The present invention relates to a dual source heating module, using energy from a solar collector and a secondary heat source, for providing hot water and/or heating for a building.

One objective of a building developer is, normally, to complete a building at minimum cost. Two ways of reducing the cost associated with a new building are to minimise the time required to complete the building and to minimise the hours of skilled labour required to complete the building. Building regulations in some countries, such as England and Wales, now require developers to install water and / or space heating systems which use a renewable energy source, which is commonly solar energy collected by a solar collector. However, because it is not always practicable to satisfy the heating requirements of a building from solar energy alone, there is an additional requirement for a supplementary energy source, for example a combustion boiler. This in turn requires both a control system to efficiently use the available solar energy and more complex ducting and / or pipe work than would be required with a single energy source, increasing the time required to complete a building and the hours of skilled labour required.

According to the present invention there is provided a heating module comprising: a mounting for a solar collector; connections for the solar collector by which the solar collector is, or can be, connected to a heating and/or hot water system of a building in which it is to be installed; and a secondary heat source connected to the heating and/or hot water system for supplementing the heat energy provided to the system by the solar collector, characterised in that the module is in the form of a construction module to be installed in a building and further comprises: a framework and / or housing enabling the module to be installed as a single unit within a building; and a weather proof exterior surface on, or in, which the mounting for the solar collector is located, which weatherproof surface is suitable for forming an integral part of the exterior of the building. A heating module in accordance with the present invention can be incorporated integrally within a building by the architect designing the building, the module being in the form of a construction module so that the complete module can be installed as a single unit. This enables the unit to be preassembled, for example in a factory, with all the connections between various components therein made and tested prior to installation in the building. Furthermore, because part of the housing forms a weather-proof surface suitable for forming an integral part of the exterior of the building, this provides an access point to the outside of the building through which any flue, vent, pipe work to an exterior solar collector, or electrical connection in the case of photovoltaic collector, can be made and sealed at the factory.

The module may conveniently be arranged to be located in the roof of a building where space below a sloping roof is often not utilised. Furthermore any solar collector, which may preferably form part of the weather-proof surface of the module, can be angled at an inclination to approximately that of the roof to which it is to be installed. This may increase efficiency if, for example, the roof on which it is installed is south facing and in the northern portion of the northern hemisphere.

The module can form an integral part of the main roof construction, or alternatively may form a dormer, mansard or clerestory roof. Alternatively, the module could be inserted in a preformed wall aperture, integrated with system glazing or system facia panels, or designed to form a porch roof.

Preferably the module has a frame and is designed to be a load bearing structure of a building to which it is to be installed. This permits the module to form an integral structural component of a building.

Preferably, where the solar collector forms part of the weather-proof surface of the module, the module is arranged such that the solar collector can be installed from inside the module. Alternatively, the solar collector can be installed and sealed in the weather-proof exterior surface during manufacture of the module, prior to installation in the building.

The secondary heat source may be a combustion boiler or furnace vented through the exterior surface of the module. Not only may the exhaust pass through the exterior surface, but also any necessary air intake can also pass through the surface, for example where a boiler or furnace incorporates a balanced flue. In this case, a boiler may be installed in a building by simply installing the module and connecting a fuel supply to the module.

As an alternative to a combustion boiler or furnace, or in addition thereto, the module may comprise a heat pump as a secondary heat energy source. If the heat pump is an air heat pump, then it may preferably be vented through the exterior surface of the module.

It may be desirable for the module to include a hot water storage tank for the hot water system of the building, the hot water storage tank being connected to both the solar collector and secondary heat energy source, wherein the hot water storage tank is arranged to be selectively heated by either the solar collector or the secondary heat energy source. This arrangement is particularly advantageous for it enables a dual source heating arrangement for the hot water to be installed in a building by installation of the module. Furthermore, all the necessary pipework and control equipment can also be pre- installed and tested within the module prior to installation in the building.

The module may further comprise a ventilation unit for forcing air into or out of the building, wherein air is drawn in and/or expelled through the weather-proof exterior surface of the module. In this manner, the module may also provide controlled ventilation of the building, without the need to provide any other conduits through the weatherproof exterior of the building.

The module may comprise a heat store for storing energy received from the solar collector and a heat exchanger for transferring the heat stored therein to a fluid medium for use in providing space heating and/or water heating within the building. The heat store may comprise a high specific heat capacity mass through which either air or liquid is ducted. Air may be ducted through the mass for direct dispersion and space heating within the building. In the case of a liquid, this may be a hot water supply for the building, a primary circuit for a remotely located hot water storage tank, or may be a primary circuit for space heating of the building by radiators or other heat emitters.

Advantageously, the module further comprises any expansion vessel necessary for any primary heating circuit, the solar collector or secondary heat energy source, thus minimising the number of connections necessary to the module.

The module preferably comprises a controller for controlling operation of the module and the module may further comprise a wireless receiver by which the controller receives signals from outside the module. This can enable any combination of the heating, ventilation or water heating of a building to be controlled from a remote location, possibly a remote handset, thus avoiding the need to provide a hard wired connection between the module and a remotely located controller. Furthermore, the wireless link can be used by a third party such as a service engineer to remotely interrogate the controller, boiler, etc., without needing to gain access into a property.

The module may comprise connections for providing space heating to at least two zones within the building, whereby the controller controls fluid flow from the module to the respective zones. The fluid flow may be a liquid conveyed to radiators / other heat emitters or warm air ducted directly to the appropriate zone. This enables all the control equipment required for independently controlled multiple zone heating to be incorporated in the module prior to installation in the building.

Preferably, the module comprises a connection panel having appropriate connections for connecting a cold water supply to the module, the hot water supply from the module, an electricity supply to the module to provide power to the module and one or more pipes or ducts of a space heating system of a building, through which the module may provide space heating for the building. Where the module comprises a combustion boiler or furnace, a connection may also be provided for supplying fuel to the boiler. The provision of a connection panel enables the developer to provide appropriate connection terminals for the module in one location to be simply connected to the module once the module has been installed in the building, ideally without requiring any hot work such as soldering.

The connection panel may include multiple pairs of feed and return pipe connections for connecting various space heating circuits of a building associated with multiple zones within a building.

According to a second aspect of the present invention, there is provided a method of constructing a building comprising installing a module in accordance with the first aspect of the invention into the building during construction of the building and making the building weather-proof by incorporating the weather-proof exterior surface of the module into an exterior weather-proof surface of the building. Such a method of construction enables the module to be installed in a building, with any conduits to the outside, necessary for the heating and/or ventilation of the building being provided through the weather-proof exterior surface of the module and tested prior to installation of the building. This reduces the need to breach the water-proof exterior of the building at other locations. Furthermore, installation of such a module in the building minimises the number of connections that need to be subsequently made and the amount of pipe work, cabling and ducting that have to be carried out within the building. Also, arranging for the module where appropriate to be load-bearing and integrating it upon installation with the overall load-bearing structure effects a considerable economy in building design & construction.

Several embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 schematically illustrates a possible arrangement of components in a heating module in accordance with the present invention;

Figure 2 is a schematic perspective view of a heating module in accordance with the present invention;

Figure 3 is a schematic cut away view of a building illustrating how a module in accordance with the present invention may be installed;

Figure 4 is a schematic external view a building with a module in accordance with the present invention installed in the roof space;

Figure 5 is a schematic external view of a building with a module in accordance with the present invention installed in a mansard roof; Figure 6 is a schematic external view of a building with a module in accordance with the present invention installed in a preformed wall aperture;

Figure 7 is a schematic external view of a building with a module in accordance with the present invention integrated with the system glazing or system facia of the building; and Figure 8 is a schematic external view of a building with a module in accordance with the present invention installed as a porch to the building.

Referring to Figure 1 , the components of a heating module in accordance with the present invention, indicated generally as 1 , are illustrated in diagrammatic form. The heating module comprises a casing 2, a solar collector 3, a hot water cylinder 4, a boiler 5, a controller 6 and a wireless transmitter/receiver 7 connected to an antenna 31.

In addition, there is provided an expansion vessel 8 for the primary circuit of the boiler 5, an expansion vessel 9 for the primary circuit of the solar collector 3, a plurality of valves 12, 13, 14, 15 for controlling the flow of fluid from a pump 10 associated with the boiler 5 and a plurality of outlet connections 17, 18 and 19 of the module 1, discussed below.

Electrical power is received by the module 1 and controller 6 through connector 16. The controller 6 is in turn wired to pumps 10 and 11, valves 12, 13, 14 and 15 and wireless transmitter/receiver 7.

In use water heated in solar collector 3 is drawn through pipe 26 by pump 11 , to heat exchanger 25 in the hot water cylinder 4, from where it is returned to the solar collector by a return pipe (not shown). The hot water cylinder 4 will normally have a thermostat (not shown) connected to the controller 6 and the controller 6 will control the pump 11 in dependence on the temperature sensed by the thermostat associated with the hot water cylinder 4. The controller may also detect the temperature of the water in the solar collector 3 and may determine whether the pump is to be actuated in dependence thereon.

Boiler 5 receives fuel via connector 22 and pipe 27, which fuel is burnt to heat water in a primary circuit which is pumped by pump 10, via pipe 29 and valve 15 into a second heat exchanger 24, located within the hot water cylinder. The water is then returned to the boiler 5 via a further pipe (not shown). Again, the controller may control operation of the pump 10 and valve 15 in dependence on the temperature detected by a thermostat (not shown) attached to the hot water cylinder 4.

Mains water is received by the module 1 through connector 21 and this is conveyed to the hot water cylinder 4. The mains water is under pressure and when a hot water tap in the building is opened, hot water is drawn off the hot water cylinder 4 via pipe 30 and connector 20.

In the embodiment illustrated, hot water is provided for space heating within the building via outlet connections 17, 18 and 19, each connected to a independently controlled heating zone within the building. Fluid flow to each of these zones is controlled by valves 12, 13 and 14. The controller 6 activates the boiler 5 and water heated by the boiler 5 is forced by pump 10 through one or more valves 12, 13 or 14, opened by the controller 6, to respective connectors 17, 18 and 19. From here it is conveyed to space heating circuits in the respective zones of the building, for which heating is required. The water is then returned to the boiler 5 via corresponding return pipes (not shown). The controller 6 controls operation of the boiler 5, pump 10 and valves 12, 13 and 14 in dependence on the signals from thermostats associated with the respective zones in the building, which are received through antenna 31 of the wireless transmitter/receiver 7. The wireless receiver 7 also receive signals from a remote interface unit, through which a user may control operation of the space heating or the hot water, or alternatively a third party such as a service engineer or property manager may gather data on system operation and/or make adjustments to system settings.

It will be realised that, depending on the application to which the module is to be put, many modifications, both to the arrangement and type of components shown in Figure 1 are possible. For example, the boiler may be a hot air furnace providing warm air heating through a plurality of ducts instead of through connectors 17, 18 and 19. In this case the valves 12, 13 and 14 would be replaced by corresponding dampers within the ducts. As a further alternative the boiler 5 could be substituted with a heat pump, in which case connections to a ground collector may be necessary, or the heat pump may be an air heat pump, in which case ducting to atmosphere will be required.

In a further alternative embodiment the solar collector 3 may also be selectively connected, via appropriate valves, to the space heating system so that it may contribute to the space heating of the building. In a further alternative arrangement the module 1 could comprise a heat store in which energy from the solar collector is stored for subsequent use in heating hot water or providing space heating. Phase change heat stores may have particular application to a heating module in accordance with the present invention, because these enable a very large amount of heat energy to be stored in a given volume and mass of material.

As will be appreciated from the above discussion, the components to be included in a heating module in accordance with the present invention may depend on the application for which it is to be used. However, essential to the present invention is the provision in the heating module 1 of a mounting 35 for a solar collector 3 and connections for the solar connector by which the solar collector 3 is connected to a heating or a hot water system 4, with the module 1 comprising a secondary energy source 5. This permits the solar collector 3, or connections there for, the secondary energy source 5 and appropriate pump valves and control system 6 to all be preassembled and tested within the module.

Referring now to Figure 2, this is a perspective view of the module 1 incorporating the components of Figure 1. The housing 2 of the module 1 comprises a framework 33 and a plurality of panels, only a side panel 34 and a weatherproof exterior panel 35, of which can be seen.

Within the side panel 34 is an access panel 39. Similar access panels are incorporated on the other major faces, including the bottom face, so that a module can be produced as a standard module. A convenient access panel can then be selected, dependent on the installation, to gain access to the interior of the module, and permit the servicing or replacement of components therein.

The side panel 34 includes a connection panel 37 on which connectors 17, 18 and 19 are provided for connecting to the space heating of three zones of the building, with corresponding connectors provided for the return flow. The connection panel also incorporates a cold water feed 21 into the module 1 and a connection 20 for the hot water supply from the module 1 to the building. Electrical power is provided to the module 1 via connection 16, also in the connection panel 37. At the bottom of the connection panel 37 there is located the antenna 31 for the transmitter/receiver 7.

Exterior panel 35 is weather-proof and it is arranged to be sealed with the weather- proof outer exterior of the building. This may simply by means of flashing which overlaps and is bonded to the flat surface of the external panel 35, or alternatively the peripheral edge of the external panel 35 may even be formed to cooperate with materials of the roofing system into which the module 1 is to be installed.

In the embodiment shown in Figure 2, the solar collector 3 forms part of the exterior panel and this is mounted on the module by being bonded to, or otherwise sealed with, an aperture within the sheet material of the exterior panel 35. The sheet material may be any conventional sheet material used for roofing. In the embodiment shown, the solar collector 3 is flush with the surface of the exterior panel 35, however in an alternative embodiment the exterior panel 35 could be a continuous sheet with the solar collector 3 located on mountings, slightly above the panel 35.

The exterior panel 35 additionally incorporates a flue 32, which may be a balanced flue for combustion boiler 5. Alternatively, or additionally, a vent may be incorporated for providing ventilation to the building, for providing a flow of air to and from an air heat pump or providing direct space heating via a furnace. The type of flue and/or vent and the number of vents will depend on the components within the module.

In an alternative arrangement the exposed surface the solar collector 3 allows for photovoltaic electricity generation with subsequent power management and storage within the unit for integration in to the house supply. Photovoltaic cells may be integrated with solar thermal collectors by, positioning alongside or by placing semi-transparent photovoltaic cells in front of the solar collectors thereby generating electricity and thermal energy simultaneously. Additionally, solar thermal collectors may be directly thermally coupled to photovoltaic cells and thereby used to remove thermal energy from the photovoltaic cells to improve their efficiency while capturing thermal energy for use within the heating module 1.

In a further alternative arrangement, the exposed surface of the unit can allow for capture of rain water for use in the building by gravity feed from the upper sections of the unit or by being pumped from the gutter. Water can then be stored in a tank towards the bottom of the unit and integrated in to the house supply.

Referring now to Figure 3, the module 1 is shown installed as part of the roof space of a building 40, with the frame 33 of the module 1 engaging with the structure 41 of the building. The frame provides the module with a load bearing capability so that it can form a structural component of the building. The edge of the weather-proof external panel 35 has a fast interlocking arrangement for engaging and sealing with an adjacent roof panel 43.

The module 1 is assembled within the factory as a complete unit and is lifted into place as a construction module during construction of the building 40. The solar collector 3 may be pre-installed and sealed in the module 1 prior to the leaving the factory, but alternatively, where the risk of damage during installation in a building is too great, the solar collector 3 can be subsequently fitted after installation of the heating module 1 in the building 40 and the solar collector may be installed from within the module 1.

Referring now to Figure 4, the module 1 is shown installed within the building 40 and externally appears as a flat panel within the roof of the building.

In the embodiments shown in Figures 2, 3 and 4 the module 1 illustrated is a wedge shape, having an exterior weather-proof panel 35 inclined at an angle to match the pitch of a roof into which it is to be installed. However, the module 1 may be contained in a housing designed so that it can be incorporated into a building as a dormer, mansard or clerestory roof, for example as illustrated in Figure 5. Alternatively, the module may be designed to fit into a preformed aperture within a wall 44, as illustrated in Figure 6, or to be integrated with system glazing or system facia panels 45, as illustrated in Figure 7. Alternatively, the heating module could be incorporated into the building as a porch, as shown in Figure 8.

Examples of the present invention have been described above by way of example only and many modifications thereto will be apparent within the scope of the appended claims.