A tile for mounting solar cells to a roof

Abstract

A tile for mounting solar cells to a roof, the tile comprising : a base suitable for mounting on a roof, the base comprising a thermal insulation layer; a solar cell mounted to the base and extending from a first edge to a second edge at an angle of inclination, relative to the base; and a reflector mounted to the base and extending from a first edge to a second edge at an angle of inclination, relative to the base, wherein the first edges of the reflector and the solar cell are joined.

Description

[0001] A TILE FOR MOUNTING SOLAR CELLS TO A ROOF

[0002] This invention relates to a tile for mounting solar cells to a roof.

[0003] Known devices and systems for mounting solar cells to a roof comprise a simple frame for attaching the solar cells to a roof. The frames serve very little, if any, additional purpose beyond their primary function.

[0004] According to a first aspect of the invention, there is provided a tile for mounting solar cells to a roof, the tile comprising: a base suitable for mounting on a roof, the base comprising a thermal insulation layer; a solar cell mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, of 30 degrees or less; and a reflector mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, of 30 degrees or less, wherein the reflector is configured to reflect sunlight towards the solar cell.

[0005] The invention provides both a thermally insulative layer and a solar cell and thereby serves a dual purpose. The invention may be of particular use for rooves of buildings in countries with hot climates where a building roof receives large amounts of sun light through the course of the year and insulating the roof helps to keep the building cool, thereby reducing or even eliminating the need for air conditioning, or similar cooling systems. The invention may also be of particular use in countries that experience both hot and cold temperatures over the course of the year. In addition to helping to keep a building cool in hot conditions, the thermal insulation layer may help to keep the building warm in cool conditions.

[0006] The solar cell of the invention is inclined at an angle of up to 30 degrees with the intention that it would be mounted on a roof to face the Sun's primary position in the sky; that is, south-facing if used in the northern hemisphere and north-facing if used in the southern hemisphere. The invention also includes a reflector configured to reflect additional sunlight towards the solar cell, thereby increasing the electrical energy which may be generated by the solar cell by as much as 15%. The inclination of the solar cell and reflector means that the invention may be particularly effective when mounted on flat rooves, such as those typically found in Mediterranean countries, which also receive large amounts of sunlight. The solar cell may be a photovoltaic (PV) solar cell.

[0007] The thermal insulation layer may be any suitable material for providing thermal insulation to a building. One example of such a material is expanded polystyrene.

[0008] In one or more embodiments, the first edges of the solar cell and the reflector may be joined. In other words, the solar cell and reflector may be arranged to have a V-shaped cross-section. Particularly when the sun is high in the sky, sun light that hits the reflector may be directed towards the solar cell.

[0009] In one or more embodiments, the tile may further comprise a drain located at the first edges of the reflector and the solar cell. Water, dust and other debris, which might otherwise accumulate on the solar cell and the reflector, may fall through the drain so that the solar cell and the reflector require cleaning less often, if at all.

[0010] The tile may further comprise a support structure configured to elevate the solar cell and the reflector from the base such that the first edges are spaced apart from the base. This allows plenty of space into which water, dust and other debris can disperse having fallen through the drain.

[0011] In one or more embodiments, at least one of the solar cell and the reflector may extend from the first edge to the second edge at a non-zero angle of inclination, relative to the base, of 25 degrees or less, optionally 20 degrees or less, further optionally 15 degrees or less. Reduced angles of inclination allow more sunlight to reach the solar cell when the sun is lower in the sky, during morning, evenings and particularly in winter months. Accordingly, lower angles of inclination are particularly beneficial in countries that are further from the equator.

[0012] In some embodiments, the solar cell and the reflector may extend from the first edge to the second edge symmetrically. In other embodiments of the invention, the solar cell and the reflector may extend from the first edge to the second edge asymmetrically.

[0013] In one or more embodiments, the reflector comprises aluminium, which is a cost effective material that provides favourable levels of sun light reflection. In other embodiments of the invention, the reflector may comprise a different reflective material that provide similarly favourable levels of sun light reflection, or may comprise a non-reflective material and a reflective layer, wherein the reflective layer is layered on the non-reflective material to form a reflector side.

[0014] In one or more embodiments, the tile may further comprise a folded panel comprising a solar cell portion and a reflector portion separated by a fold line, wherein: the solar cell portion comprises the solar cell and the first edge of the solar cell is located at the fold line; and the reflector portion comprises the reflector and the first edge of the reflector is located at the fold line.

[0015] Providing the solar cell and the reflector on a single sheet of folded material provides the tile with high structural strength while also being cost-effective to manufacture. For example, the folded panel may be formed from sheet aluminium. The sheet aluminium may be cut to the required size and folded as necessary to support the solar cell and the reflector at the desired angles of inclination.

[0016] In some embodiments, the reflector portion of the folded panel acts as the reflector. In other words, the reflector forms part of the folded panel, specifically the reflector portion. For example, if the folded panel is formed from sheet aluminium, an external surface of the sheet aluminium in the reflector portion may act to reflect sun light towards the solar cell.

[0017] In one or more embodiments, the base may comprise a connector connectable to a connector of another tile.

[0018] Accordingly, a plurality of tiles according to such embodiments of the invention may be connected to one another in a modular fashion.

[0019] In one or more embodiments, the base may comprise electrical circuitry for transmitting electricity from the solar cell. For example, the base may comprise a PV junction box and electrical wiring.

[0020] In embodiments wherein the base comprises both a connector and electrical circuitry, the connector may comprise an electrical connector for connecting the electrical circuitry of the tile to the electrical circuitry of another tile. Therefore, a plurality of tiles may be electrically connected to one another, as well as physically connected to one another. The connector may comprises a male connector and a female connector, at least one of which may be moveable relative to the respective base to enable easier connection.

[0021] In one or more embodiments the base may be waterproof. Accordingly, in addition to providing a building with electrical energy production and thermal insulation, the tile may also assist with waterproofing the building. Further, the connectors may be configured to provide a waterproof connection with an adjacent tile such that a plurality of tiles may form a continuous waterproof layer over the roof of a building.

[0022] In one of more embodiments, the tile may comprise a plurality of solar cells and reflectors mounted to the base in an alternating sequence. For example, the tile may comprise, in order: a first solar cell extending across a width of the tile; a first reflector extending across the width of the tile and positioned to reflect sunlight towards the first solar cell; a second solar cell extending across the width of the tile and oriented with substantially the same angle of inclination as the first solar cell; and a second reflector extending across the width of the tile and positioned to reflect sunlight towards the second solar cell.

[0023] According to a second aspect of the invention, there is provided a tile for mounting solar cells to a roof, the tile comprising: a base suitable for mounting on a roof; a solar cell mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base; a reflector mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, wherein the reflector is configured to reflect sunlight towards the solar cell; and a drain located at the first edges of the reflector and the solar cell.

[0024] The features and advantages of the first aspect of the invention and its embodiments apply mutatis mutandis to the second aspect of the invention and its embodiments.

[0025] For example, in one or more embodiments, one or both of the solar cell and the reflector may extend from the first edge to the second edge at a non-zero angle of inclination, relative to the base, of: 30 degrees or less, 25 degrees or less; 20 degrees or less; or 15 degrees or less.

[0026] According to a third aspect of the invention, there is provided a modular tile arrangement comprising a plurality of tiles, each tile in accordance with any one of the first and second aspects of the invention and their embodiments, wherein each of the plurality of tiles is detachably connected to one or more other of the plurality of tiles.

[0027] In embodiments of the modular tile arrangement, each of the plurality of tiles may be detachably connected to one or more other of the plurality of tiles so that the bases of the tiles form a combined base for mounting on a roof.

[0028] In further embodiments of the modular tile arrangement, each of the plurality of tiles may be detachably connected to at least two or more other of the plurality of tiles.

[0029] The features and advantages of the first and second aspects of the invention and their embodiments apply mutatis mutandis to the third aspect of the invention and its embodiments.

[0030] It will be appreciated that the use of the terms "first" and "second", and the like, in this patent specification is merely intended to help distinguish between similar features and is not intended to indicate the relative importance of one feature over another feature, unless otherwise specified.

[0031] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, and the claims and / or the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and all features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.

[0032] Preferred embodiments of the invention will now be described, by way of non-limiting examples, with candidate to the accompanying drawings in which:

[0033] Figure 1 shows schematically a tile according to a first embodiment of the invention;

[0034] Figure 2 shows the tile of Figure 1 with internal components revealed to the viewer;

[0035] Figure 3 shows a close-up of the tile of the preceding figures, particularly showing a drain; Figures 4 and 5 show further close-ups of the preceding figures, particularly showing connectors;

[0036] Figure 6 shows an array formed from a plurality of tiles;

[0037] Figure 7 shows a tile according to a second embodiment of the invention;

[0038] Figure 8 shows a folded panel forming part of the tile of Figure 7; and

[0039] Figure 9 shows a panel prior to being folded into the folded panel of Figure 8.

[0040] The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic form in the interests of clarity and conciseness.

[0041] A tile according to a first embodiment of the invention is shown in Figures 1 and 2 and is designated generally by the reference numeral 2. The tile comprises a base 4, a solar cell 6 and a reflector 8. More specifically, this embodiment comprises three solar cells 6 and three reflectors 8. However, it will be appreciated that a tile according to other embodiments of the invention may comprise any number of solar cells 6 and a corresponding number of reflectors 8.

[0042] The solar cells 6 are mounted to the base and extend from a first edge 11 to a second edge 12 at an angle of inclination, relative to the base 4, of 30 degrees. Similarly, the reflectors 8 are also mounted to the base 4 and extend from a first edge 11 to a second edge 12 at an angle of inclination, relative to the base 4, of 30 degrees. The first edges 11 of the reflector 8 and the solar cell 6 are joined.

[0043] It is envisioned that this embodiment may be used on a flat roof in Malta, where flat rooves and long periods of sunshine are common. With the solar cells 6 and reflectors 8 inclined at 30 degrees, the solar cells 6 may receive sunlight between about 9:30 am and 2:30 pm even in the dead of winter (i.e., December 21st).

[0044] In other embodiments of the invention, the angles of inclination may be less than 30 degrees, for example, one or both of the angles of inclination may be 25 degrees or less; 20 degrees or less; or 15 degrees or less (provided that the angles of inclination are greater than 0 degrees). This may be particularly beneficial in countries located further from the equator than Malta.

[0045] The base 4 is suitable for mounting on a roof (not shown). External elements of the base 4 are shown in Figure 1 while internal elements of the base 4 are sown in Figure 2. Externally, the base 4 comprises a support structure 14 and a plurality of connectors 16. The support structure 14 is configured to elevate the solar cells 6 and the reflectors 8 from the base 4 such that the first edges 11 are spaced apart from the base 4. The connectors 16 are each connectable to an adjacent connector of another tile (not shown) placed next to the tile 2.

[0046] Internally, the base 4 comprises a thermal insulation layer 18 and electrical circuitry 12. In this embodiment, the electrical circuitry 20 comprises a junction box 22 and electrical wiring 24 extending from the junction box 22 to electrical connectors 26 which form part of the connectors 16 shown in Figure 1. The electrical connectors 26 enable the electrical circuitries of a plurality of tiles 2 to be connected together.

[0047] Figure 3 shows a close-up view of the tile 2 shown in Figures 1 and 2. In particular, Figure 3 shows a drain 28 located at the first edges 11 of the solar cell 6 and reflector 8. In combination with the support structure 14, which ensures there is empty space between the drain 28 and the base 4, the drain 28 allows water, dust and other debris to disperse rather than accumulate on the collar cell 6 and reflector 8. This prevents the effectiveness of the solar cell 6 being negatively impacted by accumulations of water, duct and / or other debris and reduces or eliminates the need to clean the tile 2.

[0048] Figures 4 and 5 show further close-up views of the tile 2 shown in Figures 1 and 2. In particular, Figures 4 and 5 each show a connector forming part of the base 4.

[0049] The connector 16 in Figure 4 comprises a male connector 30 and the connector in Figure 5 comprises a female connector 32 configured to receive a male connector 30 of an adjacent tile 2. The connector 16 in Figure 4 further comprises a flexible portion 34 allowing movement of the male connector 30 to facilitate easier connection with a female connector 32.

[0050] Figure 6 shows a plurality of tiles 2 connected together to form an array 36. An array 36 of suitable size and shape may be formed to cover a roof (not shown), preferably a flat roof. Each tile 2 provides the building with electrical production capabilities and thermal insulation. Each base 4 is also waterproof, meaning that the tiles 2 may be used to improve the waterproofing of the building. Further, the bases 4 are connectable via waterproof connections so that the overall array 36 is also waterproof, enabling even better waterproofing of a building.

[0051] The array 36 of tiles 2 forms a modular tile arrangement in which each of the plurality of tiles 2 is detachably connected to one or more other of the plurality of tiles 2. The bases 4 combine to form a combined base for mounting on a roof. The modularity of the modular tile arrangement lies in the detachable connection of the tiles 2 to each other. Hence, one or more tiles 2 may be easily detached from the array 36 for maintenance, repair or replacement, and the shape and size of the modular tile arrangement can be readily varied to match the size and shape of the roof. In this regard it is preferable that the tiles are identical in shape, size and / or features. In particular, it is preferable for the tile's connectors 16,30,32 to be in the same relative positions in the tile 2, which simplifies the connection of the tiles 2 to each other.

[0052] A tile 102 according to a second embodiment of the invention is shown in Figure 7. The tile 102 is very similar to the tile 2 shown in the preceding figures except that the positioning of the solar cells 106 and reflectors 108 is different. Rather than having a second edge 12 of a solar cell 6 or reflector 8 positioned at edges of the tile (as is the case for the tile 2), a first edge 11 of a solar cell 106 is positioned at one edge of the tile 102 and a first edge 11 of a reflector 108 is positioned at the opposite edge of the tile 102.

[0053] The tile 102 functions exactly the same as the tile 2 of the preceding figures. However, to reap the full benefit of combining a solar cell 106 with a reflector 108, it is necessary to have additional tiles (not shown) positioned on either side of the tile 102.

[0054] The tile 102 further comprises a folded panel 138 which is shown, in isolation, in Figure 8.

[0055] The folded panel 138 comprises a solar cell portion 140 and a reflector portion 142 separated by a fold line 144. More specifically, the folded panel comprises three solar cell portions 140 and three reflector portions 142 arranged in an alternating sequence with a fold line 144 positioned between each portion 140, 142.

[0056] As shown in Figure 7, each solar cell portion 140 comprises a solar cell 106 and the first edge 11 of each solar cell 106 is located at a respective fold line.

[0057] Meanwhile, each reflector portion 142 of the folded panel 138 acts as a reflector 108 wherein the first edge of each reflector 108 is defined by a respective fold line 144.

[0058] In this embodiment, the folded panel 138 is formed from sheet aluminium such that the reflectors 108 may be considered as the external surface of aluminium forming part of the reflector portions 142. Figure 9 shows a panel 146 prior to being folded into a folded panel 138 as shown in Figure 8. The panel 146 is cut to the size and shape required to form the respective solar cell and reflector portions 140, 142. Drains 28 are also cut into the panel 146 along the fold lines 144 which will be located at the first edges of respective solar cells 106 and reflectors 108. The panel 146 may then be folded into the folded panel 138. This allows the tile 102 to be manufactured cost effectively. Also, by virtue of the folded panel being formed as a single piece, the tile 102 benefits from good structural strength.

[0059] It will be appreciated that any aforementioned numerical value is merely intended to help illustrate the working of the invention and may vary depending on the requirements of the invention.

[0060] The listing or discussion of an apparently prior published document or apparently prior published information in this specification should not necessarily be taken as an acknowledgement that the document or information is part of the state of the art or is common general knowledge.

[0061] Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention.

Claims

CLAIMS1. A tile for mounting solar cells to a roof, the tile comprising: a base suitable for mounting on a roof, the base comprising a thermal insulation layer; a solar cell mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, of 30 degrees or less; and a reflector mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, of 30 degrees or less, wherein the reflector is configured to reflect sunlight towards the solar cell.

2. A tile according to Claim 1, wherein the first edges of the solar cell and the reflector are joined.

3. A tile according to Claim 1 or Claim 2, further comprising a drain located at the first edges of the reflector and the solar cell.

4. A tile according to any preceding claim, further comprising a support structure configured to elevate the solar cell and the reflector from the base such that the first edges are spaced apart from the base.

5. A tile according to any preceding claim, wherein at least one of the solar cell and the reflector extend from the first edge to the second edge at an angle of inclination, relative to the base, of 25 degrees or less.

6. A tile according to any preceding claim, wherein at least one of the solar cell and the reflector extend from the first edge to the second edge at an angle of inclination, relative to the base, of 20 degrees or less.

7. A tile according to any preceding claim, wherein at least one of the solar cell and the reflector extend from the first edge to the second edge at an angle of inclination, relative to the base, of 15 degrees or less.

8. A tile according to any preceding claim, wherein the solar cell and the reflector extend from the first edge to the second edge symmetrically.

9. A tile according to any of Claims 1 to 7, wherein the solar cell and the reflector extend from the first edge to the second edge asymmetrically.

10. A tile according to any preceding claim, wherein the reflector comprises aluminium.

11. A tile according to any preceding claim, further comprising a folded panel comprising a solar cell portion and a reflector portion separated by a fold line, wherein: the solar cell portion comprises the solar cell and the first edge of the solar cell is located at the fold line; and the reflector portion comprises the reflector and the first edge of the reflector is located at the fold line.

12. A tile according to Claim 11, wherein the folded panel is formed from sheet aluminium.

13. A tile according to Claim 11 or Claim 12, wherein the reflector portion of the folded panel acts as the reflector.

14. A tile according to any preceding claim, wherein the base comprises a connector connectable to a connector of another tile.

15. A tile according to Claim 14, wherein: the base comprises electrical circuitry for transmitting electricity from the solar cell; and the connector comprises an electrical connector for connecting the electrical circuitry of the tile to the electrical circuitry of another tile.

16. A tile according to Claim 14 or Claim 15, wherein the connector comprises a male connector and a female connector.

17. A tile according to any preceding claim, wherein the base is waterproof.

18. A tile according to any preceding claim, wherein the tile comprises a plurality of solar cells and reflectors mounted to the base in an alternating sequence.

19. A tile for mounting solar cells to a roof, the tile comprising: a base suitable for mounting on a roof; a solar cell mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base;a reflector mounted to the base and extending from a first edge to a second edge at a non-zero angle of inclination, relative to the base, wherein the reflector is configured to reflect sunlight towards the solar cell; and a drain located at the first edges of the reflector and the solar cell.

20. A modular tile arrangement comprising a plurality of tiles, each tile in accordance with any preceding claim, wherein each of the plurality of tiles is detachably connected to one or more other of the plurality of tiles.

21. A modular tile arrangement according to Claim 20 wherein each of the plurality of tiles is detachably connected to one or more other of the plurality of tiles so that the bases of the tiles form a combined base for mounting on a roof.

22. A modular tile arrangement according to Claim 20 or Claim 21 wherein each of the plurality of tiles is detachably connected to at least two or more other of the plurality of tiles.

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