A composite insulating panel

Abstract

A composite insulating panel, comprising: an internal sheet; an external sheet; and an insulating body between the external sheet and the internal sheet; wherein the external sheet comprises a first longitudinally extending raised projection at a first side of the panel, a second longitudinally raised projection at a second opposing side of the panel and a substantially flat portion extending between the first longitudinally extending raised projection and the second longitudinally raised projection; and wherein the substantially flat portion comprises a first raised longitudinal shoulder member at the first side of the panel and a second raised longitudinal shoulder member at the second opposing side of the panel, the first raised longitudinal shoulder member and the second raised longitudinal shoulder member for supporting a photovoltaic module between the first longitudinally extending raised projection and the second longitudinally raised projection.

Description

TitleA composite insulating panelField of the Invention

[0001] The present invention relates to composite insulating panels and in particular composite insulating panels suitable for mounting photovoltaic modules thereupon.Background to the Invention

[0002] With increasing energy costs there is a need for a more thermally efficient system for cladding a building, and in particular, for providing a roof for a building. Various attempts have been made to provide composite insulating panels with photovoltaic material applied. EP 2925940 B1 provided a composite insulating panel having a gap provided between lateral peripheral edges of an outer face of the composite insulating panel for receiving a photovoltaic solar collector module. EP 2748859 a one provided for a composite insulating panel with photovoltaic sheets located between raised projections. GB2488902B provides a solar collector sheet laminated to the external sheet of the panel. EP2871299 provides a composite insulating panel having a cut-away opening in the external sheet of the composite insulating panel for receiving a photovoltaic panel. These solutions are not suitable for all environments. GB2521860A provides for a roofing panel where a photovoltaic module is inserted or pushed into a channel on the underlap crown of the composite insulating panel. The previous provided composite panels can often result in breakages of the photovoltaic cells, increased cost of manufacture, decreased efficiency of solar collection due to installation of the cell on the panel, the need for additional reinforcements of the composite panels where the structural integrity of the composite panel is compromised to accommodate the photovoltaic panels and the like.

[0003] With increasing volumes of solar collector installations there is a need to provide a consistently high-quality panel system for the construction industry. There is a further need to provide a robust installation suitable for a wide variety of climates. It is further desirable to provide a composite panel that can be integrated with existing composite insulating panels. It is further desirable to provide a composite insulating panel and a solar collection system incorporating this panel that can be manufactured in a factory setting and transported in an installation-ready state to the customer. The present application is directed towards providing an improved composite insulating panel and solar collection system which provides a solution to the needs outlined above.Summary of the InventionIn accordance with the present application, there is provided a composite insulating panel, comprising: an internal sheet; an external sheet; and an insulating body between the external sheet and the internal sheet; wherein the external sheet comprises a first longitudinally extending raised projection at a first side of the panel, a second longitudinally raised projection at a second opposing side of the panel and a substantially flat portion extending between the first longitudinally extending raised projection and the second longitudinally raised projection; and wherein the substantially flat portion comprises a first raised longitudinal shoulder member at the first side of the panel adjacent the first longitudinally extending raised projection and a second raised longitudinal shoulder member at the second opposing side of the panel adjacent the second longitudinally raised projection, the first raised longitudinal shoulder member and the second raised longitudinal shoulder member for supporting a photovoltaic module between the first longitudinally extending raised projection and the second longitudinally raised projection, wherein a height, h2, of the first longitudinal shoulder member and the second longitudinal raised shoulder member from the substantially flat portion is less than a height, h, of the first longitudinally extending raised projection and the second longitudinally raised shoulder member from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised projections.

[0004] The composite insulating panel provides an improved profile for the installation of a photovoltaic module. The raised longitudinal shoulder members provide a support for the photovoltaic module. The first and second longitudinally extending raised projections allow for overlap and underlap with adjacent composite insulating panels providing a robust joint, backward compatibility with existing panels a d a structural integrity for the panel. The positioning of the shoulder members provides a mounting for the photovoltaic module that does not interfere with the integrity of the joint between adjacent panels.

[0005] The composite insulating panel may further comprise at least one additional longitudinal shoulder member between the first raised longitudinal shoulder member and the second raised longitudinal shoulder member and further arranged for supporting the photovoltaic module. These additional shoulder members provide additional structural support for a photovoltaic module.

[0006] The first raised longitudinal shoulder member and the second raised longitudinal shoulder member have a trapezoidal profile having a substantially flat uppermost face at a height h above the substantially flat portion of the external sheet.

[0007] This trapezoidal profile ensures structural integrity and allows for a flat surface on the uppermost portion for supporting a photovoltaic module.

[0008] The at least one additional longitudinal shoulder member may have a trapezoidal profile having a substantially flat uppermost face at a height h above the substantially flat portion. This trapezoidal profile ensures structural integrity and allows for a flat surface on the uppermost portion for supporting a photovoltaic module. By supporting a photovoltaic module at the height h2 above the substantially flat portion a gap is provided between the photovoltaic module and the flat surface of the external sheet. This provides improved air flow and thus optimal efficiency of the photovoltaic module. The gap further allows water to run off the panel along the external top layer rather than along the outer surface of the photovoltaic module.

[0009] The first and second longitudinally extending raised projection may have a trapezoidal profile having a substantially flat uppermost face at the height h from the substantially flat portion, wherein the height h is greater than the height h2. The photovoltaic module when installed then sits below the level of the extending raised projection. This protects the photovoltaic module from damage in transit.

[0010] The first longitudinally extending raised projection may be engageable with a second longitudinally extending raised projection of an adjacent panel. This ensures a secure joint between adjacent panels.

[0011] The substantially flat portion further may comprise one or more longitudinally extending recessed indentations. This facilitates water runoff from the surface of the panel.

[0012] In an alternative embodiment, there is provided a solar collection system comprising: a composite insulating panel and a photovoltaic module, the composite insulating panel comprising an internal sheet; a profiled external sheet; and an insulating body between the external sheet and the internal sheet; wherein the external sheet comprises a first longitudinally extending raised projection at a first side of the panel, a second longitudinally raised projection at a second opposing side of the panel and a substantially flat portion extending between the first longitudinally extending raised projection and the second longitudinally raised projection; and wherein the substantially flat portion comprises a first raised longitudinal shoulder member at the first side of the panel adjacent the first longitudinally extending raised projection and a second raised longitudinal shoulder member at the second opposing side of the panel adjacent the second longitudinally raised projection, the first raised longitudinal shoulder member and the second raised longitudinal shoulder member for supporting the photovoltaic module thereon between the first longitudinally extending raised projection and the secondlongitudinally raised projection wherein a height, h2, of the first longitudinal shoulder member and the second longitudinal raised shoulder member from the substantially flat portion is less than height, h, of the first longitudinally extending raised projection and the second longitudinally raised shoulder member from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised projections.

[0013] This solar collection system can be provided as a single unit, thus ensuring robustness and guaranteed factory-controlled quality, mitigating against human installation error on site.

[0014] The system may further comprise at least one additional longitudinal shoulder member between the first raised longitudinal shoulder member and the second raised longitudinal shoulder member and further arranged for supporting the photovoltaic module.

[0015] The first raised longitudinal shoulder member and the second raised longitudinal shoulder member have a trapezoidal profile having a substantially flat uppermost face extending the height h2 above the substantially flat portion.

[0016] The at least one additional longitudinal shoulder member shoulder member may have a trapezoidal profile having a substantially flat uppermost face extending a height h2 above the substantially flat portion.

[0017] The first and second longitudinally extending raised projection may have a trapezoidal profile having a substantially flat uppermost face at a height h from the substantially flat portion, wherein the height h is greater than the height h2.

[0018] The system may further comprise mechanical means for attaching the photovoltaic module to the composite insulating panel. This ensures a secure and adaptable connection between the module and the panel and further allows a panel to be replaced or repaired. Mechanical connection can be used to account for environmental changes which causes the panel to deform, expand or contract.

[0019] The system may further comprise chemical means for attaching the photovoltaic module to the composite insulating panel.

[0020] Each of the first longitudinal shoulder member and second longitudinal shoulder member further comprise an elastically deformable layer positioned on their substantially flat uppermost face between the respective shoulder member and the photovoltaic module supported thereon. This elastically deformable layer provides for cushioned support for the photovoltaic module.

[0021] The at least one additional longitudinal shoulder member raised longitudinal shoulder member may further comprise an elastically deformable layer positioned on itssubstantially flat uppermost face between the third raised longitudinal shoulder member and the photovoltaic module supported thereon. This elastically deformable layer provides for cushioned support for the photovoltaic module.

[0022] The photovoltaic module may have a height h3 and wherein h is greater than the (h2+h3). This ensures that the photovoltaic module is protected in situ by the first and second longitudinally extending raised projection. This configuration further allows the solar collection system to be stacked vertically for efficient storage or transport.

[0023] The system may further comprise a second composite panel adjacent the composite panel and wherein the first longitudinally extending raised projection engages with a second longitudinally extending raised projection of the second composite panel.

[0024] The second longitudinally extending raised projection of the second composite panel may underlap the first longitudinally extending raised projection of the composite panel.

[0025] The system may further comprise electrical circuitry for the photovoltaic module.

[0026] The system may further comprise housing for the electrical circuitry, said housing located between a rear face of the photovoltaic module and the substantially flat portion of the profiled external sheet.

[0027] In an alternative embodiment of the present application there is provided a roof system comprising a plurality of solar collection systems as described above.

[0028] A further embodiment of the present application provides a method for manufacturing a solar collection system comprising: providing an internal sheet; providing an external sheet and providing an insulating body between the internal sheet and the profiled external sheet, wherein the profiled external sheet comprises a first longitudinally extending raised projection at a first side of the panel, a second longitudinally raised projection at a second opposing side of the panel and a substantially flat portion extending between the first longitudinally extending raised projection and the second longitudinally raised projection; and wherein the substantially flat portion comprises a first raised longitudinal shoulder member at the first side of the panel adjacent the first longitudinally extending raised projection and a second raised longitudinal shoulder member at the second opposing side of the panel adjacent the second longitudinally raised projection, the first raised longitudinal shoulder member and the second raised longitudinal shoulder member for supporting the photovoltaic module thereon between the first longitudinally extending raised projection and the second longitudinally raised projection wherein a height, h2, of the first longitudinal shoulder member and the second longitudinal raised shoulder member from the substantially flat portion is less than a height, h, of the first longitudinally extendingraised projection and the second longitudinally raised projection from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised projections; providing an elastically deformable layer on an uppermost portion of each the first raised longitudinal shoulder member and the second raised longitudinal shoulder member; attaching a photovoltaic module to the uppermost portion of the first raised longitudinal shoulder member and the second raised longitudinal shoulder member, the elastically deformable layer positioned between the uppermost portion of the respective longitudinal shoulder member and the photovoltaic module.

[0029] The method may comprise providing mechanical means or chemical means for attaching the photovoltaic module to the raised longitudinal shoulder members.

[0030] The mechanical means may comprise a first clamping member 22 for engaging the photovoltaic module with the first raised longitudinal shoulder member and a second clamping member for engaging the photovoltaic module with the second raised longitudinal shoulder member.

[0031] The chemical means may comprise an adhesive.

[0032] The elastically deformable layer may comprise a factory applied weather seal. By applying the factory applied weather seal under controlled factory conditions a more efficient seal is provided. The factory application ensures reduced on-site labour costs and installation time, providing a faster and more cost-effective alternative to traditional tape methods.

[0033] Each clamping member may comprise a first portion for attaching to the respective raised longitudinal shoulder member and a second portion for engaging the photovoltaic module.

[0034] The first portion may be mechanically engaged with the uppermost surface of the respective raised longitudinal shoulder member.

[0035] The second portion may comprise an upper jaw and a lower jaw wherein the upper jaw engages with an uppermost surface of the photovoltaic module and the lower jaw engages with a second surface of the photovoltaic module opposite the uppermost surface to hold the photovoltaic module in a vice or clamp like grip. This configuration of clamping member ensures that the photovoltaic module can be readily removed for repair or replacement as well as taking into account any environmental or operational changes with the composite insulating panel.Brief Description of the Drawings

[0036] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings in which:

[0037] Figure 1 is an isometric view of two joined composite panels according to the present invention in a side-by-side arrangement.

[0038] Figure 2 is a view of the joint of the two composite insulating panels of Figure 1.

[0039] Figure 3 is a plan view of two joined composite panels according to the present invention in the side-by-side arrangement of Figure 1.

[0040] Figure 4 is a cross sectional view of a profiled external sheet in accordance with the present invention.

[0041] Figure 5 is a cross sectional view of a composite insulating panel according to the present invention.

[0042] Figure 6 is a plan view of a solar collection system comprising a composite insulating panel and a photovoltaic module in accordance with the present invention.

[0043] Figure 7 is an isometric view of the system of claim 6.

[0044] Figure 8 is an end view of the system of Figure 6.

[0045] Figure 9 is a cross section of a composite insulating panel according to the present invention.Detailed Description of the Drawings

[0046] Referring to the drawings there is illustrated an insulating panel 1 according to the invention. The insulated panel may be provided with an included photovoltaic module 12 or without a photovoltaic module 12.

[0047] The insulating panel in this case comprises a first sheet or external sheet 3, a second sheet or internal sheet 2 with an insulating body 4, for example an insulating foam there between. The foam may, for example be polyisocyanurate foam or phenolic foam. In an embodiment, the panel 1 is a roof panel and the external sheet and the internal sheet 3 are metal, such as galvanised / or painted steel. It will be appreciated that the construction of the solar collecting system provided here in allows for a painted coating for the composite insulating panel of the present invention consistent with the remainder of the roof or panel construction on the building. It will be appreciated that the outer external sheet may be aluminium or stainless steel. In a configuration it will be appreciated that one of the internal or external sheets may be glass fibre reinforced plastic, though generally such a plastic is used only for the internal sheet.

[0048] The insulating body extends between the inner face of the internal sheet 2 and the inner faces of the external sheet 3. By extending, it is meant that the body of insulatingmaterial fills the area between the inner face of the external sheet and the inner face of the internal sheet.

[0049] The external sheet 2 has a first longitudinally extending raised projection 5 at one side of the panel and a second longitudinally extending raised projection 6 on the opposite side of the panel. The external sheet 2 has a substantially flat portion 7 between the longitudinally extending raised portions. In one configuration, the substantially flat portion extends between the first and second longitudinally raised projections on the sides of the panel. The external sheet is substantially flat in that it is substantially recessed relative to the raised projections and extends substantially linearly. It will be appreciated that the flat portion may incorporate ridges and channels as part of the roll forming process of the top sheet.

[0050] In a preferred embodiment of the invention, the substantially flat portion comprises a first raised longitudinal shoulder member 8 at the first side of the panel and a second raised longitudinal shoulder member 9 at the second opposing side of the panel. First and second raised longitudinal shoulder members are arranged to support a photovoltaic module between the first longitudinally extending raised projection 5 and the second longitudinally raised projection 6.

[0051] The first and second longitudinal shoulder members have a height, h2, from the substantially flat portion. The first longitudinally extending raised projection and the second longitudinally extending raised projection have a height h from the substantially flat portion. The height h2 of the shoulder members is less that the height, h, of the first longitudinally extending raised projection and the second longitudinally raised shoulder member from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised projections.

[0052] In a preferred configuration, the first raised longitudinal shoulder member 8 is adjacent to the first longitudinally extending raised projection 5 and the second raised longitudinal shoulder member 9 is adjacent the second longitudinally extending raised projection 6.

[0053] The raised projections 5, 6 are in the form of crowns. The crowns are of generally trapezoidal form and extend longitudinally along the length of the panel.

[0054] The first longitudinally extending raised projection 5 is provided on one side of the external sheet 3. This provides a side overlap projection. The second longitudinally extending raised projection 6 is provided on the opposite side of the external sheet and provides a side underlap projection. The side overlap projection extends beyond the internal sheet 2 and the insulating body 4 to define a side overlap for overlapping withthe raised projection 5 of an adjacent panel. In use, the adjacent like panels are overlapped by overlapping the overlap crown 6 of one panel with the underlap crown of an adjacent panel to form a joint 11 . These high raised projections or crowns serve to stiffen the panel. Mechanical fixings, for example a screw or screws are used to secure adjacent panels and the overlapped joint. Each screw has a washer or rubber seal between the screw head and the external face of the panel. Additionally, the crowns may be provided with factory applied weather seals to ensure robust and weatherproof roof structures. The factory application of weather seals ensures reduced on-site labour costs and installation time, providing a faster and more cost-effective alternative to traditional tape methods. Being a continuous and high-quality seal, a watertight barrier is provided thus promoting better thermal performance.

[0055] In an alternative configuration, such as on insulated wall panelling panels may be connected to each other using a tongue and groove joint. In some configurations concealed fixings may be used. While described herein in the context of roof panels, the composite panelling of the present application may also be suitable for wall panels with such a tongue and groove fixing and a concealed joint. In this configuration, not shown, a wall panel has a tongue on at least one longitudinal edge and a groove on the opposing longitudinal edge. The tongue on one longitudinal edge engages with a corresponding groove on an adjacent panel when installed. The tongue and groove engagement form a joint. Such tongue and groove joints may have hidden mechanical fixings, or exposed fixings. Factory applied weather seals may also be applied to the tongue and grooved edges.

[0056] With either the raised ridge or the tongue and groove joints, it will be appreciated that the composite insulating panel proposed herein provides a solution, integrate-able with existing commercially available panels.

[0057] As shown herein, the first and second longitudinally extending raised projection have a substantially flat portion at the uppermost part of the crown. This substantially flat portion is at a height h from the substantially flat portion 7 of the external sheet. In one configuration, h may be in the region of 45mm, though it will be appreciated that h is not restricted as such.

[0058] First and second shoulder members, 8 and 9 extend longitudinally along the length of the panel. These shoulder members are in the form of crowns or partial crowns. While shown herein as substantially trapezoidal, it will be appreciated that these shoulder members maybe substantially rectangular. The shoulder members may be profiled and integral to the external sheet. In an alternative configuration, the shoulder members may be bonded to the external top sheet rather than formed as a part of the rolling process.

[0059] In a first configuration, the first and second shoulder members may extend from one side of the profile of the first and second longitudinally extending raised projection, 5, 6. As shown herein the first shoulder member has a leg 15 which extends from the substantially flat portion 7 of the external sheet to a substantially flat portion 16. This substantially flat portion 16 is at a height h2 from the substantially flat portion of the external sheet. The height h2 of the substantially flat uppermost face 16 of the first shoulder member is less than the height h of the substantially flat portion of the longitudinally extending raised projection. It will be appreciated that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised projection. Accordingly, the substantially flat portion may be formed with the first longitudinally extending raised projection when the external sheet is profiled. While described in relation to the first longitudinally extending raised projection, it will be appreciated that this configuration is equally replicated and the second longitudinally extending shoulder member.

[0060] In an alternative configuration (not shown), the first and second shoulder members may have a first leg 14, a second leg 15 and a substantially flat portion 16 extending between the first leg 14 and the second leg 15. The first and second leg extend from the substantially flat portion 7 of the external sheet 3. In this configuration the first and second shoulder members 8,9 are adjacent the first and second longitudinally extending raised projections 5, 6. The first and second shoulder members 8, 9 may alternatively be positioned along the substantially flat portion of the external sheet separated from the longitudinally extending raised projections.

[0061] Additional longitudinal shoulder members having a similar form to the first and second raised longitudinal shoulder members 8, 9 are provided according to the present invention. In one configuration one additional shoulder member 10 may be provided between the first longitudinal shoulder member 8 and the second longitudinal shoulder member 9. In an alternative configuration, two additional shoulder members 10 may be provided between the first longitudinal shoulder member 8 and the second longitudinal shoulder member 9. In the configuration shown in Figure 4, three longitudinal shoulder members 10 are provided between the first longitudinal shoulder member 8 and the second longitudinal shoulder member 9.

[0062] Each additional shoulder member 10 may have a first leg 14, a second leg 15 and a substantially flat portion 16 extending between the first leg 14 and the second leg 15. The first and second leg extend from the substantially flat portion 7 of the external sheet 3.

[0063] In the configuration of Figure 4 and Figure 5, and moving from right to left as shown, a first additional raised shoulder member 18 is provided. This raised shoulder member is at a distance d1 from the first raised longitudinal shoulder member 8. Distance is measured from the centres of the substantially flat portion of the respective shoulder members. Where the first longitudinal shoulder member 8 is formed integral to the first longitudinally extending raised projection, the respective distance is from the point at which the substantially flat portion extends from the first longitudinally extending raised projection.

[0064] A second additional raised shoulder member 19 is positioned at a distance d2 from the first additional raised shoulder member 18. A third additional raised shoulder member 20 is positioned at a distance d2 from the second additional raised shoulder member. It will be appreciated that this third additional raised shoulder member is at a distance d1 from the second longitudinally extending raised projection. In some configurations d1 is substantially equal to d2. In alternative configurations d1 may be less than d2. For example, d1 may be approximately 218mm and d2 may be approximately 263mm. The substantially flat portion of each of the additional raised shoulder members may have a width w extending between the first leg 14 and second leg 15 of approximately 40mm. The substantially flat portion 16 of the first shoulder member and the second shoulder member may have a width of approximately w / 2, or 20mm when integrally formed with the respective longitudinally extending raised projection. In this configuration, for example the flat uppermost portion of the crown of the second longitudinally raised projection 6 may have a width w3 of approximately 24mm and the flat uppermost portion of the crown of the first longitudinally extending raised projection may have a width w4 of 53mm. The external sheet may have a width or transversal span of 1295mm. These dimensions are given as an example only. It will be appreciated that the composite panel provided herein may vary from the dimensions proposed.

[0065] The flat uppermost face of the raised longitudinal shoulder members is arranged to support a photovoltaic module 12 supported thereupon. While described herein as a photovoltaic module 12, it will be appreciated that this may refer to any planar energy module. As shown in the accompanying drawings the photovoltaic module is supported by the first and the second raised longitudinal shoulder members and extends transversally at a height h above the substantially flat portion of the external sheet. A gap 21 is therefore provided between an internal face of the photovoltaic module and the external face of the external sheet. The additional raised shoulder member or members 18, 19, 20 provide additional support for the photovoltaic module 12. This ensures that the photovoltaic module is adequately supported. This prevents in the cracking, saggingor breakage of the photovoltaic module. The gap 21 also allows for optimal performance of the photovoltaic module due to airflow around the module. In addition, the gap allows rainwater to drain from the roof at the rear of the module rather than along the external collecting face of the module.

[0066] The gap 21 provided further allows for the installation of electrical circuitry in close proximity to the photovoltaic module and for ease of access to this circuitry for repair and maintenance. The circuitry may be housed in a housing (not shown) which can be accommodated in the gap 21.

[0067] The photovoltaic module is mounted on the external sheet using at least one of mechanical or chemical means. For example, the photovoltaic module may be mechanically fixed to the uppermost face 16 of the first and second raised longitudinal shoulder members 8, 9. In one configuration a clamping member 22 is provided. The clamping member engages with the photovoltaic module at a first side and is mechanically fixed to the uppermost face of the corresponding raised longitudinal shoulder member on which the photovoltaic module is supported. The mechanical fixing may be a screw, a rivet, a bolt or the like. The mechanical fixing extends through the external sheet and is anchored in the insulating body. The clamping member 22 may comprise a plurality of clamping members positioned along the longitudinal length of the raised longitudinal shoulder member or may comprise a single clamping member that extends longitudinally along the shoulder and is mechanically fixed at a plurality of locations along its longitudinal extension. An example of this clamping member is shown in Figure 6. It will also be appreciated that a similar clamping means may be positioned along the width of the panel wherein the raised longitudinal shoulder members are provided with clamping members to engage with the photovoltaic module along its short edge. The long edge of the photovoltaic module is its longitudinal length. The short edge is the width of the photovoltaic module.

[0068] The photovoltaic module is held in a vice or clamping grip by the clamping portion or mouth portion of the clamping member. Each clamping member comprises a first portion for attaching to the respective raised longitudinal shoulder member and a second portion for engaging the photovoltaic module. The second portion comprises an upper jaw and a lower jaw wherein the upper jaw engages with an uppermost surface of the photovoltaic module and the lower jaw engages with a second surface of the photovoltaic module opposite the uppermost surface to hold the photovoltaic module in a vice or clamp like grip.

[0069] The photovoltaic module is thus retained in position. An elastically deformable layer such as a gasket, seal or washer or equivalent padding member (not shown) maybe provided between the engaging faces of the mouth portion of the clamping member and the photovoltaic module to minimise any slippage between the photovoltaic module and the clamping member as well as ensuring that the photovoltaic module is not damaged by the clamping action.

[0070] The mechanical attachment of brackets or clamping members to the external profile as described reduces the risk of water penetration. This mechanical attachment facilitates in the ease of removal of the photovoltaic module to allow for repairs or replacement of either the module or underlying electrical connections.

[0071] An additional elastically deformable layer 23 may be provided between the flat uppermost face of the raised longitudinal shoulder and the photovoltaic module. This elastically deformable layer provides cushioning or padding for the module. This layer may be formed of a factory applied sealant, or rubberised seal. This layer 23 may further be configured as an adhesive layer. This adhesive layer further bonds the photovoltaic module to the flat uppermost face of the raised longitudinal shoulder.

[0072] The combination of the elastically deformable layer and the mechanical attachment means facilitates the movement between the composite panel and the photovoltaic module. It will be appreciated that this accounts for thermal movement and structural movement and thus allows for a more robust panel construction.

[0073] As the photovoltaic module 12 extends between the first raised longitudinal shoulder and the second raised longitudinal shoulder it is further supported by the additional shoulder member or members, 18, 19, 20. An additional elastically deformable layer 25 may be provided between the flat uppermost face of the additional raised longitudinal shoulder and the photovoltaic module. This elastically deformable layer provides cushioning or padding for the module. This layer 25 may be formed of a factory applied sealant, or rubberised seal or gasket. This layer 25 may further be configured as an adhesive layer. This adhesive layer further bonds the photovoltaic module to the flat uppermost face of the raised longitudinal shoulder.

[0074] It will be appreciated that the combined height h2 of the longitudinal shoulder members and the photovoltaic module is less than the height h of the longitudinal extending raised projections. While the use of the extending raised projections facilitates the cooperation with like adjacent panels, it will be further appreciated that the photovoltaic module is protected within a valley bounded by the longitudinally extending raised projections. In this configuration the longitudinal shoulder members are recessed relative to the longitudinally extending raised projections.

[0075] A solar collection system in accordance with the present embodiments provides a composite insulating panel 1 as described above and a photovoltaic module 12. Thesolar collection system can be provided a single unit from a factory setting. This allows for guaranteed quality and eliminates human error in installation. Alternatively, the composite insulating panel 1 can be provided from a first manufacturing location and the photovoltaic module provided from a second manufacturing location and can be combined in a third factory setting or on site prior to installation. It will be appreciated that the configuration of the first and second longitudinally extending raised projections having a height greater than that of the shoulder members allows for solar collection systems to be stacked for transport, protecting the photovoltaic module in the stacking arrangement. The stacked panels are supported on the extending raised projections 5, 6 due to the height difference between the projections 5 and the shoulders 4 that support the photovoltaic module. Factory applied sealants and gaskets are applied in controlled environments resulting in a consistent and highly effective application. The factory application ensures reduced on-site labour costs and installation time, providing a faster and more cost-effective alternative to traditional tape methods. Being a continuous and high-quality seal, a watertight barrier is provided thus promoting better thermal performance.

[0076] To manufacture a solar collection system in accordance with the present application a series of step are implemented at a single location or at a plurality of locations as previously outlined. Preferably, the solar collection system is assembled in a single factory-based location. The method comprises providing an internal sheet 2 and providing an external sheet 3. The internal and external sheet may be formed by roll forming or the like. An insulating body is provided between the internal sheet and the external sheet. The insulating body 4 may be a roll out type insulation or an insulation panel that is cut to size or preferably a foamed insulation. The external sheet comprises a first longitudinally extending raised projection at a first side of the panel, a second longitudinally raised projection at a second opposing side of the panel and a substantially flat portion extending between the first longitudinally extending raised projection and the second longitudinally raised projection; and wherein the substantially flat portion comprises a first raised longitudinal shoulder member at the first side of the panel and a second raised longitudinal shoulder member at the second opposing side of the panel, the first raised longitudinal shoulder member and the second raised longitudinal shoulder member for supporting a photovoltaic module between the first longitudinally extending raised projection and the second longitudinally raised projection. The shoulder members and the longitudinally extending raised projections may be formed in a roll forming or profiling process.

[0077] An elastically deformable layer such as that described above may be applied on an uppermost portion of each the first raised longitudinal shoulder member and the second raised longitudinal shoulder member. Where additional shoulder members are provided as described above, an elastically deformable layer such as a factory applied sealant or rubberised layer may be applied to an uppermost portion of the shoulder members.

[0078] A photovoltaic module is then attached to the uppermost portion of the first raised longitudinal shoulder member and the second raised longitudinal shoulder member, the resiliently deformable layer positioned between the uppermost portion of the respective longitudinal shoulder member and the photovoltaic module. The attaching is at least one of a mechanical attachment or a chemical attachment. Mechanical attachment may include a clamping means as described above. Chemical attachment may include adhesive or chemical bonding.

[0079] The words “comprises / comprising” and the words “having / including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0080] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Claims

Claims1. A composite insulating panel, comprising: an internal sheet; an external sheet; and an insulating body between the external sheet and the internal sheet; wherein the external sheet comprises a first longitudinally extending raised trapezoidal projection at a first side of the panel forming a side overlap projection and a second longitudinally extending raised trapezoidal projection at a second opposing side of the panel forming a side underlap projection and a substantially flat portion extending between the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raised trapezoidal projection; and wherein the substantially flat portion comprises a first raised longitudinal trapezoidal shoulder member at the first side of the panel extending from and adjacent to the first longitudinally extending raised trapezoidal projection and a second raised longitudinal trapezoidal shoulder member at the second opposing side of the panel extending from and adjacent to the second longitudinally extending raised trapezoidal projection, the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder member for supporting a photovoltaic module, at a height h2 above the substantially flat portion, between the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raised trapezoidal projection, wherein a height, h2, of the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder member from the substantially flat portion is less than a height, h, of the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raised trapezoidal projection from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised trapezoidal projections, and an additional longitudinal trapezoidal shoulder member between the first raised longitudinal shoulder member and the second raised longitudinal shoulder member and further arranged for supporting the photovoltaic module at a height h2 above the substantially flat portion, the at least one additional raised shoulder member having the height h2 from the substantially flat portion.

2. The composite insulating panel according to any previous claim wherein the first raised longitudinal shoulder member and the second raised longitudinal have a substantially flat uppermost face at the height h2 above the substantially flat portion of the external sheet.

3. The composite insulating panel according to claim 2 wherein the at least one additional longitudinal trapezoidal shoulder member has a substantially flat uppermost face at the height h2 above the substantially flat portion.

4. The composite insulating panel according to claims 3 or 4, wherein the first and second longitudinally extending raised trapezoidal projection each have a substantially flat uppermost face at the height h from the substantially flat portion, wherein the height h is greater than the height h2.

5. The composite insulating panel according to any previous claim wherein the substantially flat portion further comprises one of more longitudinally extending recessed indentations.

6. A solar collection system comprising: a composite insulating panel according to any of claims 1 to 5, a photovoltaic module, and a plurality of clamping members for fixing the photovoltaic module to the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder, each clamping member comprising a first portion for attaching to the respective raised longitudinal trapezoidal shoulder member and a second portion for engaging the photovoltaic module.

7. The system according to claim 6 further comprising chemical means for attaching the photovoltaic module to the composite insulating panel.

8. The system according to any of claims 6 or 7 wherein the system further comprises an elastically deformable layer for positioning on the substantially flat uppermost face of the first and second raised longitudinal trapezoidal shoulder members between the respective shoulder member and a photovoltaic module supported thereon.

9. The system according to any of claims 6 to 8 further comprising an elastically deformable layer for positioning on its substantially flat uppermost face of the additional longitudinal trapezoidal member between the third raised longitudinal shoulder member and the photovoltaic module supported thereon.

10. The system according to any of claims 6 to 9 wherein the photovoltaic module has a height h3 and wherein h is greater than the (h2+h3).

11. The system according to any of claims 6 to 10 further comprising a second composite panel adjacent the composite panel and wherein the first longitudinally extending raised projection engages with a second longitudinally extending raised projection of the second composite panel.

12. The system according to claim 11 wherein the second longitudinally extending raised projection of the second composite panel underlaps the first longitudinally extending raised projection of the composite panel.

13. The system according to any of claims 8 to 12 further comprising electrical circuitry for the photovoltaic module.

14. The system according to claim 13 further comprising housing for the electrical circuitry, wherein said housing is configured to be located between a rear face of the photovoltaic module and the substantially flat portion of the profiled external sheet.

15. A roof system comprising a plurality of solar collection systems according to any of claims 6 to 14.

16. A method for manufacturing a solar collection system comprising: providing an internal sheet; providing an external sheet and providing an insulating body between the internal sheet and the profiled external sheet, wherein the external sheet comprises a first longitudinally extending raised trapezoidal projection at a first side of the panel forming a side overlap projection and a second longitudinally extending raised trapezoidal projection at a second opposing side of the panel forming a side underlap projection and a substantially flat portion extending between the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raised trapezoidal projection; and wherein the substantially flat portion comprises a first raised longitudinal trapezoidal shoulder member at the first side of the panel extending from and adjacent to the first longitudinally extending raised trapezoidal projection and a second raised longitudinal trapezoidal shoulder member at the second opposing side of the panel extending from and adjacent to the second longitudinally extending raised trapezoidal projection, the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder member for supporting a photovoltaic module, at a height h2 above the substantially flat portion, between the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raisedtrapezoidal projection, wherein a height, h2, of the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder member from the substantially flat portion is less than a height, h, of the first longitudinally extending raised trapezoidal projection and the second longitudinally extending raised trapezoidal projection from the substantially flat portion such that the first and second shoulder members are recessed relative to the first and second longitudinally extending raised trapezoidal projections, and an additional longitudinal trapezoidal shoulder member between the first raised longitudinal shoulder member and the second raised longitudinal shoulder member and further arranged for supporting the photovoltaic module at a height h2 above the substantially flat portion, the at least one additional raised shoulder member having the height h2 from the substantially flat portion.

77. providing an elastically deformable layer on an uppermost portion of each the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder member; and providing a plurality of clamping members for fixing the photovoltaic module to the first raised longitudinal trapezoidal shoulder member and the second raised longitudinal trapezoidal shoulder, each clamping member comprising a first portion for attaching to the respective raised longitudinal trapezoidal shoulder member and a second portion for engaging the photovoltaic module attaching the photovoltaic module using the plurality of clamping members.

18. The method of claim 17 further comprising chemical means for attaching the photovoltaic module to the raised longitudinal shoulder members.

19. The method of claim 17 wherein the chemical means comprises an adhesive.

20. The method of any of claims 17 to 19 wherein the second portion comprises an upper jaw and a lower jaw wherein the upper jaw is for engaging with an uppermost surface of the photovoltaic module and the lower jaw is for engaging with a second surface of the photovoltaic module opposite the uppermost surface for holding the photovoltaic module in a vice or clamp like grip.

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