circular opening, i.e., a slot or an indentation or incision on an edge of the bracket, i.e., a notch.
  • the frame may comprise a plurality of frame members that are connectable to form the frame.
  • the frame may comprise a plurality of frame members.
  • the frame extends partially or entirely around a perimeter of a photovoltaic sheet.
  • the frame may comprise a first frame member and a second frame member that are connectable to form the frame.
  • the first and second frame members may comprise L-shaped components that form a rectilinear frame when connected.
  • frame member is understood to mean a part or section of a frame.
  • the frame may comprise a pair of length- wise frame members and a pair of width-wise frame members that are connectable to form the frame.
  • the length-wise and width-wise frame members may be of equal length.
  • the pair of length-wise frame members may have different stiffness.
  • An end of one length- wise frame member may flex up to 20 mm, suitably 15-20 mm with respect to another end of the same length-wise frame member.
  • the top frame may be stiffer than the bottom frame so that the bottom frame preferentially flexes and interlocks into the upper frame of an alike solar tile when connecting the solar tiles in a top-to- bottom arrangement.
  • the difference in flexibility of the frame members may provide a conformant fit of the interconnected tiles on a roof and is particularly beneficial for installing the tiles on an uneven or undulating roof. This may also aid the formation of a water resistant seal between the interconnected tiles.
  • the frame may include a gutter for channelling water therethrough.
  • the gutter may be a channel that extends along the length of at least one of the frame members, suitably a channel located on either on the top or bottom frame member.
  • the gutter may be a channel on either the top or bottom frame member that is in fluid communication with another channel on one of the side frame members.
  • the gutter is a channel that extends from the top or bottom frame member to one of the side frame members
  • the channel forming the gutter may be an open channel.
  • the frame may comprise a first frame member and a second frame member that are connectable to form a cavity for receiving a photovoltaic sheet.
  • the first and second frame members may comprise L-shaped components that form a rectilinear frame when connected.
  • the first frame member may comprise a cover piece for covering an opening of an enclosed channel on the first frame member.
  • a portion of the second frame member may cover an opening of an enclosed channel on the first frame member when the first and second frame members are connected.
  • the frame members may be connected using a fastener to form the frame.
  • the fastener may be any known fastener in the art.
  • the fastener may be configured to frictionally engage with and form a connection between the first and second frame members.
  • the fastener may be a clip or a cleat, particularly a corner cleat.
  • the frame members may be formed by extrusion.
  • the extruded frame members may be made from metals such as aluminium, steel, or titanium, or polymers such as polyvinylchloride (PVC).
  • PVC polyvinylchloride
  • the frame may comprise a tray for supporting a cable therein.
  • the cable may be in electrical communication with the photovoltaic sheet.
  • the cable is used to electrically connect the photovoltaic sheet to a solar or photovoltaic inverter or an appropriate electrical sink such as a building lighting system.
  • the tray may be located behind the photovoltaic sheet.
  • the tray may be integrally formed with the frame.
  • the tray may be removably attached to the frame.
  • the tray may be removably attached to the frame via a co-operative arrangement such as a tongue and groove arrangement.
  • the tray may be configured to connect to an alike tray in a modular arrangement.
  • the tray may be configured to connect to an alike tray in a modular arrangement via a tongue and groove arrangement.
  • the tray may be configured to be installed on an assembled solar tile.
  • the frame may be configured to be electrically earthed.
  • the earthing may be achieved by connecting an electrically conductive element to the frame.
  • the electrically conductive element engages at least one frame member and tray when installed.
  • Suitable electrically conductive elements include an earthing bolt or a wire.
  • the electrically conductive element is a separate sub-assembly that is connectable to the frame.
  • a solar roof tile comprising a photovoltaic sheet supported by the previously mentioned frame.
  • the photovoltaic sheet is secured within a cavity of the frame.
  • the solar roof tile may comprise: a frame and a photovoltaic sheet supported by the frame, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
  • the frame may comprise a plurality of frame members.
  • the frame extends partially or entirely around a perimeter of the photovoltaic sheet.
  • the frame may be anodised to improve aesthetics, or corrosion resistance.
  • the frame may be electrically earthed by attaching an electrically conductive element to the frame.
  • the electrically conductive element is an earthing bolt or a wire, more suitably an insulated wire.
  • the disclosure also provides a method of installing solar roof tiles on a roof, each solar roof tile comprising a frame supporting a photovoltaic sheet and having an interlock for engaging an interlock on an adjacent alike frame or a roof tile the method comprising: arranging a first solar roof tile with a second solar roof tile or non-solar roof tile on a roof of a building wherein the interlock of the first solar roof tile engages the interlock of the second solar roof tile or non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
  • the method may include mounting the first solar roof tile onto a roof batten on the roof.
  • the step of mounting the first solar roof tile onto the roof batten may comprise aligning a bracket of the solar roof tile onto the roof batten.
  • the step of mounting the first solar roof tile to a roof batten on the roof may comprise abutting a mounting surface of the bracket to the roof batten.
  • the method may include securing the first solar roof tile to the roof batten on the roof.
  • the step of securing the first solar roof tile to the roof batten may comprise drilling an opening into the bracket.
  • the step of securing the first solar roof tile to the roof batten may comprise inserting a fastener into the opening in the bracket.
  • the step of securing the first solar roof tile to the roof batten may comprise driving a fastener into the bracket.
  • the method may include positioning a second solar roof tile or non-solar roof tile in a side-by-side arrangement with the first solar roof tile to interlock the two tiles together.
  • the method may include positioning the second solar roof tile or non-solar roof tile in a top-to- bottom arrangement with the first solar roof tile to interlock the two tiles together.
  • the method may include securing the second solar roof tile to the roof batten.
  • the step of securing the second solar roof tile to the roof batten includes driving a fastener into a bracket of the second solar roof tile.
  • the step of securing the second solar roof tile to the roof batten comprises inserting a fastener into an opening in the bracket.
  • the step of securing the second solar roof tile to the roof batten comprises driving a fastener into the bracket.
  • the method may include a step of electrically earthing the frame. This step may involve connecting an electrically conductive element to the frame.
  • the step of connecting an electrically conductive element to the frame may include installing a conductive fastener, such as a metal screw or bolt, to the frame.
  • a conductive fastener such as a metal screw or bolt
  • connecting an electrically conductive element to the frame involves engaging the electrically conductive element to at least one frame member and tray.
  • the electrically conductive element may be a wire.
  • An embodiment of the invention may be interchangeable with one or more non-solar roof tiles, but not necessarily all embodiments.
  • Figure 1 shows a top isometric view of an embodiment of a solar roof tile according to an embodiment of the present invention.
  • Figure 2 shows a bottom isometric view of the solar roof tile of Figure 1.
  • Figure 3 shows an exploded top isometric view of the solar roof tile of Figure 1.
  • Figure 4 shows an exploded rear isometric view of the solar roof tile of Figure 1.
  • Figure 5 shows a top view of the solar roof tile of Figure 1.
  • Figure 6 shows a bottom view of the solar roof tile of Figure 1.
  • Figure 7 shows a side view of the solar roof tile of Figure 1.
  • Figure 8 shows a magnification of a groove on the flange for contacting a roof batten from Figure 7.
  • Figure 9 shows an isometric view of a cleat of the solar roof tile of Figure 1.
  • Figure 10 shows an isometric view of a left end of a top frame member of the solar roof tile of Figure 1.
  • Figure 11 an isometric view of an opposing right end of the top frame member of the solar roof tile of Figure 1.
  • Figure 12 shows a section view of the top frame member of the solar roof tile of Figure 1.
  • Figure 13 shows a plan view of the left end of the top frame member of the solar roof tile of Figure 1.
  • Figure 14 shows an isometric view of the left end of the top frame member of the solar roof tile of Figure 1.
  • Figure 15 shows a side view of the solar roof tile of Figure 1 interlocked with an alike solar roof tile.
  • Figure 16 shows a plan view of an end of the top frame member of the solar roof tile of Figure 1.
  • Figure 17 shows a section view of the right side frame member of the solar roof tile of Figure 1.
  • Figure 18 shows a plan view of a side frame member of Figure 1.
  • Figure 19 shows a magnified top view of the end of the side frame member of Figure 18.
  • Figure 20 shows a front view of the end of the side frame member of the solar roof tile of Figure 18.
  • Figure 21 shows an isometric view of the end of the side frame member of the solar roof tile of Figure 18.
  • Figure 22 shows a plan view of a tray of the solar roof tile of Figure 1.
  • Figure 23 shows a section view of the tray of Figure 22.
  • Figure 24A shows a section view of the top frame member and tray.
  • Figure 24B shows an earthing element inserted into a cavity between the top frame member and tray of Figure 24A.
  • Figure 25 shows a top view of an embodiment of a solar roof tile according to another embodiment of the present invention.
  • Figure 26 shows an exploded top view of the solar roof tile of Figure 25.
  • Figure 27 shows a section view of the top frame member of another embodiment of a solar roof tile according to the present invention.
  • Figure 28 shows a plan view of a top frame member of Figure 27.
  • Figure 29 shows a plan view of the left end of the top frame member of the solar roof tile of Figure 27.
  • Figure 30 shows an isometric view of the left end of the top frame member of the solar roof tile of Figure 27.
  • Figure 31 shows a plan view of an end of the top frame member of the solar roof tile of Figure 27.
  • Figure 32 shows a section view of the right side frame member of the solar roof tile of Figure 26.
  • Figure 33 shows a plan view of a side frame member of Figure 26.
  • Figure 34 shows a magnified top view of the end of the side frame member of Figure 33.
  • Figure 35 shows an isometric view of the end of the side frame member of Figure 33.
  • Figure 36 shows a plan view of an end of the top frame member of Figure 27.
  • Figure 37 shows a section view of the left side frame member of Figure 26.
  • Figure 38 shows a plan view of a side frame member of Figure 26.
  • Figure 39 shows a magnified top view of the end of the side frame member of Figure 38.
  • Figure 40 shows a side view of the side frame member of Figure 39.
  • Figure 41 shows an isometric view of the side frame member of Figure 40.
  • Figure 42 shows a magnified top view of an end of the side frame member of Figure 38.
  • Figure 43 shows an isometric view of an end of the side frame member of Figure 38.
  • Figure 44 shows a section view of the bottom frame member of Figure 27.
  • Figure 45 shows a plan view of the left end of the bottom frame member of Figure 26.
  • Figure 46 shows a plan view of the bottom frame member of Figure 26.
  • Figure 47 shows a plan view of the right end of the bottom frame member of Figure 26.
  • Figure 48 shows a side view of the bottom frame member of Figure 46.
  • Figure 49 shows an isometric view of the bottom frame member of Figure 47.
  • Figure 50 shows an isometric view of a cleat of the solar roof tile of Figure 26.
  • Figure 51 shows an isometric view of a secondary cleat of the solar roof tile of Figure 26.
  • Figure 52 shows a section view of a cover of the top frame member.
  • Figure 53 shows a front view of the cover of Figure 52.
  • Figure 54 shows a side view of a pair of solar roof tiles mounted on a roof batten.
  • Figure 55 shows a cross-sectional view of a pair of connected solar roof tiles showing solar shading for a non-interlocked solar tile.
  • Figure 56 is a perspective side view of an array of solar and non-solar roof tiles mounted on a roof.
  • Figure 57 is a side view of a non-solar tile engaging a solar roof tile in a top-to-bottom arrangement.
  • Figure 58 shows an electrical earthing wire connected to the tray of a solar roof tile.
  • FIGS 1 to 8 show various views respectively of an embodiment of a solar roof tile, which is generally indicated by reference numeral 10.
  • the solar roof tile 10 is configured to engage an alike solar roof tile and a non-solar roof tile for example in the form of the PLANUMTM roof tiles manufactured by La EscandellaTM.
  • the solar roof tile 10 is generally rectangular and comprises a peripheral frame 12 forming a central cavity in which a photovoltaic sheet 14 is mounted therein.
  • the peripheral frame 12 comprises a plurality of frame members 16, 18, 20, and 22 that are generally straight and elongated, including length- wise frame members 16, 18 that are parallel and on opposite sides of the photovoltaic sheet 14, and width-wise frame members 20,22 that are parallel and perpendicular to the length-wise frame members 16, 18.
  • the plurality of frame members 16, 18, 20, and 22 are formed from extruded aluminium.
  • Figure 9 shows an isometric view of a fastener in the form of an extruded aluminium corner cleat 40 for attaching adjacent peripheral frame members 16, 18, 20, and 22, and would be hidden within the assembled frame 12.
  • Alternative fasteners such as rivets, welds, nails, crimps or stamped bosses are also suitable to connect the frame members.
  • top length-wise frame member 16 comprises a gutter 27.
  • top length-wise frame member 16 comprises an upper interlock 28 in the form of an upwardly projecting L-flange defining an outwardly (rear) facing cavity or groove 29 for engaging a lower interlock 30 visible in Figures 7, 48, 54 and 55 in the form of another downwardly projecting L-flange of the bottom length-wise frame member 18.
  • the interlocks 28, 30 are on the opposite top and bottom sides of the solar tile 10.
  • the upper flange 28 and lower flange 30 are oppositely orientated.
  • FIGs 15, 54, and 55 show the interlock 28 of one solar roof tile engaging the interlock 30 of another solar tile, to connect adjacent solar tiles 10.
  • the bottom solar roof tile 10 supports the upper roof tile 10 via the interlock.
  • the overlapping engagement of the interlocks afford a water-resistant seal between the connected tiles.
  • An array of solar tiles is formed by repeating this process with additional solar tiles across and above and below the connected tiles 10.
  • Non-solar tiles may also be connected to the solar tiles in a similar overlapping arrangement.
  • the top length-wise frame member 16 is optionally stiffer than the bottom length-wise frame member 18. This provides flexure to allow the edges of adjacent solar roof tiles 10 to mate even when the roof structure is uneven, thereby enabling a water-proof seal to be performant under adverse installation conditions.
  • One end of the frame member can be flexed 15-20 mm with respect to the other.
  • the top length-wise frame member 16 and the bottom length-wise frame member have the same stiffness. Flexibility of the length-wise frame member 16 is facilitated by the interlocks 28, 30.
  • the underside of frame member 22 and the upper side of frame member 20 are cooperatively configured to fit, such that the ends of adjacent solar tiles can overlap and fit together. This may improve water resistance, tolerate manufacturing deviances, and enhance the visual appearance of the array of solar tiles.
  • the top length-wise frame member 16 comprises a bracket in the form of a downwardly projecting mounting lug 32 for contacting a roof batten and being fixed thereto with at least one fastener in the form of a screw such that the solar roof tile 10 hangs off the batten.
  • the flange 32 defines a groove 34 for the location of the fastener and to assist in the penetration of the fastener through the flange 32.
  • One face 35 of the flange 32 is for contacting the batten, and a face 37 of the flange 32 defines the v-groove.
  • the top length- wise frame member includes the following features (see Figures 12 and 27):
  • Screw engagement ribs 161 for strengthening the frame, and align with holes in the mating extrusion.
  • Wall 162 for preventing water ingress into the frame member and into the roof.
  • the silicon optionally binds the photovoltaic sheet 14 to the frame 12.
  • Bosses 169 form water-blocking walls and gutters to direct water that penetrates the interlock to drain away in a controlled manner.
  • a “female” connector part 2402 of the modular mounting system which can receive the male connector part 2401 and allows a plurality of connected trays.
  • the left end of the top length-wise frame member has features formed by cutting the extrusion that are visible in Figures 13 and 14:
  • the other end of the top length- wise frame 16 comprises a mitre cut 1604 which enables an aesthetically pleasing joint between the top and right extrusions.
  • the right width- wise frame member includes the following features (see Figures 17 and 32):
  • Bosses 169 form the core of the transverse interlock, and permit water-resistant sealing of the width- wise edges.
  • An end of the width-wise frame member 22 has the following features formed by cutting the extrusion as visible in Figures 18 - 21 and 33 - 36:
  • Screw holes 2209 Through holes for assembly screws to pass through.
  • the solar roof tile 10 comprises a first tray 24 in the form of a cable tray disposed at the rear face of the solar roof tile 10 and a second tray 26 for protecting the end of the cables 36 at the junction box 38.
  • Figures 22, and 23 show a plan view and a section view of the trays 24 and 26.
  • the trays 24 and 26 include the following features:
  • a “female” connector part 2402 of the modular mounting system which can receive the male connector part 2401 and allows a plurality of connected trays.
  • Figures 24A and 24B show a non-earthed and an earthed cross-sectional view of the tray 24 installed into the top frame member 16.
  • Cavity 2404 formed from the mating of male and female connector parts 2401 and 2402, specifically sized to receive an earthing bolt.
  • the photovoltaic sheet 14 comprises a photovoltaic laminate comprising a plurality of photovoltaic cells, application specific glass, and an insulating backing sheet.
  • the junction box 38 attached to the rear face of the photovoltaic sheet houses a bypass diode and from which the electrical cables 36 emerge. Any suitable and desired form of photovoltaic sheet and associated electricals may generally be used.
  • FIGS 25 and 26 show a rear view and a rear exploded view of another embodiment of a solar roof tile 100.
  • the solar roof tile is configured to be compatible with non-solar roof tiles, and in this but not necessarily in all embodiments, the solar roof tile 100 is configured to be interchangeable with one or more non-solar roof tiles in the form of PREMIERETM, PRESTIGETM or ETONTM roof tiles manufactured by BRISTILETM.
  • Solar roof tile 100 shares some features with solar roof tile 10, where parts similar in form and/or function to those of the solar roof tile 10 are similarly numbered.
  • the solar roof tile 100 comprises a frame 12 comprising a plurality of members 16, 18, 20, and 22 to which is mounted a photovoltaic sheet 14.
  • the frame members 16, 18, 20, and 22 are attached using frame member fasteners in the form of corner cleats 40, 80, and 82.
  • Figures 28 to 31 show various cuts of top frame member 16.
  • Figure 28 is a profile view
  • Figures 29 and 30 are of a left edge
  • Figure 31 is of a right edge. Visible in these figures are:
  • Figure 27 shows a section view of a right side frame member of the solar roof tile 100.
  • Cavity 167 to hold the photovoltaic sheet.
  • the cavity 167 may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
  • Figures 33 to 36 show cuts of the right side frame member in top edge, top isometric view and bottom edge views. These figures show the following features:
  • Screw holes 2209 Through holes for assembly screws to pass through.
  • Figure 36 shows a mitre cut of the bottom edge of the right side frame member that provides an aesthetically pleasing joint between the right and bottom extrusions.
  • Figure 37 shows a section view of a left side frame member 20 of the solar roof tile 100 showing the following features:
  • Pocket 166 to help ensure good sealing with the silicon during the assembly process. It provides a cavity for excess silicon to flow into to mitigate inconsistent silicon extrusion. (Unknown as we are not able to discern who came up with this feature) 2.
  • Cavity 167 to hold the photovoltaic sheet. The cavity 167 may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
  • Bosses 169 form the core of the transverse interlock, and permit water-resistant sealing of the width- wise edges.
  • Partial cavity 6 for the retention of the secondary corner cleat.
  • Figures 38 to 41 show different cuts of the left frame member, including profile, and top edge views including top view, front view, and isometric view. These figures show the following features:
  • Partial depth cut 2210 - This permits the egress of water via the dedicated water channels.
  • Screw holes 2209 Through holes for assembly screws to pass through to allow mounting of the secondary cleat with screw holes.
  • Figures 42 and 43 show cuts of the left frame member, with bottom edge views including top view and front isometric view. These figures show the following features:
  • Figure 44 is a section view of a bottom frame member of the solar roof tile 100 showing the following features:
  • Tile interlock 30 This is the lower interlocking flange, and it locks into another alike solar tile placed on the batten below it. This dramatically increases the tile’s resistance to adverse weather conditions (e.g., hurricanes), and boosts the tile’s water resistance. It interacts with regular roofing tiles to provide an additional barrier against wind-driven water ingress.
  • adverse weather conditions e.g., hurricanes
  • Cavity 31 receives the upper interlocking flange 28
  • Pocket 166 to help ensure good sealing with the silicon during the assembly process. It provides a cavity for excess silicon to flow into to mitigate inconsistent silicon extrusion.
  • Cavity 167 holds the photovoltaic sheet.
  • the cavity may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
  • Cavity 168 for the retention of the corner cleats.
  • Figures 45 to 48 show cuts of the bottom frame member, including profile view, and right edge views including top view, rear view, and rear isometric view. These figures show the following features:
  • Figure 49 shows cuts of the bottom frame member, in particular a left edge view, showing the following features:
  • Figures 50 and 51 show views of a primary corner cleat and a secondary corner cleat of the solar roof tile 100.
  • the secondary corner cleat provides support in the top-left of the frame.
  • the secondary cleat can be attached with screws.
  • Figures 52 and 53 show profile and front views of edge trim 21.
  • the edge trim provides visual continuity with the non-solar tiles and shields the open cavity of left frame member 20 from debris and growth of organic matter such as moss.
  • Feature 2209 shows a through hole for a fastener.
  • the interlock may improve the security of adjacent solar roof tiles, especially during strong winds - for example wind speeds with Beaufort scale numbers 10 (storm) to 12 (Hurricane).
  • the interlock may reduce the ingress of water between adjacent tiles - for example during storms - and onto the underlying structure, where it may cause damage.
  • Flexure may allow acceptable and / or enhanced mating of adjacent solar roof tiles mounted onto uneven roof structures.
  • the electrical cabling may be managed and protected by the tray.
  • the peripheral frame members may be composed of a polymer or generally any suitable and desired material.
  • the cleats may be fastened by welding, stamping, rivets or generally any suitable and desired fastening type.
  • Embodiments may be configured to be compatible with generally any suitable and desired roof tile configuration.
  • the photovoltaic sheets may generally be any suitable and desired type.
  • the solar roof tile may alternatively be square or generally any suitable and desired shape.
  • the corner cleat may be additionally or alternatively frictionally attached.
  • the interlock may take an alternative form to the L-flanges, for example a clip arrangement.
  • a pair of length-wise frame members 16, 18 and a pair of widthwise frame members 20, 22 are assembled around a photovoltaic sheet 14.
  • the frame members are connected using corner cleats 40 to form a rectangular solar tile 10, 100.
  • a first solar roof tile 10, 100 is first mounted onto a roof batten 42 by positioning the flange 32 on the roof batten 42 such that its first mounting face 35 abuts the top surface of the roof batten and its second perpendicularly positioned mounting face 39 abuts the side surface of the roof batten.
  • the bottom surface of the roof batten adjacent to the side surface may abut the third mounting face on female connector part 2402 (depending on the size of the roof batten) which also abuts a cable tray. In this position, the roof batten is sandwiched between the cable tray of the solar roof tile and the flange 32 (see Figure 52).
  • the third mounting face on female connector part 2402 may include a projection that extends into the space between the mounting face on female connector part 2402 and the flange 32.
  • the projection is a ridge that extends along the length of the top frame member. This projection may be used to provide a friction fit between the roof batten and the top frame member.
  • the solar tile 10, 100 is then fixed onto the batten 42 by driving a screw through the notch 34 on the first mounting face.
  • the notch is replaced with an opening.
  • a second solar roof tile 10, 100 is then positioned above the first solar roof tile 10, 100 in a top-to- bottom position such that the length- wise interlock 28 of the first solar tile engages an adjacent length-wise interlock 30 of the second solar tile.
  • Both interlocks are in the form of an L-shaped flange that extends along the length of the solar tile.
  • the downwardly facing edge of the second interlock 30 is received within the outwardly (rear) facing cavity or groove 29 formed by the L-shape (see Figures 30, 54, and 55).
  • Another (third) solar roof tile 10, 100 or non-solar roof tile 300 can be positioned beside the second solar roof tile in a side-by-side position such that the width-wise interlock of the first solar tile engages an adjacent width-wise interlock of the second solar tile.
  • This process can be repeated to connect additional solar roof tiles or non-solar roof tiles to form a network of connected roof tiles (see Figure 56).
  • the overlapping connection between the tiles provides a water-resistant seal to reduce water ingress under the roof tiles.
  • the network of tiles also reduces the likelihood of the tiles being lifted from the roof under strong wind conditions.
  • Figure 55 provides a cross-sectional profile comparison of a pair of assembled solar roof tiles 10, 100 in an optimal and a sub-optimal top-to-bottom arrangement.
  • the sub-optimal profile is in blue.
  • the light orange lines represent sun rays when sun is high and the dark orange lines represent sun rays when the sun is low.
  • the figure shows that the steep arcuate profile of the bottom length-wise frame member minimizes cross-tile and self-shading of the solar tile as the sun changes position during the day. It can be appreciated that the profile of individual frame members may be optimised to reduce cross-tile and self-shading.
  • Figure 57 shows the arrangement between a non-solar roof tile 300 and a solar roof tile 100 in which the edge of the non-solar roof tile 300 fits into open channel 44 of the top length-wise frame member 16 in an overlapping arrangement.
  • the solar roof tiles are then electrically connected to an appropriate electrical sink such as a building lighting system.
  • the electrical cables of the solar tiles can be organised within a tray 24 located on the underside of the solar roof tile.
  • the terminals of the solar roof tile electrical cables are retained in the tray such that the connection between the solar roof tile and electrical sink cables is made within the tray. This enables the connection points to be easily located and protected, and comply with relevant electrical safety standards in the event of an adverse event such as fire.
  • a further tray 24 can be attached in a modular fashion to supply installers with code-compliant tie down points for the permanent fixation of cable-shielding and conduit per local construction codes.
  • the tray 24 is also electrically earthed via wire 46 which connects the top frame member to the tray using a conductive screw or bolt (see Figure 58).
  • an earthing bolt 2404 may be driven into the cavity between the top frame member 16 and tray 24 to engage both the top frame member 16 and tray 24 (see Figures 24A and 24B).

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

A solar roof tile may comprise: a frame and a photovoltaic sheet supported by the frame, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.

Description

A SOLAR ROOF TILE
Technical field
The disclosure herein generally relates to a solar roof tile.
The disclosure relates particularly, although by no means exclusively, to a frame for supporting a photovoltaic sheet to form a solar roof tile.
The disclosure also relates to a method of installing solar roof tiles on a roof.
Background
As the world moves away from non-renewable energy sources such as coal and natural gas and transitions towards renewable energy, there has been increased focus on developing technology based on renewable energy sources such as solar, wind and hydropower, and improving the efficiency of these technologies.
Solar energy is the most abundant renewable energy source and has led to the development of solar panels which have been used to generate electricity for a range of industrial and domestic applications including heating and cooling.
However, solar panels have faced barriers to mass domestic adoption due to the limitations they can impose on domestic roofs. Traditional solar panel installations negatively impact the waterproofness of standard roofs, their resistance to adverse weather conditions, and can have a negative aesthetic impact on their environment.
This has led to the development of solar roof tiles. These tiles include a photovoltaic component that have similar dimensions to traditional non-solar roof tiles that can be installed on a roof in a similar manner to improve the visual appearance of the roof.
Unfortunately, solar tiles have a number of deficiencies. Firstly, solar tiles are not as efficient as solar panels. For example, solar panels can be mounted to a moveable support or frame to allow the panels to be tilted to maximise sun exposure throughout the day. This is not possible with solar tiles.
Secondly, solar tiles are generally more expensive than solar panels because of their smaller surface area. As such, more solar tiles are required to produce the same electricity output as would be achieved using conventional solar panels. In addition, solar tiles frequently require specialist installers, equipment, and mounting arrangements. For this reason, it is also more expensive to install solar tiles than solar panels.
Thirdly, solar tiles may reduce the resistance of the roof to weather elements, particularly resistance to water ingress into the roof cavity, and lifting of tiles due to highspeed winds thanks to their different mechanical properties.
The present invention seeks to ameliorate one or more of the above disadvantages.
Summary
Disclosed herein is a frame for a solar roof tile, the frame being configured to support a photovoltaic sheet to form the solar roof tile, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
Strong wind conditions encompass wind speeds with Beaufort scale numbers ranging from 10 (storm) to 12 (Hurricane).
A key feature of the present invention is an interlock that is configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form a network of interconnected tiles when mounted on a roof.
This feature provides a number of advantages including:
(i) Enabling the frame to be co-operable with the frame of an alike solar tile and/or a generic non-solar roof tile. (ii) Improving installation efficiency over conventional solar tiles by reducing the number of fasteners required to secure the solar roof tiles to the roof. This is achieved by partially supported each solar roof tile by at least one adjacent solar roof tile or non-solar roof tile.
(iii) Improving weather resistance including restricting lifting of tiles from the roof because of high speed wind and restricting water ingress into the roof cavity.
In this specification, the term “photovoltaic sheet” encompasses any substrate that contains photovoltaic cells which convert solar radiation into electricity.
In this specification, the term “frame” refers to a structure that is mechanically strong to support the photovoltaic sheet.
A water-resistant seal may be formed between a pair of connected tiles when the interlock of a frame is engaged with another interlock on the adjacent alike frame. Suitably, a water-proof seal is formed between a pair of connected tiles when the interlock of a frame is engaged with another interlock on the adjacent alike frame. This may reduce or prevent water ingress under the roof tiles.
The interlock may comprise a male or female element that is co-operable with a corresponding male or female element on an alike frame to connect the frames. The co-operative elements may be an integral part of the frame.
In one example, the male element may be a projection and the female element may be a recess, wherein the projection is received within the recess.
The interlock may comprise a flange that is configured to engage a flange of an adjacent alike frame or roof tile. Suitably, the flange extends along the horizontal dimension of the frame. The interlock may allow the tiles to engage in a non-permanent manner.
The flange may form a groove for receiving the flange of an adjacent alike frame or roof tile. Suitably, the flange may be L-shaped, U-shaped, Z-shaped, S-shaped, T-shaped, or V-shaped.
The interlock may be located along a side of the frame. Suitably, a frame comprises an interlock along a length-wise side of the frame. More suitably, a frame comprises an interlock along a length- wise side of the frame and another interlock along a width-wise side of the frame.
The interlock may be positioned to engage an interlock on an adjacent alike frame or non-solar roof tile when the tiles are in a side-by-side arrangement on a roof.
The interlock may be positioned to engage an interlock on an adjacent alike frame or non-solar roof tile when the tiles are in a top-to-bottom arrangement on a roof.
The interlock may provide a guide to align the solar tile with an adjacent solar tile or roof tile. Suitably, the interlock is shaped to permit unidirectional connection with an alike interlock of an adjacent solar tile or roof tile. More suitably, the engaged interlocks are immobile. This minimises the risk of the tiles being misaligned during installation.
The frame may further comprise a mounting arrangement for mounting the frame to a roof batten. Suitably, the mounting arrangement comprises a bracket configured to engage the roof batten.
The term “bracket” encompasses a protruding lip, flange, lug or shelf that includes a mounting face to enable the frame to rest on the batten. Suitably, the mounting face may include an opening to receive a fastener or a groove or notch to guide a fastener through the mounting face to secure the frame to the roof batten.
The mounting arrangement may comprise at least one mounting face configured to abut a surface of the roof batten to align the frame with the roof batten.
The mounting arrangement may comprise a first and second mounting faces that abut respective top and side surfaces of a roof batten to allow the frame to rest on the roof batten. The mounting arrangement may comprise a third mounting face that abuts an opposing side surface of the roof batten. The mounting faces may be orthogonal to each other.
The bracket may have an opening that is configured to receive a fastener to secure the frame to the roof batten.
The opening may be a circular opening, i.e., a hole, a non-circular opening, i.e., a slot or an indentation or incision on an edge of the bracket, i.e., a notch. The frame may comprise a plurality of frame members that are connectable to form the frame. The frame may comprise a plurality of frame members. Suitably, the frame extends partially or entirely around a perimeter of a photovoltaic sheet.
The frame may comprise a first frame member and a second frame member that are connectable to form the frame. The first and second frame members may comprise L-shaped components that form a rectilinear frame when connected.
In this specification, the term “frame member” is understood to mean a part or section of a frame.
The frame may comprise a pair of length- wise frame members and a pair of width-wise frame members that are connectable to form the frame. The length-wise and width-wise frame members may be of equal length.
The pair of length-wise frame members may have different stiffness.
An end of one length- wise frame member may flex up to 20 mm, suitably 15-20 mm with respect to another end of the same length-wise frame member.
The top frame may be stiffer than the bottom frame so that the bottom frame preferentially flexes and interlocks into the upper frame of an alike solar tile when connecting the solar tiles in a top-to- bottom arrangement. The difference in flexibility of the frame members may provide a conformant fit of the interconnected tiles on a roof and is particularly beneficial for installing the tiles on an uneven or undulating roof. This may also aid the formation of a water resistant seal between the interconnected tiles.
The frame may include a gutter for channelling water therethrough.
The gutter may be a channel that extends along the length of at least one of the frame members, suitably a channel located on either on the top or bottom frame member.
The gutter may be a channel on either the top or bottom frame member that is in fluid communication with another channel on one of the side frame members. Suitably, the gutter is a channel that extends from the top or bottom frame member to one of the side frame members
The channel forming the gutter may be an open channel.
The frame may comprise a first frame member and a second frame member that are connectable to form a cavity for receiving a photovoltaic sheet. The first and second frame members may comprise L-shaped components that form a rectilinear frame when connected.
The first frame member may comprise a cover piece for covering an opening of an enclosed channel on the first frame member.
A portion of the second frame member may cover an opening of an enclosed channel on the first frame member when the first and second frame members are connected.
The frame members may be connected using a fastener to form the frame.
The fastener may be any known fastener in the art.
The fastener may be configured to frictionally engage with and form a connection between the first and second frame members.
The fastener may be a clip or a cleat, particularly a corner cleat.
The frame members may be formed by extrusion. The extruded frame members may be made from metals such as aluminium, steel, or titanium, or polymers such as polyvinylchloride (PVC).
The frame may comprise a tray for supporting a cable therein. The cable may be in electrical communication with the photovoltaic sheet. Suitably, the cable is used to electrically connect the photovoltaic sheet to a solar or photovoltaic inverter or an appropriate electrical sink such as a building lighting system.
The tray may be located behind the photovoltaic sheet.
The tray may be integrally formed with the frame. The tray may be removably attached to the frame.
The tray may be removably attached to the frame via a co-operative arrangement such as a tongue and groove arrangement.
The tray may be configured to connect to an alike tray in a modular arrangement.
The tray may be configured to connect to an alike tray in a modular arrangement via a tongue and groove arrangement.
The tray may be configured to be installed on an assembled solar tile.
The frame may be configured to be electrically earthed. The earthing may be achieved by connecting an electrically conductive element to the frame. Suitably, the electrically conductive element engages at least one frame member and tray when installed.
Suitable electrically conductive elements include an earthing bolt or a wire. Suitably, the electrically conductive element is a separate sub-assembly that is connectable to the frame.
Also disclosed herein is a solar roof tile comprising a photovoltaic sheet supported by the previously mentioned frame. Suitably, the photovoltaic sheet is secured within a cavity of the frame.
The solar roof tile may comprise: a frame and a photovoltaic sheet supported by the frame, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
The frame may comprise a plurality of frame members. Suitably, the frame extends partially or entirely around a perimeter of the photovoltaic sheet.
The frame may be anodised to improve aesthetics, or corrosion resistance. The frame may be electrically earthed by attaching an electrically conductive element to the frame. Suitably, the electrically conductive element is an earthing bolt or a wire, more suitably an insulated wire. An advantage of the present invention is that the frame can be earthed by simply connecting an electrically conductive element to the frame without having to break the anodised surface of the frame to form a non-anodised region for connection with the electrically conductive element beforehand.
The disclosure also provides a method of installing solar roof tiles on a roof, each solar roof tile comprising a frame supporting a photovoltaic sheet and having an interlock for engaging an interlock on an adjacent alike frame or a roof tile the method comprising: arranging a first solar roof tile with a second solar roof tile or non-solar roof tile on a roof of a building wherein the interlock of the first solar roof tile engages the interlock of the second solar roof tile or non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof.
The method may include mounting the first solar roof tile onto a roof batten on the roof.
The step of mounting the first solar roof tile onto the roof batten may comprise aligning a bracket of the solar roof tile onto the roof batten.
The step of mounting the first solar roof tile to a roof batten on the roof may comprise abutting a mounting surface of the bracket to the roof batten.
The method may include securing the first solar roof tile to the roof batten on the roof.
The step of securing the first solar roof tile to the roof batten may comprise drilling an opening into the bracket.
The step of securing the first solar roof tile to the roof batten may comprise inserting a fastener into the opening in the bracket.
The step of securing the first solar roof tile to the roof batten may comprise driving a fastener into the bracket. The method may include positioning a second solar roof tile or non-solar roof tile in a side-by-side arrangement with the first solar roof tile to interlock the two tiles together.
The method may include positioning the second solar roof tile or non-solar roof tile in a top-to- bottom arrangement with the first solar roof tile to interlock the two tiles together.
The method may include securing the second solar roof tile to the roof batten.
The step of securing the second solar roof tile to the roof batten includes driving a fastener into a bracket of the second solar roof tile. Suitably, the step of securing the second solar roof tile to the roof batten comprises inserting a fastener into an opening in the bracket. Alternatively, the step of securing the second solar roof tile to the roof batten comprises driving a fastener into the bracket.
The method may include a step of electrically earthing the frame. This step may involve connecting an electrically conductive element to the frame. The step of connecting an electrically conductive element to the frame may include installing a conductive fastener, such as a metal screw or bolt, to the frame. Suitably, connecting an electrically conductive element to the frame involves engaging the electrically conductive element to at least one frame member and tray.
The electrically conductive element may be a wire.
An embodiment of the invention may be interchangeable with one or more non-solar roof tiles, but not necessarily all embodiments.
Any of the various features of each of the above disclosures, and of the various features of the embodiments described below, can be combined as suitable and desired.
Brief description of the figures
Embodiments of the invention will now be described by way of example only with reference to the accompanying figures in which:
Figure 1 shows a top isometric view of an embodiment of a solar roof tile according to an embodiment of the present invention.
Figure 2 shows a bottom isometric view of the solar roof tile of Figure 1. Figure 3 shows an exploded top isometric view of the solar roof tile of Figure 1.
Figure 4 shows an exploded rear isometric view of the solar roof tile of Figure 1.
Figure 5 shows a top view of the solar roof tile of Figure 1.
Figure 6 shows a bottom view of the solar roof tile of Figure 1.
Figure 7 shows a side view of the solar roof tile of Figure 1.
Figure 8 shows a magnification of a groove on the flange for contacting a roof batten from Figure 7.
Figure 9 shows an isometric view of a cleat of the solar roof tile of Figure 1.
Figure 10 shows an isometric view of a left end of a top frame member of the solar roof tile of Figure 1.
Figure 11 an isometric view of an opposing right end of the top frame member of the solar roof tile of Figure 1.
Figure 12 shows a section view of the top frame member of the solar roof tile of Figure 1.
Figure 13 shows a plan view of the left end of the top frame member of the solar roof tile of Figure 1.
Figure 14 shows an isometric view of the left end of the top frame member of the solar roof tile of Figure 1.
Figure 15 shows a side view of the solar roof tile of Figure 1 interlocked with an alike solar roof tile.
Figure 16 shows a plan view of an end of the top frame member of the solar roof tile of Figure 1. Figure 17 shows a section view of the right side frame member of the solar roof tile of Figure 1.
Figure 18 shows a plan view of a side frame member of Figure 1.
Figure 19 shows a magnified top view of the end of the side frame member of Figure 18.
Figure 20 shows a front view of the end of the side frame member of the solar roof tile of Figure 18.
Figure 21 shows an isometric view of the end of the side frame member of the solar roof tile of Figure 18.
Figure 22 shows a plan view of a tray of the solar roof tile of Figure 1.
Figure 23 shows a section view of the tray of Figure 22.
Figure 24A shows a section view of the top frame member and tray.
Figure 24B shows an earthing element inserted into a cavity between the top frame member and tray of Figure 24A.
Figure 25 shows a top view of an embodiment of a solar roof tile according to another embodiment of the present invention.
Figure 26 shows an exploded top view of the solar roof tile of Figure 25.
Figure 27 shows a section view of the top frame member of another embodiment of a solar roof tile according to the present invention.
Figure 28 shows a plan view of a top frame member of Figure 27.
Figure 29 shows a plan view of the left end of the top frame member of the solar roof tile of Figure 27. Figure 30 shows an isometric view of the left end of the top frame member of the solar roof tile of Figure 27.
Figure 31 shows a plan view of an end of the top frame member of the solar roof tile of Figure 27.
Figure 32 shows a section view of the right side frame member of the solar roof tile of Figure 26.
Figure 33 shows a plan view of a side frame member of Figure 26.
Figure 34 shows a magnified top view of the end of the side frame member of Figure 33.
Figure 35 shows an isometric view of the end of the side frame member of Figure 33.
Figure 36 shows a plan view of an end of the top frame member of Figure 27.
Figure 37 shows a section view of the left side frame member of Figure 26.
Figure 38 shows a plan view of a side frame member of Figure 26.
Figure 39 shows a magnified top view of the end of the side frame member of Figure 38.
Figure 40 shows a side view of the side frame member of Figure 39.
Figure 41 shows an isometric view of the side frame member of Figure 40.
Figure 42 shows a magnified top view of an end of the side frame member of Figure 38.
Figure 43 shows an isometric view of an end of the side frame member of Figure 38.
Figure 44 shows a section view of the bottom frame member of Figure 27.
Figure 45 shows a plan view of the left end of the bottom frame member of Figure 26. Figure 46 shows a plan view of the bottom frame member of Figure 26.
Figure 47 shows a plan view of the right end of the bottom frame member of Figure 26.
Figure 48 shows a side view of the bottom frame member of Figure 46.
Figure 49 shows an isometric view of the bottom frame member of Figure 47.
Figure 50 shows an isometric view of a cleat of the solar roof tile of Figure 26.
Figure 51 shows an isometric view of a secondary cleat of the solar roof tile of Figure 26.
Figure 52 shows a section view of a cover of the top frame member.
Figure 53 shows a front view of the cover of Figure 52.
Figure 54 shows a side view of a pair of solar roof tiles mounted on a roof batten.
Figure 55 shows a cross-sectional view of a pair of connected solar roof tiles showing solar shading for a non-interlocked solar tile.
Figure 56 is a perspective side view of an array of solar and non-solar roof tiles mounted on a roof.
Figure 57 is a side view of a non-solar tile engaging a solar roof tile in a top-to-bottom arrangement.
Figure 58 shows an electrical earthing wire connected to the tray of a solar roof tile.
Description of embodiments
Figures 1 to 8 show various views respectively of an embodiment of a solar roof tile, which is generally indicated by reference numeral 10. The solar roof tile 10 is configured to engage an alike solar roof tile and a non-solar roof tile for example in the form of the PLANUM™ roof tiles manufactured by La Escandella™.
The solar roof tile 10 is generally rectangular and comprises a peripheral frame 12 forming a central cavity in which a photovoltaic sheet 14 is mounted therein. The peripheral frame 12 comprises a plurality of frame members 16, 18, 20, and 22 that are generally straight and elongated, including length- wise frame members 16, 18 that are parallel and on opposite sides of the photovoltaic sheet 14, and width-wise frame members 20,22 that are parallel and perpendicular to the length-wise frame members 16, 18. The plurality of frame members 16, 18, 20, and 22 are formed from extruded aluminium.
Figure 9 shows an isometric view of a fastener in the form of an extruded aluminium corner cleat 40 for attaching adjacent peripheral frame members 16, 18, 20, and 22, and would be hidden within the assembled frame 12. Alternative fasteners such as rivets, welds, nails, crimps or stamped bosses are also suitable to connect the frame members.
When the solar roof tile 10 is installed on a pitched roof, an active - sunlight receiving - face 15 of the photovoltaic sheet 14 faces outwards, and the length-wise frame members 16, 18 are generally horizontal with the top length-wise frame member 16 higher than the bottom length-wise frame member 18. The width- wise left and right frame members 20, 22 are generally inclined with one end pointing upwards and another end pointing downwards. As seen in Figures 12, 14 and 27, for example, top length-wise frame member 16 comprises a gutter 27.
As seen in the detail shown in the Figures 7, 11, 12, and 26, for example, top length-wise frame member 16 comprises an upper interlock 28 in the form of an upwardly projecting L-flange defining an outwardly (rear) facing cavity or groove 29 for engaging a lower interlock 30 visible in Figures 7, 48, 54 and 55 in the form of another downwardly projecting L-flange of the bottom length-wise frame member 18. The interlocks 28, 30 are on the opposite top and bottom sides of the solar tile 10. The upper flange 28 and lower flange 30 are oppositely orientated.
Figures 15, 54, and 55 show the interlock 28 of one solar roof tile engaging the interlock 30 of another solar tile, to connect adjacent solar tiles 10. When the interlocks 28, 30 are engaged, the bottom solar roof tile 10 supports the upper roof tile 10 via the interlock. The overlapping engagement of the interlocks afford a water-resistant seal between the connected tiles. An array of solar tiles is formed by repeating this process with additional solar tiles across and above and below the connected tiles 10. Non-solar tiles may also be connected to the solar tiles in a similar overlapping arrangement.
The top length-wise frame member 16 is optionally stiffer than the bottom length-wise frame member 18. This provides flexure to allow the edges of adjacent solar roof tiles 10 to mate even when the roof structure is uneven, thereby enabling a water-proof seal to be performant under adverse installation conditions. One end of the frame member can be flexed 15-20 mm with respect to the other. In an alternative embodiment, the top length-wise frame member 16 and the bottom length-wise frame member have the same stiffness. Flexibility of the length-wise frame member 16 is facilitated by the interlocks 28, 30.
The underside of frame member 22 and the upper side of frame member 20 are cooperatively configured to fit, such that the ends of adjacent solar tiles can overlap and fit together. This may improve water resistance, tolerate manufacturing deviances, and enhance the visual appearance of the array of solar tiles.
As seen in Figures 12 and 27 for example, the top length-wise frame member 16 comprises a bracket in the form of a downwardly projecting mounting lug 32 for contacting a roof batten and being fixed thereto with at least one fastener in the form of a screw such that the solar roof tile 10 hangs off the batten. As seen in Figures 8, 12, and 27 the flange 32 defines a groove 34 for the location of the fastener and to assist in the penetration of the fastener through the flange 32. One face 35 of the flange 32 is for contacting the batten, and a face 37 of the flange 32 defines the v-groove.
The top length- wise frame member includes the following features (see Figures 12 and 27):
• Screw engagement ribs 161 for strengthening the frame, and align with holes in the mating extrusion.
• Wall 162 for preventing water ingress into the frame member and into the roof.
• Cavity 167 for receiving an edge of the photovoltaic sheet 14. Drafts may assist in seal formation.
• Pocket 166 for receiving excess silicon sealant and may assist in the homogenisation of a seal formed during assembly. In this embodiment, the silicon optionally binds the photovoltaic sheet 14 to the frame 12.
• Cavity 168 for receiving corner cleats 40. • Bosses 169 form water-blocking walls and gutters to direct water that penetrates the interlock to drain away in a controlled manner.
• A “female” connector part 2402 of the modular mounting system, which can receive the male connector part 2401 and allows a plurality of connected trays.
The left end of the top length-wise frame member has features formed by cutting the extrusion that are visible in Figures 13 and 14:
• Partial depth cut 1601 for enabling the solar tile to fit the tile to the left.
• Full depth partial cut 1602 for enabling the left frame member to be installed in a watertight fashion.
• Mitre cut 1603 for enabling an aesthetically pleasing joint between the top 16 and left 20 frame members.
As visible in Figure 16, the other end of the top length- wise frame 16 comprises a mitre cut 1604 which enables an aesthetically pleasing joint between the top and right extrusions.
The right width- wise frame member includes the following features (see Figures 17 and 32):
• Cavity 167 for receiving an edge of the photovoltaic sheet 14.
• Pocket 166 for assisting silicon sealing.
• Cavity 168 for receiving corner cleats 40.
• Bosses 169 form the core of the transverse interlock, and permit water-resistant sealing of the width- wise edges.
An end of the width-wise frame member 22 has the following features formed by cutting the extrusion as visible in Figures 18 - 21 and 33 - 36:
• Full depth angled cut 2205 - Clearance cut for the solar tile to lay correctly with the tile to the right.
• Full depth partial cut 2206 - This allows the top edge to be installed in a watertight fashion.
• Mitre cut 2208 - This permits an aesthetically pleasing joint between the right and top extrusions.
• Screw holes 2209 - Through holes for assembly screws to pass through.
As seen in Figures 2 and 4, the solar roof tile 10 comprises a first tray 24 in the form of a cable tray disposed at the rear face of the solar roof tile 10 and a second tray 26 for protecting the end of the cables 36 at the junction box 38. Figures 22, and 23 show a plan view and a section view of the trays 24 and 26. The trays 24 and 26 include the following features:
• A “male” connector part of 2401 for a modular mounting system.
• A “female” connector part 2402 of the modular mounting system, which can receive the male connector part 2401 and allows a plurality of connected trays.
• Cavity 2403 for receiving electrical cables.
Figures 24A and 24B show a non-earthed and an earthed cross-sectional view of the tray 24 installed into the top frame member 16. These figures detail the following features:
• Cavity 2404 formed from the mating of male and female connector parts 2401 and 2402, specifically sized to receive an earthing bolt.
• Earthing bolt 2405.
• Engagement 2406 of installed earthing bolt 2405 into male and female connector parts 2401 and 2402, which enables a permanent mechanical and electrical bond to be formed between the two parts.
Visible in Figures 1 - 6, the photovoltaic sheet 14 comprises a photovoltaic laminate comprising a plurality of photovoltaic cells, application specific glass, and an insulating backing sheet. The junction box 38 attached to the rear face of the photovoltaic sheet houses a bypass diode and from which the electrical cables 36 emerge. Any suitable and desired form of photovoltaic sheet and associated electricals may generally be used.
Figures 25 and 26 show a rear view and a rear exploded view of another embodiment of a solar roof tile 100. The solar roof tile is configured to be compatible with non-solar roof tiles, and in this but not necessarily in all embodiments, the solar roof tile 100 is configured to be interchangeable with one or more non-solar roof tiles in the form of PREMIERE™, PRESTIGE™ or ETON™ roof tiles manufactured by BRISTILE™. Solar roof tile 100 shares some features with solar roof tile 10, where parts similar in form and/or function to those of the solar roof tile 10 are similarly numbered.
The solar roof tile 100 comprises a frame 12 comprising a plurality of members 16, 18, 20, and 22 to which is mounted a photovoltaic sheet 14. The frame members 16, 18, 20, and 22 are attached using frame member fasteners in the form of corner cleats 40, 80, and 82. Figures 28 to 31 show various cuts of top frame member 16. Figure 28 is a profile view, Figures 29 and 30 are of a left edge, and Figure 31 is of a right edge. Visible in these figures are:
1. Full depth partial cut 1602 - This allows the gutter to direct water into the left extrusion.
2. Mitre cut 1603 - This permits an aesthetically pleasing joint between the top and left extrusions.
Figure 27 shows a section view of a right side frame member of the solar roof tile 100.
Features of the right side frame member of Figure 27 include:
1. Pocket 166 to help ensure good sealing with the silicon during the assembly process. It provides a cavity for excess silicon to flow into to mitigate inconsistent silicon extrusion.
2. Cavity 167 to hold the photovoltaic sheet. The cavity 167 may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
3. Cavity 168 for the retention of the corner cleats.
Figures 33 to 36 show cuts of the right side frame member in top edge, top isometric view and bottom edge views. These figures show the following features:
1. Full depth angled cut 2205 - Clearance cut for the solar tile to lay correctly with the tile to the right.
2. Full depth partial cut 2206 - This allows the top edge to be installed correctly.
3. Mitre cut 2208 - This permits an aesthetically pleasing joint between the right and top extrusions.
4. Screw holes 2209 - Through holes for assembly screws to pass through.
Figure 36 shows a mitre cut of the bottom edge of the right side frame member that provides an aesthetically pleasing joint between the right and bottom extrusions.
Figure 37 shows a section view of a left side frame member 20 of the solar roof tile 100 showing the following features:
1. Pocket 166 to help ensure good sealing with the silicon during the assembly process. It provides a cavity for excess silicon to flow into to mitigate inconsistent silicon extrusion. (Unknown as we are not able to discern who came up with this feature) 2. Cavity 167 to hold the photovoltaic sheet. The cavity 167 may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
3. Cavity 168 for the retention of the corner cleats.
4. Bosses 169 form the core of the transverse interlock, and permit water-resistant sealing of the width- wise edges.
5. Screw port 161 for the installation-dependent installation of the cover piece.
6. Partial cavity 6 for the retention of the secondary corner cleat.
Figures 38 to 41 show different cuts of the left frame member, including profile, and top edge views including top view, front view, and isometric view. These figures show the following features:
1. Partial depth cut 2210 - This permits the egress of water via the dedicated water channels.
2. Full depth angled cut 2205 - Clearance cut for the solar tile to lay correctly with the tile to the right.
3. Full depth partial cut 2206 - This allows the top edge to be installed correctly.
4. Mitre cut 2208 - This permits an aesthetically pleasing joint between the left and top extrusions.
5. Screw holes 2209 - Through holes for assembly screws to pass through to allow mounting of the secondary cleat with screw holes.
Figures 42 and 43 show cuts of the left frame member, with bottom edge views including top view and front isometric view. These figures show the following features:
1. Mitre cut 2208 - This provides an aesthetically pleasing joint between the left and bottom extrusions.
Figure 44 is a section view of a bottom frame member of the solar roof tile 100 showing the following features:
1. Tile interlock 30. This is the lower interlocking flange, and it locks into another alike solar tile placed on the batten below it. This dramatically increases the tile’s resistance to adverse weather conditions (e.g., hurricanes), and boosts the tile’s water resistance. It interacts with regular roofing tiles to provide an additional barrier against wind-driven water ingress.
2. Cavity 31 receives the upper interlocking flange 28
3. Pocket 166 to help ensure good sealing with the silicon during the assembly process. It provides a cavity for excess silicon to flow into to mitigate inconsistent silicon extrusion.
4. Cavity 167 holds the photovoltaic sheet. The cavity may be filled with silicon during the assembly process to ensure that the photovoltaic sheet is centred in this cavity. It has drafts that along with feature 167 help to ensure the silicon assembles as easily as possible.
5. Cavity 168 for the retention of the corner cleats.
Figures 45 to 48 show cuts of the bottom frame member, including profile view, and right edge views including top view, rear view, and rear isometric view. These figures show the following features:
1. Full depth partial cut 1602 - This allows the right edge to be installed correctly, and provides both an aesthetic and weather-sealed end face to the next tile’s left front edge.
2. Mitre cut 2208 - This provides an aesthetically pleasing joint between the bottom and right extrusions.
Figure 49 shows cuts of the bottom frame member, in particular a left edge view, showing the following features:
1. Full depth partial cut 1602 - This allows the right edge to be installed correctly, and provides an aesthetic end face to the next tile’s left front edge.
2. Mitre cut 2208 - This permits an aesthetically pleasing joint between the bottom and right.
Figures 50 and 51 show views of a primary corner cleat and a secondary corner cleat of the solar roof tile 100. The secondary corner cleat provides support in the top-left of the frame. The secondary cleat can be attached with screws.
Figures 52 and 53 show profile and front views of edge trim 21. The edge trim provides visual continuity with the non-solar tiles and shields the open cavity of left frame member 20 from debris and growth of organic matter such as moss. Feature 2209 shows a through hole for a fastener.
Now that embodiments have been described, it will be appreciated that some embodiments may have some of the following advantages:
• The interlock may improve the security of adjacent solar roof tiles, especially during strong winds - for example wind speeds with Beaufort scale numbers 10 (storm) to 12 (Hurricane).
• The interlock may reduce the ingress of water between adjacent tiles - for example during storms - and onto the underlying structure, where it may cause damage.
• Flexure may allow acceptable and / or enhanced mating of adjacent solar roof tiles mounted onto uneven roof structures.
• The electrical cabling may be managed and protected by the tray.
Variations and/or modifications may be made to the embodiments described without departing from the spirit or ambit of the invention. For example:
• The peripheral frame members may be composed of a polymer or generally any suitable and desired material.
• The cleats may be fastened by welding, stamping, rivets or generally any suitable and desired fastening type.
• Embodiments may be configured to be compatible with generally any suitable and desired roof tile configuration.
• The photovoltaic sheets may generally be any suitable and desired type.
• The solar roof tile may alternatively be square or generally any suitable and desired shape.
• The corner cleat may be additionally or alternatively frictionally attached.
• The interlock may take an alternative form to the L-flanges, for example a clip arrangement.
To form a solar roof tile 10, 100, a pair of length-wise frame members 16, 18 and a pair of widthwise frame members 20, 22 are assembled around a photovoltaic sheet 14. The frame members are connected using corner cleats 40 to form a rectangular solar tile 10, 100.
To install the solar roof tiles on a roof, a first solar roof tile 10, 100 is first mounted onto a roof batten 42 by positioning the flange 32 on the roof batten 42 such that its first mounting face 35 abuts the top surface of the roof batten and its second perpendicularly positioned mounting face 39 abuts the side surface of the roof batten. The bottom surface of the roof batten adjacent to the side surface may abut the third mounting face on female connector part 2402 (depending on the size of the roof batten) which also abuts a cable tray. In this position, the roof batten is sandwiched between the cable tray of the solar roof tile and the flange 32 (see Figure 52). The third mounting face on female connector part 2402 may include a projection that extends into the space between the mounting face on female connector part 2402 and the flange 32. Suitably, the projection is a ridge that extends along the length of the top frame member. This projection may be used to provide a friction fit between the roof batten and the top frame member.
The solar tile 10, 100 is then fixed onto the batten 42 by driving a screw through the notch 34 on the first mounting face. In other embodiments, the notch is replaced with an opening.
A second solar roof tile 10, 100 is then positioned above the first solar roof tile 10, 100 in a top-to- bottom position such that the length- wise interlock 28 of the first solar tile engages an adjacent length-wise interlock 30 of the second solar tile. Both interlocks are in the form of an L-shaped flange that extends along the length of the solar tile. In the engaged position, the downwardly facing edge of the second interlock 30 is received within the outwardly (rear) facing cavity or groove 29 formed by the L-shape (see Figures 30, 54, and 55).
Another (third) solar roof tile 10, 100 or non-solar roof tile 300 can be positioned beside the second solar roof tile in a side-by-side position such that the width-wise interlock of the first solar tile engages an adjacent width-wise interlock of the second solar tile.
This process can be repeated to connect additional solar roof tiles or non-solar roof tiles to form a network of connected roof tiles (see Figure 56). The overlapping connection between the tiles provides a water-resistant seal to reduce water ingress under the roof tiles. The network of tiles also reduces the likelihood of the tiles being lifted from the roof under strong wind conditions.
Figure 55 provides a cross-sectional profile comparison of a pair of assembled solar roof tiles 10, 100 in an optimal and a sub-optimal top-to-bottom arrangement. The sub-optimal profile is in blue. The light orange lines represent sun rays when sun is high and the dark orange lines represent sun rays when the sun is low. The figure shows that the steep arcuate profile of the bottom length-wise frame member minimizes cross-tile and self-shading of the solar tile as the sun changes position during the day. It can be appreciated that the profile of individual frame members may be optimised to reduce cross-tile and self-shading.
Figure 57 shows the arrangement between a non-solar roof tile 300 and a solar roof tile 100 in which the edge of the non-solar roof tile 300 fits into open channel 44 of the top length-wise frame member 16 in an overlapping arrangement.
Once the network of tiles is assembled, the solar roof tiles are then electrically connected to an appropriate electrical sink such as a building lighting system. The electrical cables of the solar tiles can be organised within a tray 24 located on the underside of the solar roof tile. Suitably, the terminals of the solar roof tile electrical cables are retained in the tray such that the connection between the solar roof tile and electrical sink cables is made within the tray. This enables the connection points to be easily located and protected, and comply with relevant electrical safety standards in the event of an adverse event such as fire. A further tray 24 can be attached in a modular fashion to supply installers with code-compliant tie down points for the permanent fixation of cable-shielding and conduit per local construction codes. The tray 24 is also electrically earthed via wire 46 which connects the top frame member to the tray using a conductive screw or bolt (see Figure 58). In another embodiment, an earthing bolt 2404 may be driven into the cavity between the top frame member 16 and tray 24 to engage both the top frame member 16 and tray 24 (see Figures 24A and 24B).
The present embodiments are, therefore, to be considered in all respects as illustrative and non-restrictive. Reference to a feature disclosed herein does not mean that all embodiments must include the feature.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, that is to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

Claims A frame for a solar roof tile, the frame being configured to support a photovoltaic sheet to form the solar roof tile, the frame comprising an interlock configured to engage an interlock on an adjacent alike frame or a non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof. The frame of claim 1, wherein the interlock comprises a flange that is configured to engage a flange of an adjacent alike frame or roof tile. The frame of either claim 1 or 2, wherein the interlock is located along a side of the frame. The frame of claim 3, wherein the interlock is located along a length-wise side of the frame. The frame of claim 4, including another interlock located on a width-wise side of the frame. The frame of any one of the preceding claims wherein the interlock is configured to engage an interlock on an adjacent alike frame to form a water-resistant seal. The frame of any of the preceding claims having a profile which reduces the risk of crosstile shading. The frame of any one of the preceding claims comprising a plurality of frame members including opposing top frame and bottom frame members and opposing left and right side frame members that are connectable to form the frame. The frame of claim 8, wherein the top frame member is stiffer than the bottom frame member. The frame of claim 9, wherein an end of the bottom frame member can flex up to 20mm with respect to an opposing end of the bottom frame member. The frame of any one of claims 8 to 10, wherein the top frame member has a profile optimised to reduce cross-tile shading. The frame of any one of the preceding claims, further comprising a tray for supporting cables therein. The frame of claim 12, wherein the tray is configured to connect to an alike tray in a modular arrangement. The frame of any one of the preceding claims being configured to be electrically earthed. The frame of claim 14 including an electrically conductive element electrically connecting a top frame member to a tray of the frame. A solar roof tile comprising: a frame according to any one of claims 1 to 15 and a photovoltaic sheet supported by the frame. The solar roof tile of claim 16, wherein the interlock is positioned to engage an interlock on an adjacent alike frame or roof tile when the tiles are in a side-by-side arrangement on a roof. The solar roof tile of either claim 16 or 17, wherein the interlock is positioned to engage an interlock on an adjacent alike frame or roof tile when the tiles are in a top-to-bottom arrangement on a roof. The solar roof tile of any one of claim 16 to 18, wherein the interlock or frame is adapted to flex when connected to an adjacent alike frame to provide a conformant fit on a roof. The solar roof tile of any one of claims 16 to 19, wherein interlock provides a guide to align the solar tile with an adjacent solar tile or roof tile. A method of installing solar roof tiles on a roof, each solar roof tile comprising a frame supporting a photovoltaic sheet and having an interlock for engaging an interlock on an adjacent alike frame or a roof tile the method comprising: arranging a first solar roof tile with a second solar roof tile or non-solar roof tile on a roof of a building wherein the interlock of the first solar roof tile engages the interlock of the second solar roof tile or non-solar roof tile in an overlapping arrangement to form interconnected tiles that are resistant to lifting under strong wind conditions when mounted on a roof. The method of claim 21, including mounting the first solar roof tile onto the roof batten comprising aligning a bracket of the solar roof tile on the roof batten. The method of claim 22, including securing the first solar roof tile to the roof batten on the roof. The method of either claim 22 or 23, including positioning a second solar roof tile or nonsolar roof tile in a side-by-side arrangement with the first solar roof tile to interlock the two tiles together. The method of claim 24, including positioning the second solar roof tile or non-solar roof tile in a top-to-bottom arrangement with the first solar roof tile to interlock the two tiles together. The method of claim 25, including securing the second solar roof tile to the roof batten on the roof. The method of any one of claims 21 to 26, including electrically earthing the frame. The method of claim 27, including a step of connecting an electrically conductive element to the frame. The method of claim 28, wherein the step of connecting an electrically conductive element to the frame includes electrically connecting a top frame member to a tray of the frame.
PCT/AU2023/051075 2022-10-26 2023-10-26 A solar roof tile WO2024086890A1 (en)

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AU2022903164A AU2022903164A0 (en) 2022-10-26 A solar roof tile
AU2022903164 2022-10-26

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JP4474212B2 (en) * 2004-03-01 2010-06-02 株式会社鶴弥 Fixing structure of solar cell module to roof tile
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CN214851100U (en) * 2021-07-05 2021-11-23 固德威电源科技(广德)有限公司 Photovoltaic tile frame system

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Publication number Priority date Publication date Assignee Title
JP4474212B2 (en) * 2004-03-01 2010-06-02 株式会社鶴弥 Fixing structure of solar cell module to roof tile
US20140237915A1 (en) * 2010-12-10 2014-08-28 Solus Engineering LLC. Roof tiles and related systems
JP2013249582A (en) * 2012-05-30 2013-12-12 Toshiba Corp Roof tile type solar cell module
US20190028054A1 (en) * 2017-07-18 2019-01-24 Solarcity Corporation Building integrated photovoltaic tile mounting system
KR20190036131A (en) * 2017-09-27 2019-04-04 유한회사 중앙강재 Solar panel integrated exterior material
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