A connector mechanism for joining panels for mounting on a roof structure

Abstract

A connector mechanism 10 for joining a pair of panels 12 for mounting on a roof structure 14. The mechanism comprises a first elongate connector (30, fig 4A) having a substantially uniform cross secti

Description

The present invention relates to a connector mechanism for joining a pair of panels for mounting on a roof structure and relates particularly, but not exclusively, to a connector for integrally mounting solar panels on a low pitch roof. Our previous patent application, published under the number WO2017 / 162433, discloses an invention for mounting solar panels integrally into a tiled roof structure of a building. The system enables panels to be installed into a roof as a building is being constructed while ensuring that the roof does not allow water ingress from rainwater contacting the panels, the connectors and the surrounding tiles. This system works extremely well for normally pitched roofs, that is with a pitch angle of greater than 10° measured between the roof and the horizontal when viewed from the side. However, this system is not designed for roofs where the pitch is less than 10°. In particular a combination of capillary action between connected components and wind direction can result in water working its way into the space below the roof structure which can result in damage . Preferred embodiments of the present invention seek to overcome or alleviate the above described disadvantages of the prior art. According to an aspect of the present invention there is provided a connector mechanism for joining a pair of panels for mounting on a roof structure, the mechanism comprising: a first elongate connector having a substantially uniform cross section and having a first panel engaging portion, a first extension, a first rib extending from the first extension and a first fin extending from the first rib; a second elongate connector having a substantially uniform cross section and having a second panel engaging portion, a second extension, a second rib extending from the second extension and a second fin extending from the second rib, wherein in use the first and second extensions and the first and second ribs together enclose a channel and wherein a portion of the second rib and the second fin adjacent an, in use, upper end of the second connector have been removed; and at least one insert for engaging the channel where the second rib and fin have been removed. By removing a short section of the second rib and second fin from adjacent and upper end of the second connector and inserting an insert into the space created provides the advantage that water is prevented from entering the inside of the roof structure by capillary action or being blown by the wind. In particular, removal of the portion of the second rib and second fin creates an opening which is bounded by the first and second extensions, the first rib and another wall of the first connector. The size of this opening is precisely defined and it is therefore possible for the insert to provide a secure fitting seal to the upper end of the first and second connectors in use. As a result, the tolerance or play, which is required between the first and second connectors, can be maintained while ensuring that water is unable to enter the roof structure in the inevitable small channels which exist between the two connectors as a result of that necessary tolerance and the insert is not damaged by any slight movement of the panels. It is therefore possible to use the connectors of this connection mechanism in extremely low angle pitch roofs of less than 10°. In a preferred embodiment the first and second elongate connectors are used on opposing sides of the panel. In another preferred embodiment the first fin is not perpendicular to the first rib or the first extension. The first connector may further comprise an enclosed channel between the first panel engaging portion and the first extension with the first extension extending from the first enclosed channel. Furthermore, the second connector may further comprise an enclosed channel between the second panel engaging portion and the second extension with the second extension extending from the second enclosed channel. In a preferred embodiment the insert comprises a rubberised material. In another preferred embodiment the insert comprises a tapered portion. According to another aspect of the present invention, there is provided a solar array for mounting on a roof of a building, the array comprising a plurality of solar panels, at least a plurality of the panels connected together using a connector mechanism as set out above. According to an additional aspect of the present invention, there is provided a roof for a building, the roof comprising a solar array as set out above and a plurality of tiles joined to the array. According to a further aspect of the present invention, there is provided a building comprising a plurality of walls and a roof as set out above. Preferred embodiments of the present invention will now be described, by way of example only, and not in any limitative sense with reference to the accompanying drawings in which:- Figure la is a perspective view, from the top of a roof structure looking down, of a portion of connector mechanism for joining a pair of panels for mounting in a roof structure; Figure lb is perspective view almost equivalent to figure 1 but with some components removed; Figure 2 is a perspective view of an insert used and the mechanism of figure 1; Figures 3A, 3B, 3C and 3D are top, left, front and right views of the insert of figure 2; Figures 4A and 4B are two examples of connectors used in the connector mechanism of figure 1; and Figure 5 is a perspective view, from the bottom of a roof structure looking up, of another portion of the connector mechanism of figure 1. Referring initially to figure 1, a connector mechanism 10 is provided for joining a pair of panels 12 to a roof structure 14. In the examples shown, the panels 12 are solar panels. However, the connector mechanism 10 of the present invention can be used for connecting any similarly structured products integrally into a roof of a building. Examples of such panels include, but are not limited to, glass panels and metal panels. The connector mechanism of the present invention is particularly designed for use with low pitch roofs. That is, roofs with a pitch of less than 10°. However, the connector mechanism can be used in roofs with a higher pitch angle although it is generally considered that the present invention is not required in such roofs except where there is a risk of exceptionally strong winds regularly hitting the roof such as those as on exposed hillsides and coastlines. The connector mechanism 10 is used primarily for connecting adjacent left and right edges of the panels 12. With additional reference to figure 5, it can be seen that the typical arrangement of panels is to have vertically adjacent panels connected by an over and under lap. As a result, the top edges 16 of a panel 12 and the bottom edges 18 of an adjacent panel are joined to top and bottom frame pieces 20 and 22 respectively. These frame pieces are placed one over the other, to create the over and underlap, and water is prevented from getting between the frame pieces by a pair of seals 24 which extend horizontally across the frame pieces. Returning to figure 1 and with additional reference to figure 4A, the left and righthand sides 26 and 28 of the panels 12 engage the connector mechanism 10 via a pair of connectors 30 and 32 respectively. The connectors 30 and 32 are substantially uniform in cross section and are formed by extrusion typically from aluminium. The first connector 30 has a panel engaging recess 34 which runs along the length of the connector and, in use, engages the panel 12. A seal receiving recess 36 is formed in one of the walls of the panel engaging recess 34 and receives a seal (not shown) which cushions the panel and helps to retain engagement of the panel within the connector 30 as well as preventing water from passing around the panel and into the roof structure. A first enclosed channel 38, of substantially rectangular form, is attached to the panel engaging recess and can be used to carry cables associated with the panel 12 around the solar panel array. A first extension 40 extends from a bottom surface of the enclosed channel 38 and is coplanar with that surface. Extending perpendicular to the first extension 40 is a first rib 42 and extending from the first rib 42 is a first fin 44. The fin 44 extends from the first rib 42 adjacent the junction between the rib and the first extension 40 at an angle that is not perpendicular to the rib and is at approximately 45°. Next to the first rib 42 is an open channel 46 formed by the rib 42 extension 40 and a wall 48. The second connector 32 is somewhat similar in its form to the first connector 30 having a panel engaging recess 50 and a seal receiving recess 52. There is also a second enclosed channel 54 which extends into a second extension 56. A second rib 58 extends from the second extension 56 and a second fin 60 extends from the second extension 56. However, the second fin 60 extends perpendicularly from the second extension 56. There is no open channel in the second connector 32 that is equivalent to the open channel 46 in the first connector 30. Referring now to figures 2, 3A, 3B, 3C and 3D as well as figure 1, an insert 62 is provided to work in conjunction with the first and second connectors 30 and 32. As seen in particular from figure 2, the insert 62 is substantially cuboid in shape having a substantially square first end 64 but also having a fin receiving channel 66 formed therein. The insert 62 is divided into two portions, there is a linear portion 68 which has a uniform cross section and a tapering portion 70 which ends with a second end surface 72 which is similar in shape to the first end 64 although slightly smaller as a result of the tapering of portion 70. The shape of the tapering portion 70 is provided to enable easy insertion of the insert 62, as will be described in more detail below, although it should be noted that only three of the sides of the insert 62 are angled to form the tapering portion 70. That is, as viewed in figure 2 the top 74, base 76 and side 78 are or angled whereas the other side 80 is planar . Operation of the apparatus of the present invention will now be described. The solar panels 12 are inserted into the frame which includes the top and bottom frame portions 20 and 22 and the first and second connectors 30 and 32. The assembly of each panel in its frame onto the roof is undertaken starting with the top left panel, working towards the right and then filling further rows down. The present invention is concerned with the interconnection between the first and second connectors and this occurs after the first framed panel has been inserted. When the second framed panel is added the second connector fits onto the first connector as seen in figures 4A and 5. The second rib 58 and the second fin 60 extend into the space between the first rib 42 and the side surface of the enclosed channel 38. The perpendicular extending second fin 60 engages the transverse extending first fin 44. The second fin 60 is not as long as the gap between the first rib 42 and the wall of the first enclosed channel 38 and as a result two small gaps, labelled 82 and 84 can be present. The gap 82 exists between the second rib 58 and the wall of the first enclosed channel 38 and the gap 84 exists between the end of the second fin 60 and the first rib 42. The size of these gaps 82 and 84 depends upon the exact position of the second connector relative to the first connector 30 and allows for some tolerance or play between the two connectors. Typically, this tolerance, that is the total width of the two gaps 82 and 84, is 4mm, which is sufficient to accommodate in perfections in the roof structure 14 to which the panel array is being attached. Figures 4A and 5 are viewing the connectors 30 and 32 from the bottom end of the joint panels and can therefore be considered to be looking up the pitch of the roof. It is the gap 82 which causes particular problems when the pitch of the roof is very low. Water inevitably enters the channel-like gap 82 and capillary action and / or wind can blow water up that gap and under the overlap of the top frame 22 over the bottom frame 20. In higher pitch roofs this is not a problem because the angle of the roof relative to the horizontal prevents the water from being drawn up by capillary action and winds that are strong enough to blow water up an angle of more than 10° are rare. In lower pitch roofs this problem is overcome in a two-step process. Firstly, a portion of the second rib 58 and second fin 60 are cut from the second connector 32. That portion is ideally 25mm long. With particular reference to figure 1, when the first and second connectors 30 and 32 are brought together this end of the second connector which has had a portion of the second rib 58 and second fin 60 removed, an opening is created which is bound by a wall of the first enclosed channel 38, the first extension 40, the first rib 42 and the second extension 56. Because three of the surfaces that define this opening are parts of the first connector 30 (namely the wall of the first enclosed channel 38, the first extension 40 and the first rib 42) and the other surface comes from the second extension 56 of the second connector 32 which sits on top of the first connector, the dimensions of that opening are very precisely defined. The first fin 44 also extends into that opening and its position is also precisely known as it is attached to the first rib of the first connector. As a result, the insert 62 is manufactured to precisely fill the opening so that the fin receiving channel 66 engages the first fin 44, the side face 78 engages the first rib 42, planar face 80 engages the second extension 56, base 76 engages the wall of the enclosed channel 38 and flat face 80 engages the first extension 40. The insert 62 is shorter in length (typically 12mm) than the portions of the second rib and second fin that are cut away (typically 25mm). As a result of the snug fit of the insert 62 in the opening created for it, any water which enters the gap 82 is unable to pass the insert 62 to enter the space below the roof and potentially cause damage. Furthermore, any movement of the first and second connectors 30 and 32 relative to each other as a result of, for example, strong winds, subsidence or earth tremors, will not apply excessive forces to the insert or compress it resulting in damage and degradation. It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the protection which is defined by the appended claims. For example, figure 4B shows an alternative embodiment of the first and second connectors in which the first fin 44 extends perpendicularly from the first rib 42 rather than transverse at an angle of 45°.

Claims

1. A connector mechanism for joining a pair of panels for mounting on a roof structure, the mechanism comprising:a first elongate connector having a substantially uniform cross section and having a first panel engaging portion, a first extension, a first rib extending from said first extension and a first fin extending from said first rib;a second elongate connector having a substantially uniform cross section and having a second panel engaging portion, a second extension, a second rib extending from said second extension and a second fin extending from said second rib, wherein in use said first and second extensions and said first and second ribs together enclose a channel and wherein a portion of said second rib and said second fin adjacent an, in use, upper end of said second connector have been removed; andat least one insert for engaging said channel where said second rib and fin have been removed.

2. A connector mechanism according to claim 1 wherein said first and second elongate connectors are used on opposing sides of said panel.

3. A connector mechanism according to claim 1 or 2 wherein said first fin is not perpendicular to said first rib or said first extension.

4. A connector mechanism according to any preceding claim wherein the first connector further comprises an enclosed channel between the first panel engaging portion and the first extension with the first extension extending from said first enclosed channel.

5. A connector mechanism according to any preceding claim wherein the second connector further comprises an enclosed channel between the second panel engaging portion and the secondextension with the second extension extending from said second enclosed channel.

6. A connector mechanism according to any preceding claimwherein said insert comprises a rubberised material.5 7. A connector mechanism according to any preceding claimwherein said insert comprises a tapered portion.

8. A solar array for mounting on a roof of a building, the array comprising a plurality of solar panels, at least a plurality of said panels connected together using a connector 10 mechanism according to any of the preceding claims.

9. A roof for a building, the roof comprising a solar array according to claim 8 and a plurality of tiles joined to said array.

10. A building comprising a plurality of walls and a roof 15 according to claim 9.

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