A mounting system for a photovoltaic module on an insulating panel.

Abstract

A clamping system for mounting a Photovoltaic solar collector module to a trapezoidal insulating roof panel includes a pair of non-identical rails 4,5 for mounting on opposite longitudinal sides of th

Description

Field of the Invention

[0001] The present invention relates to a clamping system for mounting a photovoltaic module on a trapezoidal panel. Background to the Invention

[0002] With increasing energy costs there is a need fora 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. Many of these systems are difficult to install, difficult to retrofit and difficult to upgrade.

[0003] With increasing volumes of solar collector installations there is a need to provide a consistently high-quality product 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 mounting system that facilitates easy installation, replacement and retrofitting. It is further desirable to provide a solar collection system incorporating a photovoltaic module 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 solar collection mounting system which provides a solution to the needs outlined above. 04 07 25 Summary of the Invention

[0004] The invention is described herein with reference to the appended claims.

[0005] In one aspect, the present invention provides a clamping system for mounting a photovoltaic module on a trapezoidal panel, comprising: a pair of non-identical rails for mounting on the opposing longitudinal sides of the photovoltaic module; a first panel bracket for engaging a first rail of the pair of rails and a second panel bracket for engaging a second rail of the pair of rails, wherein the first and second panel brackets are attachable to the trapezoidal panel; and a first stop member for mounting on the first rail of the pair of rails and a second stop member for mounting on the second rail of the pair of rails; wherein the first panel bracket comprises a first bracket mounting plate and a first rail engaging head, the first rail engaging head extending from the first bracket mounting plate and configured to engage a corresponding aperture of a first rail of the pair of rails; and the second panel bracket comprises a second bracket mounting plate and a second rail engaging head, the second rail engaging head extending from the second bracket mounting plate and configured to engage a corresponding aperture of a second rail of the pair of rails, wherein the first rail engaging head and the second rail engaging head are different.

[0006] This configuration allows for an easy installation and replacement system. The use of non-identical rails and different brackets compatible with each rail allow for secure, robust and more reliable installation, while accommodating with the environmental stresses to which a solar collection system is subject. Further the use of the stop members allows for secure engagement of a photovoltaic module with the underlying structure on which it is mounted. The use of non-identical brackets and rails ensures manufacturing and assembly tolerance of the end product ensuring function and secure fitting for the duration of the product lifespan and taking into account environmental conditions.

[0007] The first rail engaging head may comprise a neck portion and a head portion, wherein the head portion is substantially perpendicular to the neck portion.

[0008] A first side of the head portion of the first rail engaging head may comprises a lip for slidably engaging with the first rail of the pair of rails, wherein the lip is aligned with the neck portion. This facilitates the alignment and securing of the first bracket to the first rail. 04 07 25

[0009] The lip may extend from the head portion substantially in parallel with the mounting plate. The lip may form a channel between the neck portion of the first rail engaging head and the lip.

[0010] The first rail engaging head may have a substantially T shaped cross section.

[0011] The lip may further comprise an end lip extending inwardly towards the neck portion.

[0012] In an alternative configuration, the neck portion and the head portion of the first rail engaging head may be bifurcated forming a substantially U-shaped or V-shaped channel between a first section and a second section, the first section comprising a first neck portion and a first head portion and the second section comprising a second neck portion and a second head portion.

[0013] The clamping system in this configuration may further comprise a lip extending from the second neck portion distal the head second head portion.

[0014] The first bracket mounting plate may comprise an aperture for receiving a connector for connecting the first bracket mounting plate to the panel.

[0015] The first bracket mounting plate may be sloped for correspondence with a trapezoidal crown of the panel.

[0016] The first bracket mounting plate may further comprise a shoulder member extending from the first bracket mounting plate between the mounting plate and the neck portion of the rail engaging head.

[0017] The clamping system may further comprise a resilient element underlying the mounting plate and shoulder member.

[0018] The second panel bracket may comprises a second bracket mounting plate and a second rail engaging head, extending from the second bracket mounting plate, wherein the second bracket mounting plate comprises a shoulder and wherein the second rail engaging head extends comprises a first head portion perpendicular to the second bracket mounting plate shoulder and a second head portion extending from the second portion parallel to the second bracket mounting plate shoulder such that a channel is formed between the shoulder and the second portion.

[0019] The second head portion may further comprise a lip at an edge thereof distal the first head portion, the lip extending from the edge towards the second bracket mounting plate.

[0020] The lip may be bifurcated to form a substantially U-shaped or V-shaped channel between a first lip section and a second lip section.

[0021] The second bracket mounting plate may comprise an aperture for receiving a connector for connecting the second bracket mounting plate to a trapezoidal panel. 04 07 25

[0022] The second bracket mounting plate may be sloped for correspondence to a trapezoidal crown profile of a trapezoidal panel.

[0023] The clamping system may further comprise a resilient element underlying the mounting plate and its shoulder member.

[0024] The first rail of the pair of rails may have a substantially S shaped cross section comprising an upper photovoltaic module engaging portion and a lower bracket engaging portion.

[0025] The lower bracket engaging portion may comprise a lower jaw, wherein said lower jaw comprises at least one opening along a longitudinal edge, said opening dimensioned to receive the first panel bracket.

[0026] The upper photovoltaic module engaging portion may comprise an upper jaw, a lower jaw and a joining wall extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw and the lower jaw wherein in use the photovoltaic module is engaged between the upper jaw and the lower jaw.

[0027] The joining wall may extend beyond the lower jaw forming a retaining edge for retaining the first panel bracket.

[0028] The lower bracket engaging wall may comprise a joining wall extending between the lower jaw of the upper photovoltaic module engaging portion and the lower jaw of the lower bracket engaging portion.

[0029] The clamping system may further comprise one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the first stop member.

[0030] The second rail of the pair of rails may have a substantially S shaped cross section comprising an upper photovoltaic module engaging portion and a lower bracket engaging portion.

[0031] The lower bracket engaging portion may comprise a lower jaw, wherein said lower jaw comprises at least one opening along a longitudinal edge, said opening dimensioned to receive the second panel bracket.

[0032] The upper photovoltaic module engaging portion may comprise an upper jaw, a lower jaw and a joining wall extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw and the lower jaw wherein in use the photovoltaic module is engaged between the upper jaw and the lower jaw.

[0033] The lower bracket engaging portion may comprise a joining wall extending between the lower jaw of the upper photovoltaic module engaging portion and the lower jaw of the lower bracket engaging portion. 04 07 25

[0034] The upper jaw of the upper photovoltaic module engaging portion may comprise one or more profiled edges.

[0035] The clamping system may further comprise one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the second stop member.

[0036] The first stop member may be dimensioned to sit within the lower bracket engaging portion of the first rail of the pair of rails and wherein the second stop member is dimensioned to sit within the lower bracket engaging of the second rail of the pair of rails.

[0037] The first stop member and the second stop member may each have a II-shaped cross section.

[0038] The first stop member may comprise an aperture for receiving a fixing means for fixing the first stop member to the first rail.

[0039] The second stop member may comprise an aperture for receiving a fixing means for fixing the second stop member to the second rail.

[0040] Such a clamping system is easily attached to a composite insulating panel and so facilitates the attachment of a photovoltaic module to a composite insulating panel. Further such a clamping system allows for a photovoltaic module to be easily removed for repair and maintenance. Portions of the clamping system are equally replaceable in the event of damage or wear and tear. Further the clamping system is not visible in use thus providing a streamlined profile on the panel.

[0041] A further embodiment includes a solar cell system comprising a clamping system as outlined above, a photovoltaic module and a composite insulating panel having a trapezoidal profile.

[0042] The trapezoidal panel may be 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 04 07 25 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 the 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. Brief Description of the Drawings

[0043] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings in which:

[0044] Figure 1 is a trapezoidal panel with a photovoltaic module mounted thereon using a clamping system in accordance with the present invention.

[0045] Figure 2 is an end view of a trapezoidal panel having a photovoltaic module mounted thereon using a clamping system in accordance with the present invention.

[0046] Figure 3 is a first embodiment of a first panel bracket in accordance with the present invention.

[0047] Figure 4 is a second embodiment of a first panel bracket in accordance with the present invention.

[0048] Figure 5 is a third embodiment of a first panel bracket in accordance with the present invention.

[0049] Figure 6 is a first embodiment of a second panel bracket in accordance with the present invention

[0050] Figure 7 is a second embodiment of a second panel bracket in accordance with the present invention. 04 07 25

[0051] Figure 8 is a cross section of longitudinal edge of a first rail engaging a stop member in accordance with the present invention

[0052] Figure 9 is an embodiment of the first rail in accordance with the present invention.

[0053] Figure 10 is a side view of a first longitudinal edge of a clamping system mounted on a trapezoidal panel in accordance with an embodiment of the present invention.

[0054] Figure 11 is a cross section of a longitudinal edge of a first rail engaging a stop member in accordance with the present invention

[0055] Figure 12 is an embodiment of the second rail in accordance with the present invention.

[0056] Figure 13 is a side view of a first longitudinal edge of a clamping system mounted on a trapezoidal panel in accordance with an embodiment of the present invention. Detailed Description of the Drawings

[0057] Referring to the drawings, and in particular Figure 1 and Figure 2 there is illustrated a solar collection system 1. The insulated panel 2 as shown is a trapezoidal panel having an outer layer 201, an inner layer 202 and an insulating layer 203 sandwiched therebetween. A photovoltaic module 3 is mounted on the trapezoidal panel outer layer 201 using the two-part clamping system as described in further detail below. While shown herein as a two layer panel, a single skin or layer panel with metal only on the outer layer is also suitable for use with the present application. While not shown in Figure 1, the stop members prevent slippage of the photovoltaic module relative to the panel. For example, the stop members may be installed at a longitudinal end of the panel assembly to prevent said slippage.

[0058] The insulating layer 203 may comprise an insulating foam. The foam may, for example be polyisocyanurate foam or phenolic foam. The panel 2 may be a roof panel and the external sheet and the inner layer 202I 3 are manufactured from metal, such as galvanised or painted steel. 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. The outer external layer 201 may be aluminium or stainless steel. In a configuration 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. 04 07 25

[0059] The insulating body extends between the inner face of the internal sheet or inner layer 202 and the inner faces of the external or outer sheet or layer 201. By extending, it is meant that the body of insulating material fills the area between the inner face of the external sheet and the inner face of the internal sheet.

[0060] The external sheet or outer layer 201 has a first longitudinally extending raised projection 204 at one side of the panel and a second longitudinally extending raised projection 205 on the opposite side of the panel. The outer layer 201 has a substantially flat or planar portion 206 between the longitudinally extending raised projections. 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 substantially flat portion may incorporate ridges and channels as part of the roll forming process of the top sheet.

[0061] The substantially flat portion 206 comprises a first raised longitudinally extending shoulder member 207 at the first side of the panel and a second raised longitudinally extending shoulder member 208 at the second opposing side of the panel. First and second raised longitudinally extending shoulder members are arranged to support the photovoltaic module between the first longitudinally extending raised projection 204 and the second longitudinally raised projection 205.

[0062] The first and second longitudinally extending 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.

[0063] The first raised longitudinally extending shoulder member 207 is adjacent to the first longitudinally extending raised projection 204 and the second raised longitudinally extending shoulder member 208 is adjacent the second longitudinally extending raised projection 205.

[0064] The longitudinally extending raised projections 204,205 are in the form of crowns. The crowns are of generally trapezoidal form and extend longitudinally along the length of the panel.

[0065] The first longitudinally extending raised projection 204 is provided on one side of the external sheet or outer layer 201. This provides a side overlap projection. The second 04 07 25 longitudinally extending raised projection 205 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 202 and the insulating body 203 to define a side overlap for overlapping with the raised projection 204 of an adjacent panel. In use, the adjacent like panels are overlapped by overlapping the overlap crown 205 of one panel with the underlap crown of an adjacent panel to form a joint. 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.

[0066] In an alternative configuration, such as on insulated wall panelling, panels may be connected to each other using a tongue and groove joint (not shown). 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.

[0067] 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.

[0068] 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 206 of the external sheet. In one configuration, h is in the region of 45mm, though it will be appreciated that h is not restricted as such.

[0069] First and second shoulder members, 207 and 208 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 04 07 25 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.

[0070] 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, The first shoulder member has a leg 215 which extends from the substantially flat portion 206 of the external sheet to a substantially flat portion 216. This substantially flat portion 216 is at a height h2 from the substantially flat portion of the external sheet. The height h2 of the substantially flat uppermost face 216 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 firstand second shoulder members are recessed relative to the first and second longitudinally extending raised projection. Accordingly, the substantially flat portion 216 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.

[0071] In an alternative configuration (not shown), the first and second shoulder members may have a first leg, a second leg 215 and a substantially flat portion 216 extending between the first leg and the second leg 215. The first and second leg extend from the substantially flat portion 206 of the external sheet 3. This formation is a standalone crown. In this configuration the first and second shoulder members 207, 208 are adjacent the first and second longitudinally extending raised projections. The first and second shoulder members 207, 208 may alternatively be positioned along the substantially flat portion of the external sheet separated from the longitudinally extending raised projections.

[0072] Additional longitudinally extending shoulder members 211 having a similar form to the first and second raised longitudinally extending shoulder members are also provided. One or more additional shoulder members may be provided between the first longitudinally extending shoulder member 207 and the second longitudinally extending shoulder member 208. Each additional shoulder member may have a first leg, a second leg, and a substantially flat portion or plateau extending between the first leg and the second leg. The first and second leg extend from the substantially flat portion 206 of the external sheet 201.

[0073] The flat uppermost face of the raised longitudinally extending shoulder member(s) is arranged to support a photovoltaic module 3 supported thereupon. A photovoltaic module 3, refers to any planar energy module. As shown in the 04 07 25 accompanying drawings the photovoltaic module is supported by the first and the second raised longitudinally extending shoulder members and extends transversally at a height h2 above the substantially flat portion of the external sheet. A gap 210 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 211 provide additional support for the photovoltaic module 3. This ensures that the photovoltaic module is adequately supported. This prevents in the cracking, sagging or breakage of the photovoltaic module. The gap 210 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.

[0074] The gap 210 provided, further allows for the installation of electrical circuitry 212 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 which can be accommodated in the gap 210.

[0075] The photovoltaic module is mounted on the outer layer using the clamping system described herein. The clamping system comprises a pair of non-identical rails, 4, 5 for mounting on the opposing longitudinal sides of the photovoltaic module. The clamping system is mounted on the longitudinally extending members 207, 208 such that the photovoltaic module, when mounted sits below the level of the longitudinally extending raised projections, thus allowing for a photovoltaic module to be factory applied to a trapezoidal panel and shipped from the factory ready for installation. This provides for a guaranteed quality and removes any installer-based error.

[0076] The clamping mechanism or clamping system is suitable for mounting a photovoltaic panel on a trapezoidal panel. It will equally be appreciated that the clamping system can be used on any panel whether double layer or single layer having a trapezoidal profile or other raised profile or shoulder for engaging the clamping system as described herein.

[0077] The clamping system comprises a pair of rails 4, 5 for mounting on opposing longitudinal sides of a photovoltaic module. The clamping system comprises a a first panel bracket 6 for engaging a first rail of the pair of rails 4 and a second panel bracket 7 for engaging a second rail 5 of the pair of rails, wherein the first and second panel brackets are attachable to the trapezoidal panel. A first rail of the clamping system is a free end rail and the second rail of the clamping system is a datum rail. A plurality of panel brackets may be used to engage the corresponding rail at a plurality of points along the longitudinal length of the rail. 04 07 25

[0078] The first rail and the second rail in the pair of rails are non-identical. Nonidentical rails have different cross-sections. In addition, the clamping system comprises a first stop member 8 and a second stop member 9, for engaging the first and second rail respectively. These stop members stop the relative movement of the rails and the brackets so that the photovoltaic module remains in position when installed. While not shown in Figure 1, in one configuration the stop members are installed at a first upper longitudinal edge 10 of the panel assembly to prevent relative slippage of the rails and the brackets.

[0079] The first panel bracket 6 comprises a first bracket mounting plate 601 and a first rail engaging head 602, the first rail engaging head extending from the first bracket mounting plate and configured to engage with a corresponding opening or aperture in a first rail of the pair of rails.

[0080] The first rail engaging head comprises a neck portion 603 and a head portion 604, wherein the head portion is substantially perpendicular to the neck portion. The neck portion 603 is a substantially planar member. The head portion is a substantially planar member that is supported on the neck portion. The rail engaging head therefore has a T shaped cross section where the head portion extends either side of the neck portion.

[0081] A first side of the head portion 604 of the first rail engaging head 602 comprises the lip 606 for slidably engaging with the first rail of the pair of rails, wherein the lip is aligned with the neck portion. The lip extends from a first longitudinal edge of the head portion and angles downwardly therefrom in the direction of the mounting plate 601.

[0082] A second side of the head portion 605b extends from the neck portion in the same direction as a shoulder 611 of the mounting plate.

[0083] The lip extends from the head portion 605 of the first rail engaging head substantially in parallel with the mounting plate. The lip allows engagement with the first rail.

[0084] The lip 606 forms a channel between the neck portion 604 of the rail engaging head and the lip 606. The depth of the channel is determined by the distance that the lip extends from the head portion. As shown in Figure 3 a shallow channel is formed. In contrast in figure 4, the depth of the channel is greater than that shown in Figure 3.

[0085] In the embodiments of Figure 3 and Figure 4, the first rail engaging head has a substantially T shaped cross section formed by the combination of the neck portion 604 and the head portion 605. 04 07 25

[0086] The lip in Figure 4 further comprises an end lip extending inwardly towards the neck portion. This allows for more secure and guidable engagement with the corresponding rail.

[0087] In an alternative configuration shown in Figure 5, the neck portion 604 and the head portion 605 are bifurcated forming a substantially U-shaped or V-shaped channel between a first section and a second section, the first section comprising a first neck portion 604a and a first head portion 605a and the second section comprising a second neck portion, 604b, and a second head portion, 605b.

[0088] A lip 609 is provided extending from the second neck portion distal the head second head portion to provide further engagement with the corresponding rail. The configuration although bifurcated is still substantially T-shaped.

[0089] The panel bracket in the three configurations described above comprise one or more apertures 610 for receiving a connector for connecting the first bracket mounting plate to the panel. The connector may be a screw, a bolt, a rivet or the like.

[0090] The first bracket mounting plate is sloped for correspondence with a trapezoidal crown of the panel such that when in position a secure fit is provided between the crown and the mounting plate. For example, when mounted on a longitudinally extending raised shoulder as described above the mounting plate will lie along the leg 215 of the shoulder. A mechanical fixing 613 can be inserted through the aperture to secure the panel bracket to the underlying panel on the longitudinally extending shoulder member 215.

[0091] The first bracket mounting plate 601 further comprises a shoulder member 611 extending from the first bracket mounting plate between the mounting plate and the neck portion of the rail engaging head. This shoulder when a first bracket is mounted on a longitudinally extending raised shoulder will overly the substantially flat portion or plateau 216 of the longitudinally extending raised shoulder.

[0092] A resilient element 612 such as a seal, washer or gasket or other deformable resilient material underlies the mounting plate and shoulder member. When the first panel bracket 6 is in position on a corresponding longitudinally extending raised shoulder, this resilient element provides a cushioning as well as a high friction surface to assist with engagement of the underlying panel.

[0093] As outlined above the head portion 605 extends either side of the neck portion. A second side 605b extends parallel to the shoulder member 611 to form a substantially U-shaped channel 614 between the second side of the head portion 605b and the shoulder member 611. 04 07 25

[0094] The first panel bracket therefore comprises an upper portion and a lower portion, where the upper portion is substantially T-shaped and the lower portion is substantially L-shaped. The L-shaped second lower portion is inverted relative to the T shaped portion such that the base or flattened portion of the L-shaped lower portion and the top of the T-shaped portion form a substantially C or U-shaped channel or slot.

[0095] The substantially L shaped portion is dimensioned to overly or rest a trapezoidal crown or longitudinal extending shoulder member as described above, in one configuration an obtuse angle is provided between the horizontal leg of the L-shaped portion and the vertical leg of the L-shaped portion. The vertical leg of the L-shaped portion forms the first bracket mounting plate.

[0096] The second panel bracket 7 as shown in Figures 6 and 7 is different to the first panel bracket in that it has a different cross section. The second panel bracket 7 comprises a second bracket mounting plate 701 and a second rail engaging head 702, the second rail engaging head extending from the second bracket mounting plate and configured to engage a corresponding aperture of a second rail of the pair of rails.

[0097] The second bracket mounting plate comprises a shoulder 703 extending therefrom and wherein the second rail engaging head 702 comprises a first head portion 704 perpendicular to the second bracket mounting plate shoulder 703 and a second head portion 705 extending from the first head portion parallel to the shoulder 703 such that a channel 707 is formed between the shoulder and the second portion.

[0098] The second portion 705 of the rail engaging head further comprises a lip 706 at an edge thereof distal the first head portion 705, the lip 706 extending from the longitudinal edge towards the second bracket mounting plate 701.

[0099] In the configuration of Figure 7, the lip 706 is bifurcated to form a substantially U-shaped or V-shaped channel between a first lip section 706a and a second lip section 706b. In an alternative configuration as shown in figure 6 the lip is formed as a single element and has a substantially trapezoidal profile.

[00100] The second bracket mounting plate 701 comprises one or more apertures 708 for receiving a connector 709 for connecting the second bracket mounting plate to a trapezoidal panel.

[00101] When installed on a trapezoidal panel such as the trapezoidal panel described in relation to Figure 1 or Figure 2, the mounting plate and shoulder overly the second longitudinal extending shoulder member 208.

[00102] The second bracket mounting plate is sloped for correspondence to a trapezoidal crown profile of a trapezoidal panel. 04 07 25

[00103] A resilient element 710 underlying the mounting plate and its shoulder member is also provided. This resilient element provides cushioning for the underlying trapezoidal panel. When the second panel bracket 6 is in position on a corresponding longitudinally extending raised shoulder, this resilient element provides a cushioning as well as a high friction surface to assist with engagement of the underlying panel.

[00104] The first and second panel brackets are metal and formed from steel, stainless steel, aluminium or the like.

[00105] As shown in Figure 8 a first rail of the pair of rails is provided. The first rail and the second rail have different configurations, with different cross sections. The first rail of the pair of rails has a substantially S shaped cross section comprising an upper photovoltaic module engaging portion 401 and a lower bracket engaging portion 402. Effectively there are two c shaped clamping members in a stacked and opposing configuration wherein the upper and lower clamps share a joining wall therebetween.

[00106] The lower bracket engaging portion 402 comprises a lower jaw, wherein said lower jaw comprises at least one opening 403 along a longitudinal edge, said opening dimensioned to receive the first panel bracket. The first panel bracket slides into the opening and engages with the first rail. The lower jaw extends along the longitudinal edge of the rail and defines the lower portion of the bracket engaging portion.

[00107] The upper photovoltaic module engaging portion 401 comprises an upper jaw 405, a lower jaw 405 and a joining wall 406 extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw and the lower jaw. When engaging with a photovoltaic module, the module sits between the upper jaw and the lower jaw.

[00108] In the configuration shown in Figure 9, the joining wall extends beyond the lower jaw forming a retaining edge for retaining the first panel bracket. Extending beyond the lower jaw, the retaining edge extends across the mount of the lower bracket engaging portion, towards the lower jaw.

[00109] The lower jaw 406 of the photovoltaic module engaging portion is wider than the lower jaw of the bracket engaging portion, such that the substantially S shaped cross section is askew.

[00110] The lower bracket engaging portion 402 comprises a joining wall 409 extending between the lower jaw 406 of the upper photovoltaic module engaging portion and the lower jaw 404 of the lower bracket engaging portion. The joining 407 wall of the upper portion 401 and the joining wall 409 of the lower portion are substantially parallel. The lower jaw of the upper portion 401 extends a distance x from 04 07 25 the joining wall 409 of the lower portion towards the joining wall 407 of the upper portion. The lower jaw of the lower bracket engaging portion extends a distance y from the joining wall 409. The distance y is less than the distance x. The lower jaw of the upper portion provides a secure support for a mounted photovoltaic module. The lower joining wall also extends beyond the lower jaw of the upper photovoltaic module engaging portion to provide a supporting edge on which the photovoltaic module rests when engaged with the first bracket. Accordingly, an air gap 414 is provided between the lower jaw 406 of the upper portion and the PV module. This prevents overheating and damage to the photovoltaic module and the underlying rail.

[00111] The lower bracket engaging portion is also configured to receive a first stop member. The lower jaw further comprises one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the first stop member. The stop member may be mechanically fixed to the lower jaw for example using a screw, a rivet, a bolt or the like. When the first panel bracket engages with the rail, the stop member prevents the relative movement of the rail and the bracket, such that the rail bracket is prevented from sliding out of the lower bracket engaging portion.

[00112] As previously mentioned, the upper photovoltaic module engaging portion is configured to engage a photovoltaic module 3. The lower bracket engaging portion 402 is configured to engage a first panel bracket 6 as shown in Figure 10. The panel bracket 6 is attached to the longitudinally extending raised projection 204 using a mechanical fixing inserted through the aperture 610 in the mounting plate 601. The first rail engaging head 602, is inserted into the opening 403 in the lower jaw of the lower bracket engaging portion. The relative dimensions of the lower jaw of the lower bracket engaging portion and the lower jaw of the upper photovoltaic module engaging section allows the head portion of the panel bracket to be retained behind the retaining edge 408. In particular, a second side 605b of the head portion abuts the retaining edge. The longitudinal edge of the lower jaw 404 of the lower bracket engaging portion 402 abuts the neck portion 604 of the first rail engaging head. In particular, the longitudinal edge of the lower jaw abuts the next portion below the lip 606 of the rail engaging head.

[00113] The upper jaw 405 and the lower jaw 406 of the upper photovoltaic module engaging portion may be profiled or toothed to form mitred edges 410, 411 to ensure a secure engagement with the PV module.

[00114] To prevent relative motion of the bracket and the rail, a stop member 8 is provided. A mechanical fixing 412 extends through the aperture in the lower jaw of the lower bracket engaging portion through a corresponding aperture in the stop 04 07 25 member and is secured. For example, a nut and bolt may be used to secure the stop member to the rail

[00115] The stop member is a U-shaped component. It may be made from metal such as stainless steel or extruded aluminium or the like. The stop member has a similar profile to the lower bracket engaging portion but the dimensions are such that the stop member is retained in a secure fit between the lower jaw of the lower bracket engaging portion and the lower jaw of the upper photovoltaic module. The stop member stops or prevents the free movement of the panel bracket inside the lower bracket engaging portion of the first rail. The stop member 8 may be located on either or both longitudinal edges of the first rail to prevent the relative movement of the rail and the brackets.

[00116] It will be appreciated that while described herein as a single first panel bracket engaging with a rail, a plurality of first panel brackets may be provided.

[00117] The second rail 5 of the pair of rails has a substantially S shaped cross section comprising an upper photovoltaic module engaging portion 501 and a lower bracket engaging portion 502.

[00118] The lower bracket engaging portion comprises a lower jaw 504, wherein said lower jaw comprises at least one opening along a longitudinal edge, said opening dimensioned to receive the second panel bracket.

[00119] The upper photovoltaic module engaging portion 501 comprises an upper jaw 505, a lower jaw 506 and a joining wall 507 extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw 505 and the lower jaw 506 wherein in use the photovoltaic module is engaged between the upper jaw and the lower jaw. The upper jaw and lower jaw have profiled edges 510, 511. These profiled edges engage the photovoltaic module

[00120] The lower bracket engaging portion 502 comprises a joining wall 509 extending between the lower jaw of the upper photovoltaic module 506 engaging portion and the lower jaw 504 of the lower bracket engaging portion. The lower bracket engaging portion 502 and in particular the lower jaw 504 comprises one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the second stop member.

[00121] The lower jaw 506 of the photovoltaic module engaging portion is narrower than the lower jaw 504 of the bracket engaging portion, such that the substantially S shaped cross section is askew.

[00122] The lower bracket engaging portion 502 comprises a joining wall 509 extending between the lower jaw 506 of the upper photovoltaic module engaging 04 07 25 portion and the lower jaw 504 of the lower bracket engaging portion. The joining wall 507 of the upper portion 501 and the joining wall 509 of the lower portion are substantially parallel. The lower jaw of the upper portion 501 extends a distance x2 from the joining wall 509 of the lower portion parallel to the joining wall 507 of the upper portion. The lower jaw of the lower bracket engaging portion extends a distance y2 from the joining wall 509. The distance x2 is less than the distance y2. The lower jaw 506 of the upper portion provides a secure support for a mounted photovoltaic module. The lower joining wall also extends beyond the lower jaw of the upper photovoltaic module engaging portion to provide a supporting edge on which the photovoltaic module rests when engaged with the first bracket. Accordingly, an air gap 514 is provided between the lower jaw 506 of the upper portion and the PV module. This prevents overheating and damage to the photovoltaic module and the underlying rail. In an alternative configuration the lower joining wall does not extend beyond the lower jaw. In this configuration, the lower jaw further comprises a raised ridge 513 extending longitudinally along the lower jaw for supporting the photovoltaic module when installed. This raised ridge provides an air gap beneath the photovoltaic module between the module and the bracket.

[00123] The lower bracket engaging portion is also configured to receive a first stop member 9. The lower jaw further comprises one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the first stop member. The stop member may be mechanically fixed to the lower jaw for example using a screw, a rivet, a bolt or the like. When the second panel bracket engages with the rail, the stop member prevents the relative movement of the rail and the bracket, such that the rail bracket is prevented from sliding out of the lower bracket engaging portion.

[00124] As previously mentioned, the upper photovoltaic module engaging portion is configured to engage a photovoltaic module 3. The lower bracket engaging portion 502 is configured to engage a second panel bracket 7 as shown in Figure 13. The panel bracket 7 is attached to the longitudinally extending raised shoulder 208 using a mechanical fixing inserted through the aperture 708 in the mounting plate 701. The second rail engaging head 702, is inserted into the opening 503 in the lower jaw of the lower bracket engaging portion. The relative dimensions of the lower jaw of the lower bracket engaging portion and the lower jaw of the upper photovoltaic module engaging section allows the head portion of the panel bracket to be retained within the lower bracket engaging portion. 04 07 25

[00125] To prevent relative motion of the bracket and the rail, a stop member 9 is provided. A mechanical fixing 512 extends through an aperture in the lower jaw of the lower bracket engaging portion and through a corresponding aperture in the stop member and is secured. For example, a nut and bolt may be used to secure the stop member to the rail

[00126] The stop member is a U-shaped component. It may be made from metal such as stainless steel or extruded aluminium or the like. The stop member has a similar profile to the lower bracket engaging portion but the dimensions are such that the stop member is retained in a secure fit between the lower jaw of the lower bracket engaging portion and the lower jaw of the upper photovoltaic module. The stop member stops or prevents the free movement of the panel bracket inside the lower bracket engaging portion of the first rail. The stop member 8 may be located on either or both longitudinal edges of the first rail to prevent the relative movement of the rail and the brackets.

[00127] 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.

[00128] 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. 05 03 26

Claims

1. A clamping system for mounting a photovoltaic module on a trapezoidal panel, comprising:a pair of non-identical rails for mounting on the opposing longitudinal sides of the photovoltaic module;a first panel bracket for engaging a first rail of the pair of rails and a second panel bracket for engaging a second rail of the pair of rails, wherein the first and second panel brackets are attachable to the trapezoidal panel, the first panel bracket comprising a first bracket mounting plate and a first rail engaging head, the first rail engaging head extending from the first bracket mounting plate and configured to engage a corresponding aperture of a first rail of the pair of rails; and the second panel bracket comprising a second bracket mounting plate and a second rail engaging head, the second rail engaging head extending from the second bracket mounting plate and configured to engage a corresponding aperture of a second rail of the pair of rails, wherein the first rail engaging head and the second rail engaging head have different cross-sections; anda first stop member for mounting on the first rail of the pair of rails, and a second stop member for mounting on the second rail of the pair of rails;wherein the first rail of the pair of rails has a substantially S shaped cross section comprising an upper photovoltaic module engaging portion and a lower bracket engaging portion and wherein the second rail of the pair of rails has a substantially S shaped cross section comprising an upper photovoltaic module engaging portion and a lower bracket engaging portion and wherein the first stop member is dimensioned to sit within the lower bracket engaging portion of the first rail of the pair of rails and wherein the second stop member is dimensioned to sit within the lower bracket engaging of the second rail of the pair of rails.

2. The clamping system of claim 1 wherein the first rail engaging head comprises a neck portion and a head portion, wherein the head portion is substantially perpendicular to the neck portion.

3. The clamping system of claim 2, wherein a first side of the head portion of the first rail engaging head comprises a lip for slidably engaging with the first rail of the pair of rails, wherein the lip is aligned with the neck portion.05 03 264. The clamping system according to claim 3 wherein the lip extends from the head portion of the first rail engaging head substantially in parallel with the mounting plate.

5. The clamping system according to claim 4 wherein the lip forms a channel between the neck portion of the rail engaging head and the lip.

6. The clamping system of any of claims 3 to 5 wherein the first rail engaging head has a substantially T-shaped cross section.

7. The clamping system according to any of claims 3 to 6 wherein the lip further comprises an end lip extending inwardly towards the neck portion.

8. The clamping system according to claim 2 wherein the neck portion and the head portion are bifurcated forming a substantially U-shaped or V-shaped channel between a first section and a second section, the first section comprising a first neck portion and a first head portion and the second section comprising a second neck portion and a second head portion.

9. The clamping system according to claim 8 further comprising a lip extending from the second neck portion distal the head second head portion.

10. The clamping system of any previous claim wherein the first bracket mounting plate comprises an aperture for receiving a connector for connecting the first bracket mounting plate to the panel.

11. The clamping system of any previous claim wherein the first bracket mounting plate is sloped for correspondence with a trapezoidal crown of the panel.

12. The clamping system of any previous claim wherein the first bracket mounting plate further comprises a shoulder member extending from the first bracket mounting plate between the mounting plate and the neck portion of the rail engaging head.05 03 2613. The clamping system of claim 12 further comprising a resilient element underlying the mounting plate and shoulder member.

14. The clamping system of any previous claim, wherein the second bracket mounting plate comprises a shoulder and wherein the second rail engaging head extends comprises a first head portion perpendicular to the second bracket mounting plate shoulder and a second head portion extending from the first head portion parallel to the second bracket mounting plate shoulder such that a channel is formed between the shoulder and the second portion.

15. The clamping system of claim 14 wherein the second head portion further comprises a lip at an edge thereof distal the first head portion, the lip extending from the edge towards the second bracket mounting plate.

16. The clamping system of claim 15 wherein the lip is bifurcated to form a substantially U-shaped or V-shaped channel between a first lip section and a second lip section.

17. The clamping system of any previous claim wherein the second bracket mounting plate comprises an aperture for receiving a connector for connecting the second bracket mounting plate to a trapezoidal panel.

18. The clamping system of any of claims 14 to 17 wherein the second bracket mounting plate is sloped for correspondence to a trapezoidal crown profile of a trapezoidal panel.

19. The clamping system of any of claims 14 to 17 further comprising a resilient element underlying the mounting plate and its shoulder member.

20. The clamping system according to claim 1 wherein the upper photovoltaic module engaging portion of the first rail comprises an upper jaw, a lower jaw and a joining wall extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw and the lower jaw wherein in use the photovoltaic module is engaged between the upper jaw and the lower jaw.05 03 2621. The clamping system according to claim 20 wherein the joining wall extends beyond the lower jaw forming a retaining edge for retaining the first panel bracket.

22. The clamping system according to any of claims 20 or 21 wherein the lower bracket engaging portion comprises a joining wall extending between the lower jaw of the upper photovoltaic module engaging portion and the lower jaw of the lower bracket engaging portion.

23. The clamping system according to any of claims 20 to 22 wherein the first rail further comprises one or more fixing apertures at a first longitudinal edge thereof for receiving a fixing means for securing the first stop member.

24. The clamping system according to claim 20 wherein the upper photovoltaic module engaging portion comprises an upper jaw, a lower jaw and a joining wall extending between the upper jaw and the lower jaw and perpendicular to both the upper jaw and the lower jaw wherein in use the photovoltaic module is engaged between the upper jaw and the lower jaw.

25. The clamping system according to any of claims 20 to 24 wherein the lower bracket engaging portion comprises a joining wall extending between the lower jaw of the upper photovoltaic module engaging portion and the lower jaw of the lower bracket engaging portion.

26. The clamping system according to any of claims 20 to 24 wherein the upper jaw of the upper photovoltaic module engaging portion comprises one or more profiled edges.

27. The clamping system according to any of claims 23 to 26 wherein the lower bracket engaging portion further comprises one or more apertures at a first longitudinal edge thereof for receiving a fixing means for engaging the second stop member.

28. The clamping system according to claim 27 wherein the first stop member and the second stop member each have a U-shaped cross section.05 03 2629. The clamping system according to any previous claim wherein the first stop member comprises an aperture for receiving a fixing means for fixing the first stop member to the first rail.

30. The clamping system according to any previous claim wherein the second stop member comprises an aperture for receiving a fixing means for fixing the second stop member to the second rail.

31. A solar cell system comprising a clamping system according to any of claims 1 to 30, a photovoltaic module and a composite insulating panel having a trapezoidal profile.

32. The solar cell system according to claim 31 wherein the trapezoidal panel is a composite insulating panel, comprising:an internal sheet;an external sheet; andan 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; andwherein 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 the 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 longitudinaltrapezoidal 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.03 26

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