US-12620928-B2 - Solar roof structure

US12620928B2US 12620928 B2US12620928 B2US 12620928B2US-12620928-B2

Abstract

Described herein is a solar roof tile system ( 102 ) for a building. The system ( 102 ) includes a supporting structure ( 108 ) adapted to be mounted to the building and having one or more supporting formations ( 110, 112 ) for supportively engaging one or more solar roof tiles ( 104 ). The solar roof tiles ( 104 ) are adapted to be releasably engaged with the supporting structure ( 108 ) such that the solar roof tiles ( 104 ) can be independently released from the roof ( 100 ) without removing adjacent solar or non-solar roof tiles ( 106 ). Each of the solar roof tiles ( 104 ) include one or more electrical junction boxes ( 152, 154 ) disposed on an underside surface ( 150 ) for receiving electrical cables to form an electric circuit with others of the one or more solar roof tiles ( 104 ) and an inverter. The supporting formations ( 110 ) are fixedly mounted to the building and adapted to releasably support the one or more solar roof tiles ( 104 ) in respective operative positions, and wherein each supporting formation is electrically connected to an earthing circuit.

Inventors

Randal STEVENSON

Assignees

Nulok Global Pty Ltd

Dates

Publication Date: 20260505
Application Date: 20210825
Priority Date: 20201127

Claims (20)

1 . A solar roof tile system for a building, the system including: a supporting structure adapted to be mounted to the building and having one or more supporting formations for supportively engaging one or more solar roof tiles, wherein the supporting structure and the one or more solar roof tiles collectively define a roof of the building having an internal roof cavity; one or more solar roof tiles adapted to be releasably engaged with the supporting structure such that the one or more solar roof tiles can be independently released from the roof to access the roof cavity without removing adjacent solar or non-solar roof tiles, the one or more solar roof tiles having an upper active solar surface and an underside surface; wherein each of the one or more solar roof tiles include one or more electrical junction boxes disposed on the underside surface for receiving electrical cables to form an electric circuit with others of the one or more solar roof tiles and an inverter; wherein the supporting formations are fixedly mounted to the building and adapted to releasably support the one or more solar roof tiles in respective operative positions; and wherein, in an engaged operative position, the supporting structure maintains the one or more solar roof tiles in a partially overlaid position with a lower region of the one or more solar roof tiles positioned above a lower roof tile and separated by a vertical gap between the solar roof tile and lower roof tile.
2 . The solar roof tile system according to claim 1 wherein each of the one or more solar roof tiles include a positive junction box disposed at a first location on the underside surface and a negative junction box disposed at a second location on the underside surface separate from the first location.
3 . The solar roof tile system according to claim 1 wherein the one or more solar roof tiles include a first lateral side and a second lateral side and wherein the first location is adjacent the first lateral side and the second location is adjacent the second lateral side.
4 . The solar roof tile system according to claim 2 wherein, in an engaged operative position in the supporting structure, the positive junction box of a first solar roof tile is positioned adjacent the negative junction box of a laterally adjacent second solar roof tile.
5 . The solar roof tile system according to claim 4 wherein the one or more solar roof tiles include flexible electrical conduits for connecting the positive junction box of the first solar roof tile to the negative junction box of the second solar roof tile.
6 . The solar roof tile system according to claim 5 wherein the flexible electrical conduits are colour coded based on electrical polarity.
7 . The solar roof tile system according to claim 5 wherein the flexible electrical conduits include a non-conductive cut resistant material around cables.
8 . The solar roof tile system according to claim 1 wherein the supporting formations include a plurality of horizontally extending battens fixedly mounted to the building, and wherein each batten is electrically connected to a common earthing circuit.
9 . The solar roof tile system according to claim 8 wherein the supporting formations further include a plurality of channels mounted to the battens and including a U-shaped hook at a lower end of each channel for receiving a lower side of a solar roof tile.
10 . The solar roof tile system according to claim 9 wherein the U-shaped hooks are formed of a metallic material having a non-conductible material coating.
11 . The solar roof tile system according to claim 8 , wherein each batten is electrically connected by one or more metal strips extending down a vertical section of the roof between the battens to form the common earthing circuit.
12 . The solar roof tile system according to claim 11 wherein the battens and metal strips extend perpendicularly and are connected by a conductive metal joining bracket.
13 . The solar roof tile system according to claim 11 wherein the battens and metal strips are connected together by one or more conductive screws.
14 . The solar roof tile system according to claim 8 wherein each batten is electrically connected by one or more earthing wires connected between battens.
15 . The solar roof tile system according to claim 8 wherein the supporting formations include a plurality of metal link channels connecting substantially perpendicularly between adjacent battens and wherein the battens and link channels form a continuous earthing circuit.
16 . The solar roof tile system according to claim 1 wherein the vertical gap provides airflow to internal roof sarking of the roof.
17 . The solar roof tile system according to claim 1 wherein each solar roof tile is independently slideably releasable from the supporting structure to provide access to the roof cavity.
18 . A solar roof tile system for a building, the system including: a plurality of solar roof tiles adapted to be releasably engaged on a supporting structure mounted to a roof of the building in operative positions, wherein each solar roof tile includes one or more junction boxes for electrically connecting to another solar roof tile or to an electrical junction box to form a series electric circuit; one or more electrical junction boxes configured to electrically connect the plurality of solar roof tiles to an electrical inverter and/or solar battery system; a plurality of electrical cables for electrically connecting the junction boxes of each solar roof tile and the one or more electrical junction boxes; wherein the electrical cables include a flexible protective coating that is non-conductive and formed of a cut resistant material; and wherein the protective coatings are colour coded such that cables of a first colour are to be connected to positive junction boxes while cables of a second colour are to be connected to negative junction boxes; wherein the supporting structure and the one or more solar roof tiles collectively define a roof of the building having an internal roof cavity; and wherein one or more of the solar roof tiles are adapted to be releasably engaged with the supporting structure such that the one or more solar roof tiles can be independently released from the roof to access the roof cavity without removing adjacent solar or non-solar roof tiles.
19 . A solar roof tile adapted for installing in a roof tile system according to claim 1 .
20 . The solar roof tile system according to claim 1 wherein the solar roof tile system has an underside comprising an open configuration, thereby allowing access from beneath the system to the one or more electrical junction boxes and or the electrical cables.

Description

TECHNICAL FIELD The present invention relates to rooftop solar installations and in particular to a solar roof tile system and associated cable management and junction box housing. While some embodiments will be described herein with particular reference to that application, it will be appreciated that the invention is not limited to such a field of use, and is applicable in broader contexts. BACKGROUND OF INVENTION Traditional solar panels are installed on top of the roof meaning that all electrical cables relating to the solar panels are outside the roof cavity. An example of this type of system is described in US Patent Application Publication 2017/0237390 to SolarCity Corporation and entitled “Building Integrated Photovoltaic Roofing Assemblies and Associated Systems and Methods”. This document discloses a rooftop solar system that is installed over an existing rooftop structure but has the appearance of an integrated solar installation. This system requires an entirely new structure to be formed over the existing roof and intermediate layers to be installed between the structure and roof. Solar panels are installed into pans that are fit onto this new structure and no access is available to roof sarking or an internal roof cavity. Furthermore, the system in US 2017/0237390 does not provide for airflow under the solar panels, which can give rise to failure and reduced operational lifetime of the panels. In an alternative type of system, termed a “roof integrated solar system”, the solar roof tiles are directly integrated into the roof structure in place of traditional roof tiles. In these systems, solar roof tiles or solar inserts make up part of the roof and lay flush with the surrounding roof tiles when installed to provide a seamless integrated appearance. When installed on a roof, the electrical cables of a solar roof tile are inside the roof cavity and can become a safety hazard for both installers and future home and solar maintenance. As the electrical cables are laid on top of the roof sarking/felt and over the battens, installers have often step on these when installing the roof. As a result, the cables can be damaged very easily causing connection problems or earthing issues. In some cases, the damaged cables can result in parts of the roof becoming electrically live, which is very dangerous. Furthermore, it is also difficult to replace faulty cables or solar roof tiles once the roof tiles have been installed. This currently involves the removal of a number of roof tiles so the faulty tile/cable can be disconnected from the system and replaced. Another concern is that if a worker cuts a hole in the sarking/felt from inside the roof space they run the risk of cutting through a live electrical cable, which could cause serious injury. There is also a fire risk if a damaged cable is not noticed initially but becomes more damaged over time. A reference herein to a patent document or any other matter identified as prior art, is not to be taken as an admission that the document or other matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims. SUMMARY OF INVENTION A first aspect of the present invention provides a solar roof tile system for a building, the system including: a supporting structure adapted to be mounted to the building and having one or more supporting formations for supportively engaging one or more solar roof tiles, wherein the supporting structure and the one or more solar roof tiles collectively define a roof of the building having an internal roof cavity;one or more solar roof tiles adapted to be releasably engaged with the supporting structure such that the one or more solar roof tiles can be independently released from the roof to access the roof cavity without removing adjacent solar or non-solar roof tiles, the one or more solar roof tiles having an upper active solar surface and an underside surface;wherein each of the one or more solar roof tiles include one or more electrical junction boxes disposed on the underside surface for receiving electrical cables to form an electric circuit with others of the one or more solar roof tiles and an inverter; andwherein the supporting formations are fixedly mounted to the building and adapted to releasably support the one or more solar roof tiles in respective operative positions, and wherein each supporting formation is electrically connected to an earthing circuit. In some embodiments, each of the one or more solar roof tiles include a positive junction box disposed at a first location on the underside surface and a negative junction box disposed at a second location on the underside surface separate from the first location. In some embodiments, the one or more solar roof tiles include a first lateral side and a second lateral side and wherein the first location is adjacent the first lateral side and the second location is adjacent the second lateral sid