Roof tray

Abstract

A tray (10) for a green roofing system has a bottom plate (12) and four sides (14) and is molded from a plastic material. At the center of each side wall and towards the base of each side wall there is a circular hole / orifice (20) for connecting the interior of one tray with an adjacent tray. The trays may be connected together using male connectors (24) and female connectors (30) and are particularly useful for temporary (or more durable water storage of roofs and for planting boxes used as green roofs. The trays (10) may be connected together by a fluid flow connection (50) including a shorter length conduit / conduit connecting the apertures of adjacent trays for fluid flow between the trays. A connector is also provided that blocks fluid transfer between two adjacent trays. Additional connectors having partial channels including dam walls are also provided. The trays (10) may be connected to form a reservoir on the roof of a building, where the connections are used to control the flow of water, such as to block the passage of water on downhill slopes.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to Australian Provisional Patent Application No. 2022903422 filed on November 14, 2022, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present invention relates to a planter or roof tray for forming a "green roof" on top of a building, typically but not limited to the roof of a high-rise building in an urban environment. Background Art

[0004] Cities tend to be much warmer than surrounding rural areas due to the accumulation of heat in the buildings that make up them. It is well known that "green" building (especially tall buildings) roofs are highly desirable, providing a benefit to the building's occupants by covering them with growing plants / gardens, reducing reflected heat and generally improving the environment by absorbing rainwater and carbon dioxide, etc.

[0005] Existing green roofs can be grown in situ in a planting medium supported on various layers including waterproofing, mulch, drainage, etc.

[0006] Such systems do not work well on all types of roofs, often leading to leaks and other problems, and it is known to provide planting trays that sit on top of the roof of a building.

[0007] However, planting trays also have some issues. In particular, the seal between the pipes connecting the planting trays is not always reliable and can cause water to leak onto the roof. Setting up a green roof is cumbersome. The steps of fluidly connecting the trays to each other are often inconvenient. Removing a tray and replacing it with another one is also difficult.

[0008] Any discussion of documents, acts, materials, devices, articles or the like included in this specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application. Summary of the Invention

[0009] Thus, according to the present invention, there is provided a modular green roof system comprising base trays having a base, side walls and connecting means for connecting the trays in a side-by-side array, the side walls defining apertures for enabling fluid to flow from or into the trays, wherein the side walls of the trays are connectable together at the tops of the trays by (male and female) connecting structures defined on the side walls of the trays, in which arrangement the apertures of the connected trays are opposed and separated by a gap, the modular green roof system further comprising a fluid flow connector which is slidable between the apertures and defines a tubular portion connecting the apertures together to allow fluid to pass from one tray to the connected trays.

[0010] Advantageously, when using the system, the trays can initially be quickly connected together in any array using connectors on the tops of the trays, and connectors can subsequently be inserted between the trays to allow fluid to flow from one tray to another.

[0011] Typically, a pallet is roughly square in plan and has four side walls, with an aperture located in the center of each side wall, toward the base of the pallet. The side walls preferably slope outward from the base to the top. This makes the pallet easier to manufacture and stack for shipping.

[0012] In a preferred feature, there are a series of inner walls extending upwardly from the base of the tray for supporting an inner tray, geotextile sheet or the like.

[0013] Typically, the interior walls may be in the form of structures and may be cross-shaped in plan. They may slope from their base to their top.

[0014] In a preferred embodiment, a small horizontal step is defined in the side wall above the aperture but below the rim, typically at about the level of the top of the inner wall defining the series of drainage holes.

[0015] In a preferred embodiment, the tray includes a protruding rim, and the male and female connecting formations are defined on the rim.

[0016] Mounting the male and female connectors on the rims makes connections faster and easier than coupling the trays with pipes, and the raised rims ensure there is enough clearance between the trays to receive the fluid flow connectors.

[0017] The system may further include an inner tray positionable within a base tray supported by the structure, the tray defining an array of cavities depending from an upper surface of the inner tray, the surface defining a plurality of apertures.

[0018] Preferably, the wall of the tray defines a recess in which the aperture is defined, the recess having opposing side walls extending vertically upwards, and wherein at a top of the recess a protrusion enters the recess from an edge.

[0019] Preferably, the fluid flow connection defines two opposing walls connected by a tubular portion and a top portion connecting the two walls, and the top portion defines one or more grooves for receiving the projections defined in the rim.

[0020] Preferably, the fluid flow connection defines an aperture size that can receive a standard size drain pipe. This makes connection of the system to a roof top drainage system or the like much simpler.

[0021] The present invention also encompasses a single base tray and a single fluid flow connector, and particularly in trays for green roof systems, the trays having a base, side walls and connecting means for connecting the trays in a side-by-side array, the side walls defining apertures that enable fluid to flow from or into the trays, wherein the side walls of the trays are connectable together by (male and female) connecting structures defined on the side walls of the trays, in which arrangement the apertures of the connected trays are opposed and separated by a gap, the gap being configured to receive a connector that is slidable between the apertures and defines a tubular portion that connects the apertures together, thereby allowing fluid to pass from one tray to the connected trays.

[0022] Advantageously, green roof systems offer low maintenance costs because most of the water required to maintain a green roof is provided by rainwater. Fluid flow connections allow excess water that falls on one portion of the roof to flow and irrigate other areas. This makes the system particularly suitable for use on roofs with solar panels, as the panels cover the roof to some extent. Green roofs can also help keep the solar panels cooler than if they were installed on a bare concrete roof.

[0023] The present invention also encompasses a green roof system comprising a plurality of trays according to the first aspect, the trays interconnected and including fluid flow connections allowing fluid to flow between the trays, wherein the trays define a series of walls extending upwardly from a base of the trays, the walls supporting an inner tray above the base of the trays and defining a water reservoir below the trays, the green roof system further comprising a control unit operatively connected to an adjustable valve, such as a rotary valve, to control and vary the flow rate of water from the green roof to the roof drainage system / downpipe, the system including one or more sensors indicating water levels in one or more water tanks provided to the control unit, the control unit regulating water flow to the system based on the indicated water levels.

[0024] Preferably, the control unit is provided with weather information like expected rainfall amount and rainfall duration and is arranged to regulate the valve also based on said weather information.

[0025] Throughout this specification, the word "comprise" or variations such as "comprises" or "comprising" will be understood to imply the inclusion of a stated element, integer or step or group of elements, integers or steps but not the exclusion of any other element, integer or step or group of elements, integers or steps. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Specific embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:-

[0027] Figure 1 An assembly including a roof tray and an inner tray, as well as additional components, is shown;

[0028] Figure 2 A top isometric view of the base roof tray is shown;

[0029] Figure 2a yes Figure 2 An enlarged view of a corner of the tray;

[0030] Figure 3 Shown Figure 2 Bottom isometric view of the base of the roof tray;

[0031] Figure 4 Shown Figure 2 A side view of the base of the roof tray;

[0032] Figure 5 Shown Figure 2 A top plan view of the base of the roof tray;

[0033] Figure 5ashows an enlarged perspective view illustrating male and female connectors positioned on either side of an aperture defined in one side of the tray;

[0034] Figure 5b Shown Figure 5b An enlarged view of a portion of the top plan view is shown showing the connector in greater detail.

[0035] Figure 6 Isometric view of the inner pallet showing the base roof pallet

[0036] Figure 7 Shown Figure 3 A side view of the inner tray;

[0037] Figure 8 Shown Figure 2 a top isometric view of the roof pallet including the base of the inner pallet;

[0038] Figure 9 Shown Figure 2 A top isometric view of the base roof tray including the inner tray and erosion guard;

[0039] Figure 10 showing a front perspective view of an open fluid flow connection adapter;

[0040] Figure 11 Shown Figure 10 an end view of a fluid flow connection;

[0041] Figure 12 Shown Figure 10 a top view of a fluid flow connection;

[0042] Figure 13 Shown Figure 10 A front view of a fluid flow connection;

[0043] Figure 14 shows a front perspective view of a closed fluid flow connection;

[0044] Figure 16 is a perspective view showing two trays connected together along one side;

[0045] Figure 17 yes Figure 15 A top perspective view of the two trays shown;

[0046] Figure 17a yes Figure 16 A partial enlarged view showing the gap between the two trays;

[0047] Figure 18 Demonstrated the use of geotextiles to form cores; and

[0048] Figure 19 is a diagram showing the use of pallets as part of a "blue roof." DETAILED DESCRIPTION

[0049] With reference to the accompanying drawings, Figure 1 An assembly 100 is shown that includes the roof tray 10 and a number of additional components, which will be described in detail below.

[0050] Figures 2 to 5b The roof tray 10 is shown in more detail. The roof tray has a base 12, four identical side walls 14 and an open top. Figure 3 and 4 As can be clearly seen in the figure, a series of intersecting channels 16 in the shape of a hash mark are defined on the underside of the tray. This is to allow water to pass from under the tray and to prevent water from accumulating under or near the tray.

[0051] The pallet 10 is generally square in plan view, with sides 12 measuring approximately 500 mm long and 150 mm high. The sides slope slightly outward from the base to the open top. This allows the pallets to nest together when stacked one on top of the other, and also ensures that when the tops of the sides are connected, a gap is defined between the sides of adjacent pallets at the base. The pallet is injection molded from a suitable plastic material (typically recycled or partially recycled plastic).

[0052] In the center of each side wall 14, towards the base 12 of the tray, there is a circular aperture 20. Inside the tray there is a row of tapered cross-shaped structures / inner walls 18 that extend upward from the base to about half the height of the sides of the base. The cross-shaped structures 18 are inclined from their base to their top to allow them to be removed from the mold more easily. The top of the structure / wall is the secondary tray 50 (see Figure 6 and 7 ), geotextile sheets, etc., or provide other support for the growing medium and / or plants. Figure 5 As can be clearly seen in the figure, there is a gap / slot 19 between the walls 18, which spans the two axes of the tray, the purpose of which is described below. Figure 2 As can be seen in the figure, one of the walls / structures 18 extends all the way to the aperture 20 and divides it in two. It supports the edge of the geotextile sheet (not shown) located inside the tray and prevents the geotextile or growing medium from falling and blocking the aperture.

[0053] like Figure 4 As can be clearly seen in FIG, the side walls 14 slope slightly outwards from the base to the open top. There is a small step 15 approximately in the middle of the wall, which defines a number of drainage holes 15a, such as Figure 2aThere is a raised edge 22 at the top that extends outwardly beyond the plane of the side walls, except above each aperture 20 where there is a gap in the edge. Figures 5 to 5b As can be clearly seen in FIG, two or more trays can be connected together by using male and female connection structures / connectors defined on the edge 22. On the left side of the side wall relative to the aperture 20, there is a protruding male connector 24. Figure 5a and 5b As best seen in FIG, the male connector 24 has a generally T-shaped constant cross-section in the vertical axis defining a narrow stem 26 and a wider crosspiece or end flange 28. A corresponding female socket 30 is configured to receive a male locking element to the right of the aperture so that the trays 10 can be joined together side-by-side in a sliding arrangement. Figure 5b The female socket 30 defines a narrow slot 32 in the edge 22 which receives the rod 26 , behind which there is space for receiving the flange 28 .

[0054] like Figures 5 to 5b As can be clearly seen in the figure, the tray is slightly recessed at the location defining the aperture 20. The recess 21 has opposite side walls extending vertically upwards. At the top of the recess, a projection or tongue 34 extends from the edge into the recess which, in use, inserts into a corresponding groove on the connector or edge closure, as described in detail below. Figure 5a One tongue 34a is shown, and an opposing tongue 34b is shown. Figure 5a Hidden in but Figure 2 Shown in.

[0055] In normal use, multiple trays are connected side by side in a continuous array extending in the x and y directions in a generally horizontal plane. Figure 16 and 17 Only two trays 10 connected along opposite sides are shown. Figure 17a As best seen in FIG, at the top of each tray, the edge 22 meets a male connector 24 on one side of the tray, which mates with a corresponding female connector 30 of an adjacent tray. Figure 17 and 17aAs can be clearly seen in the diagram, when this connection is made there is a gap 40 between the side walls above the outlet. It is important to note that the connection between the male and female connectors can be somewhat loose and allow for some play and relative movement between the trays. The tray array sits on top of the trays, well above the apertures 20, and because they are not required to provide fluid flow, the tray array can be assembled very quickly as they easily plug together. The gaps 40 receive fluid flow connectors 50 (described below) which plug into the gaps 40. The choice of connector determines whether water can flow between adjacent trays. In most cases, a connector such as Figures 10 to 13 Straight-through fluid flow connection shown.

[0056] Figures 10 to 13 An open fluid flow connection 50 is shown for connecting the outlets of the trays together. The fluid flow connection defines two opposing walls 52 and 54 connected at the top by a horizontal top plate or roof portion 56. The two side edges of the top 56 define two notches or grooves 58 (only two of which are open at the top). Figure 10 It can be seen that Figure 12 2 and 3. As will be explained in detail below, these two notches or grooves cooperate with tongues 34 defined in the rim 22 of the tray in a tongue-and-groove connection to locate the fluid flow connection and secure it in place. Opposing circular apertures 60 are defined near the base of each wall 52, 54, connected by a short annular through-tube 62. The tubes are sized to receive standard size drain pipes to facilitate connection of the system to building drainage systems, downpipes, etc. Extending around the periphery of each aperture 60 is a recess or channel 64 of semi-circular cross-section which, in use, receives an O-ring seal 67 (in Figures 10 to 13 Not shown, but in Figure 16 ). Vertical tabs 66 extend upward from the top portion 56 and can be grasped to manipulate the connector and push it into the gap 40. In an alternative embodiment not shown, the tabs 66 can define holes to assist in pulling the fluid flow connector out of the gap when it is necessary to remove a tray from the array. In use, the connector 50 is inserted into the gap 40 between two adjacent trays and, when the connector is pushed to the base of the gap, the tubes 60 align with the apertures in the adjacent trays, allowing water to pass from one tray to the other. O-rings 67 are located in recesses 64 on each side of the connector to enhance the functionality of the system and ensure optimal sealing, although a reasonable seal can be achieved without the use of O-rings. Advantageously, the O-rings are compressed in the gap 40 and tend to force the trays apart, thereby eliminating most of the gap provided by the male and female connectors. When inserted into the gap 40, the tabs 32 engage with the grooves 58 in a tongue-and-groove locking arrangement.

[0057] Figure 14 A closed connection 70 is shown which is substantially identical to the open fluid flow connection and like parts have the same reference numerals. The only difference between the open fluid flow connection 40 and the closed connection 70 is that the tube 60 between the two walls is closed by a seal / plate 72 to prevent water from passing through the tube.

[0058] Figure 15 An edge closer 80 is shown, configured to close the aperture of the tray facing the exterior of the array. The edge closer is essentially one half of a closed connector, and like features have the same reference numerals. The edge closer is located in the recess 21 of the array and closes the aperture 20 via end seals 72 and O-rings (not shown). The edge closer 80 is locked in the recess 21 by a tongue and groove mechanism provided by projections 34 in the edge 22, which engage in grooves 58 on either side of the edge closer.

[0059] Figure 6 and 7 A secondary or inner tray 90 is shown which, when in use, can be placed inside the tray 10 supported on the inner wall structure 16. The tray is shaped like a chocolate box tray, defining an 8×8 array of generally square, tapered cavities 92 that depend from the top of the tray. A series of circular apertures 94 are defined in the top of the tray.

[0060] When in use, the auxiliary tray is Figure 8 The main tray is shown as being placed in a master tray, and a layer of geotextile is placed directly on top of it, and finally the growing medium and optionally plants (not shown) are placed on top of the growing medium. Rainwater that falls into the tray tends to accumulate in the cavities, and as the cavities fill, the water level will rise to the level of the top of the tray and flow into the main tray through the apertures 94. If a wick (not shown) is placed in the apertures of the growing medium extending from the bottom of the main tray into the upper portion of the tray, the apertures can also be used to wick any water in the main tray into the growing medium.

[0061] Figure 9 The use of an optional erosion guard 96 is shown, which is a cross-shaped plastic plate. The ends of the plates fit into recesses 98 formed in the inner wall of the tray 10 (e.g. Figure 2 Erosion guards help keep the growing medium evenly distributed in the tray, especially on sloped roofs.

[0062] Figure 1 Two further accessories are shown which may be clipped onto the pallet to increase the height / depth of the pallet in the form of side extensions 110 and side extension panels 112 .

[0063] In use, a plurality of trays 10 are assembled into an array and where the side walls face each other, the apertures 20 are connected or closed using closed connectors 70 or open connectors 50. Edge closers 80 are used to cover the apertures 20 around the edges of the array. Some edge apertures may alternatively be connected to storm drains, downpipes or other pipes to carry excess water, for example, during heavy rain or storms. The structure on the tray 10 may be covered with a geotextile sheet 200 or the like, or with an inner tray 90 which is then covered with geotextile. Figure 18 As shown, the geotextile 200 covering the structure 18 can be pushed down into the gap / trough 19 between two adjacent wall structures. In this case, the geotextile will act as a core and wick moisture upwards. As an alternative (not shown), rather than pushing the geotextile into the gap, individual strips of geotextile (typically about 500mm x 300mm) can be pushed into the groove to form the "T" shape before the geotextile is placed over the "T" shaped core. The tray can then be filled with growing medium and plants. Where a greater depth of growing medium is required or where the growing plants need to be protected from wind etc., side extensions 110 and / or side extension panels 112 can be used.

[0064] The provision of connectors can allow or block water from passing from one tray to another, thereby allowing for control of water flow within a rooftop tray array. Typically, edge closures are used around the edges of the array to keep rain and stormwater within the array, but some apertures around the exterior of the array can be connected to stormwater sewers, drainpipes, etc., and the connectors are sized to accept standard-sized drainpipes for easy connection. For example, in the case of a sloped roof, closed connectors can be used on the downslope side of the tray to encourage water flow across the slope rather than downhill. It is also contemplated that additional connectors, partially enclosed above the partially enclosed pipe 60, could be provided for water control. The modular nature of the system allows for different configurations to be assembled from basic components. Trays can be assembled together, pre-loaded with growing medium and plants. The connection system is waterproof and reliable, and also allows individual trays to be removed and replaced with new ones, for example, if plants in a tray die or become diseased, or if the tray becomes damaged.

[0065] refer to Figure 19 The system can be used as a "blue roof" system where the water level can be controlled by using one or more control valves. During heavy rain, water is retained in the tray (which acts as a retention tank) and then slowly released into the drainage system by opening the control valve. This helps prevent the drainage network from being overloaded during heavy rain. When the system is used as a "blue roof" and the drainage system cannot handle the water flow, the perimeter drain holes 15a (see Figure 2a ) also allows excess water to drain from the tank.

[0066] In particular, Figure 19 A control unit 200 is shown connected to and controlling a rotary valve 210. As is well known, rotary valves are controllable and can be opened to varying degrees to regulate fluid flow. One or more valves control the flow of water from the green roof to the roof drainage system / sewer. Other suitable valves may also be used. A water tank 120 is located adjacent to the valve, and the tank has a sensor that indicates the water level in the tank and feeds this information back to the control unit 200. Alternatively or additionally, sensors in one or more roof trays can measure the water level in the roof trays. Valve 110 can initially be closed or partially closed. When it rains, the plant's growing medium first receives water, and excess water collects in trays 90 beneath the plants. Once the trays are full, excess water then collects in the main tray. The valve opens and closes to regulate the outflow of water, preferably allowing excess water to flow out of the tank within a certain period of time (e.g., 24 hours). The control unit is also linked to weather information so that the expected rainfall amount and duration can be known in advance. Thus, if rain is predicted in a few hours and there is still water in the tank 120, the valve can be fully opened to release all the water contained in the tank, thereby preparing for the next rain.

[0067] Those skilled in the art will appreciate that numerous changes and / or modifications may be made to the above embodiments without departing from the broad overall scope of the present disclosure. Therefore, the embodiments of the present invention should be considered to be illustrative and not restrictive in all aspects.

Claims

1. A modular green roof system comprising base trays having a base, side walls and connecting means for connecting the trays in a side-by-side array, the side walls defining apertures for enabling fluid to flow from or into the trays, wherein the side walls of the trays are connectable together by preferably male and female connecting structures defined at the tops of the side walls of the trays, in which arrangement the apertures of the connected trays are opposed and separated by a gap, and the trays are at least loosely connected together It further comprises a further fluid flow connector slidable between the apertures and defining a tubular portion connecting the apertures together to allow fluid to pass from one tray to the connected tray.

2. A system as claimed in any preceding claim, wherein the tray is generally square in plan and has four side walls that slope outwardly from the base to the top, and wherein the aperture is located in the centre of each side wall towards the base of the tray.

3. A system as claimed in any preceding claim, wherein the tray includes a protruding edge and the male and female connecting structures are defined on the edge, the male connector being generally T-shaped and comprising a rod and a cross-piece, and the female connector defining a slot for receiving the rod which is narrower than the cross-piece, and a space behind the slot for receiving the cross-piece.

4. A system as claimed in any preceding claim, wherein the connection between the male and female connections is relatively loose and allows some movement between the trays.

5. A system as claimed in any preceding claim in which there is a series of internal walls extending upwardly from the base of the tray for supporting an inner tray, geotextile sheet or the like.

6. A system as claimed in any preceding claim, wherein the inner wall is in the form of a cruciform structure in plan view, and wherein preferably the structure slopes from the base to its top.

7. A system as claimed in claim 5 or 6, wherein a small horizontal step is defined in the side wall above the aperture but below the rim, typically at about the level at which the series of drainage holes are defined.

8. The system of any preceding claim, further comprising an inner tray positionable in the base tray supported by the structure, the tray defining an array of cavities depending from an upper surface of the inner tray, the surface defining a plurality of apertures.

9. The system of any preceding claim, the wall of the tray defining a recess, the aperture being defined in the recess, the recess having opposing side walls extending vertically upwardly, and wherein at a top of the recess a protrusion enters the recess from the edge.

10. The system of claim 9, wherein the connector defines two opposing walls connected by the tubular portion and a top portion connecting the two walls, and the top portion defines one or more grooves for receiving the protrusions defined in the rim.

11. The system of any preceding claim, wherein the connector defines an aperture size capable of receiving a standard size drain pipe.

12. A tray for a green roof system, the trays having a base, side walls, and connecting means for connecting the trays in a side-by-side array, the side walls defining apertures for enabling fluid to flow from or into the trays, wherein the side walls of the trays are connectable together by (male and female) connecting structures defined on the side walls of the trays, the trays being at least loosely connectable together by means of the connecting structures, in this arrangement the apertures of the connected trays being opposed and separated by a gap, the gap being configured to receive a fluid flow connector, the fluid flow connector being slidable between the apertures and defining a tubular portion connecting the apertures together to allow fluid to be transferred from one tray to the connected trays.

13. A green roof system comprising a plurality of trays as claimed in claim 11, the trays being interconnected and including fluid flow connections that allow fluid to flow between the trays, wherein the trays define a series of walls extending upwardly from a base of the trays, the walls supporting an inner tray above the base of the trays and defining a water reservoir below the trays, the green roof system further comprising a control unit operatively connected to an adjustable valve, such as a rotary valve, to control and vary the flow rate of water from the green roof to the roof drainage system / downpipe, the system including one or more sensors that indicate water levels in one or more water tanks provided to the control unit, the control unit regulating water flow to the system based on the indicated water levels.

14. A green roof system according to claim 13, wherein the control unit is provided with weather information such as expected rainfall amount and rainfall duration and is arranged to regulate the valve also based on the weather information.

15. A green roof system as claimed in claim 13 or 14 including growing medium and plants supported by the inner tray.

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