The present disclosure relates to a roof support structure. More particularly, it relates to such a structure for use in association with car parking spaces, canopies, shelters and walkways, for example. The supported roof may comprise photovoltaic (PV) panels.

Background to the disclosure

There is a need to provide roof support structures in a more cost-effective manner. There is likely to be a rapidly growing market for such structures to support PV panels over car parking spaces as the use of electric vehicles increases.

Summary of the disclosure

The present disclosure provides a roof support structure comprising:

two support struts;

a roof beam coupled to one end of each of the support struts; and

a coupling attached to the other end of each of the support struts for coupling the struts to a driven pile.

The structure provides a cost-effective roof support structure. It may support PV panels. In a car port application, it may be combined with electric vehicle charging, battery energy storage, "vehicle-to-grid" services and integration using the "Internet of Things".

The structure may include two support struts only together with the or each coupling. Preferably, an acute angle is defined between the struts, to form a "V". The acute angle may be between 30 and 40°, for example. Each strut is preferably linear. Each stmt may comprise a C-section length of metal. More particularly, each strut may comprise two C-section lengths of metal ("double C-section" struts) for greater strength. The C-sections may be attached back-to-back to each other.

Preferably, each strut is formed from cold-rolled metal, such as cold-rolled lightweight steel.

The roof beam is preferably linear. The beam may comprise a C-section length of metal. More particularly, the beam may comprise a double C-section for greater strength. The C-sections of the beam may be attached back-to-back to each other.

Preferably, the beam is formed from cold-rolled metal, such as cold-rolled lightweight steel.

The strong configuration of the roof structure described herein allows the use of relatively lightweight material to form the struts and/or roof beam whilst still providing the desired strength characteristics. The use of more lightweight materials leads to cost savings associated with reduced material costs and transportation costs, and costs associated with any surface treatments such as painting or galvanising.

The roof beam may be coupled to two support struts only. In another configuration, the roof beam is coupled to two pairs of support struts only.

The coupling may comprise a first component formed from a single piece of sheet metal to which the other end of each support strut attached. This provides a strong connection between the two struts. The first component may be folded to define two planes perpendicular to each other. The first plane may be attached to the struts. The second plane may define a pair of parallel slots.

The coupling may be configured to facilitate adjustment of the location of the two struts relative to an associated support or pile in three mutually perpendicular directions. The coupling may comprise a second component formed from a single piece of sheet metal which is folded to form two planes perpendicular to each other. Each plane may define a pair of parallel slots, with the slots in each plane perpendicular to the slots the other plane. Each pair of slots of the second component may be perpendicular to the slots defined in the first component in the assembled coupling.

The first component may be attached to the second component using rods or bolts which extend through a slot in each of them. Similarly, the second component may be attached to a support or pile using rods or bolts extending through respective slots in the second component and through the support or pile. In this way, the slots may facilitate adjustment of the location of two struts relative to the support or pile in three mutually perpendicular directions.

The roof support structure may include a driven pile for insertion into a supporting substrate such as the ground. The coupling may connect the other end of each of the support struts directly to the driven pile. The driven pile may comprise a circular tube or a universal beam. The universal beam may be in the form of a H-beam, with its width similar to its height, or an I-beam having a central web which (in transverse cross-section) is relatively tall compared to the width of the end flanges of the beam.

Existing solar car port structures utilise large supports mounted in large concrete bases. They therefore have a large associated footprint, meaning that the structures reduce the amount of space available for cars. Use of a driven pile support in accordance with the present disclosure substantially reduces the footprint of the roof support structure. Such a structure may be installed in an existing car park without needing to reduce the number of car parking spaces. The footprint may be confined to be within the white lines of an existing car park, for example. Furthermore, the lightweight yet strong configuration of the roof support structure enables the use of driven pilings with a relatively small footprint. Also, such a structure may be configured to meet the relevant requirements in terms of wind resistance, carrying snow and withstanding an impact from a car. A driven pile comprising a circular tube may include a planar element surrounding the tube, arranged with its plane perpendicular to the longitudinal axis of the tube. In use, the tubular pile may be located with the planar element at ground level. An additional square tube may be provided inside the circular tube to provide additional strength.

A roof support structure may include a plurality of roof beams, each associated with a respective combination of two support struts and a coupling as defined above. In a preferred arrangement, one or more roof beams and/or one or more pairs of support struts may have different strength characteristics to others. In this way, in larger structures, cost savings may be obtained by using some lighter weight structures whilst still achieving the required strength for the structure as a whole.

According to a further aspect, the present disclosure provides a method of installing a roof support structure in a supporting substrate, wherein the method comprises driving a driven pile only partway into the supporting substrate, and mounting a roof support structure onto the upper, exposed end of the driven pile. Preferably, the driven pile is driven partway into the supporting substrate so as to leave at least 40cm of the driven pile extending above the supporting substrate.

The driven pile may extend above the supporting surface so that it is likely to take the impact of any accidental collisions with the support structure. This allows the remainder of the structure to be more lightweight (and therefore less costly) as it need not be designed to withstand such collisions. For example, when the support structure is used in association with car parking spaces, the driven pile may extend sufficiently far above the supporting surface (such as by at least 40cm) to receive any accidental impacts with the support structure from road vehicles.

The present disclosure also provides an assembly for coupling two adjacent PV panels together, comprising:

an elongate fixing clamp having a central section for receiving a fastener, and two laterally extending members on either side of the central section; and an elongate support rail having a mid-section for receiving a fastener to fasten it to the fixing clamp, and two laterally extending side portions on either side of the mid-section.

In use of the assembly, the support rail is fastened to the fixing clamp, with the central section of the fixing clamp and/or the mid-section of the support rail extending between the edges of two adjacent PV panels. The fixing clamp and support rail are drawn towards each other so as to receive one PV panel between a first laterally extending member of the fixing clamp and a lateral extending side portion of the support rail, and receive the other PV panel between a second laterally extending member of the fixing clamp and a second laterally extending side portion of the support rail.

The central section of the fixing clamp and mid-section of the support rail may be slidably engaged with each other. They may be slidable towards and away from each other in a transverse direction with respect to longitudinal axes of the clamp and rail. The mid-section of the support rail may define a pair of parallel planar members for slidably receiving a pair of parallel, substantially planar members of the fixing clamp. This arrangement serves to guide the fixing clamp towards the support rail as they are drawn together by a fastener during installation.

Preferably, on a side of the support rail facing away from the fixing clamp, an opening is defined for receiving a fastener to enable the support rail to be attached to a supporting structure. The opening may be shaped to receive a nut or bolt head for example.

Each laterally extending side portion of the support rail may, together with the midsection of the support rail, define an axially extending channel. In use of the assembly, this channel may provide a gutter for carrying away any rainwater passing between the two adjacent panel edges. Preferably, the laterally extending side portions of the support rail have a greater lateral extent than the laterally extending members of the fixing clamp to provide a greater cross-section for the channel. The fixing clamp and/or the support rail may each be integrally formed. They may be formed from a plastic material, for example.

The assembly may include a pair of edge protectors for receiving a respective edge of an adjacent PV panel. In use, the laterally extending members of the fixing clamp may engage with a respective edge protector on one side of each PV panel and the laterally extending side portions of the support rail may engage with respective edge protectors on the other side of the PV panels.

The assembly may also include an extender component for attachment to the distal end of the mid-section of the support rail to increase its length. This enables the assembly to be adapted to receive PV panels having a greater thickness, or PV panels having a peripheral frame.

A plurality of PV panels may be coupled together using an assembly as disclosed herein in order to form a roof. Such a roof may be provided in combination with a roof support structure as described herein. The PV panels may therefore also fulfil the role of a roof themselves, removing the need for an additional roof to provide sufficient shelter. The assembly may provide a substantially watertight seal between the edges of adjacent panels.

In an assembly as described herein, both a fastener for attaching the support rail to a fixing clamp and a fastener for attaching the assembly to a supporting structure may be inserted from same side of the support rail. This facilitates installation of the assembly in a roof support structure from beneath the panels, simplifying the installation procedure.

Brief description of the drawings

Examples of the present disclosure will now be described with reference to the accompanying schematic drawings wherein:

Figures 1 to 3 are end, side and perspective views of a roof support structure according to the present disclosure; Figure 4 is an enlarged view of the region marked A in Figure 3;

Figures 5 to 7 are end, side and perspective views of another roof structure according to the present disclosure;

Figures 8 to 10 are enlarged views of the regions marked A, B and C in Figure 7; Figures 11 to 14 are perspective, side and plan views of a tubular pile according to the present disclosure;

Figure 15 is a side view a fin employed in a driven pile of Figures 11 to 14;

Figures 16 to 19 are front perspective, rear perspective, front and plan views of a coupling according to the present disclosure;

Figures 20 to 23 are front perspective, rear perspective, front and plan views of another coupling according to the present disclosure;

Figures 24 and 25 are front perspective and rear perspective views of a further coupling according to the present disclosure;

Figures 26 to 28 are perspective views of a purlin hanger according to the present disclosure;

Figure 29 is a perspective view of two PV panels together with a coupling assembly according to the present disclosure;

Figure 30 is an enlarged view of region A of Figure 29 showing an exploded view of a coupling assembly according to the present disclosure;

Figure 31 is a cross-sectional side view of a coupling assembly according to the present disclosure in combination with the edges of two PV panels;

Figure 32 is a cross-sectional side view of a panel gasket;

Figures 33 and 34 are cross-sectional side views of a first example of a coupling assembly according to the present disclosure with different spacings between respective fixing clamps and support rails; and

Figures 35 and 36 are cross-sectional side views of a second example of a coupling assembly according to the present disclosure with different spacings between respective fixing clamps and support rails.

Detailed description of the drawings

A roof support structure 2 according to the present disclosure is depicted in Figures 1 to 4. It comprises two pairs of support struts 4, 6 attached to a roof beam 8 at their upper ends. The lower ends of each pair of struts are attached to respective couplings 10. The couplings are in turn attached to respective driven piles 12. Only the upper portions of the piles are shown in the drawings. A plurality of purlins 14 are attached to the upper surface of the beam 8 and extend perpendicular thereto.

The spacing between the struts of each pair increases away from the coupling to define a V-shape. Each strut and the beam preferably consists of cold-rolled lightweight C-section steel.

The roof support structure 2' of Figures 5 to 10 differs from that shown in Figures 1 to 4 in that each strut 4', 6' is formed from two sections of C-section steel (forming a double C-section) for greater strength. Also, the purlins 14' are formed as double C- sections of steel.

Figures 11 to 15 relate to a tubular driven pile 20 according to the present disclosure. It comprises a circular tube 22. A square planar member 24 is located towards one end of the tube, with its plane orientated perpendicular to the longitudinal axis 26 of the tube. The planar member extends around the outer circumference of the tube. A plurality of fins 28 extend between the planar member and the outer circumferential surface of the tube at circumferentially evenly spaced locations around the tube to increase the resistance of the planar member to forces exerted on its underside as the pile is driven into the ground. The lower end of the pile is cut to define a V-shape to assist penetration of the pile into the ground.

A coupling according to the present disclosure is depicted in Figures 16 to 19. It comprises a first component 30 for attachment to a pair of struts 4, 6, and a second component 32 for attachment to a tubular driven pile 20.

First component 30 is formed from sheet metal and folded to define two mutually perpendicular planar sections 34 and 36. Section 36 defines a pair of parallel elongate slots 38. Second component 32 is also formed from sheet metal and folded to define two mutually perpendicular planar sections 37 and 40. Section 38 defines a pair of parallel elongate slots 42. The upper end of driven pile 20 carries a planar member 44 which defines a pair of parallel elongate slots 46. The slots in the first component, second component and planar member 44 are mutually perpendicular and together facilitate adjustment of the relative position of the struts and the pile in three mutually perpendicular directions, with rods or bolts extending through slots in the first component and second component, and the second component and plate 44, respectively.

Figures 20 to 23 show a coupling 10' similar to that depicted in Figures 16 to 19. The coupling 10' of Figures 20 to 23 is adapted to connect the struts to a universal beam form of driven pile 50. The second component 32' defines a pair of slots 52 to cooperate with slots 54 defined near the end of the beam 50 in the assembled structure.

Figure 24 and 25 show a coupling 10" similar to that depicted in Figures 20 to 23 for coupling the struts to a universal beam driven pile. Whereas first component 30 in Figure 20 projects into the channels defined by the C-section of the struts, in Figure 24, the first component 30' is configured for attachment to the rear, outer surface of the C-section struts.

Figures 26 to 28 depict a purlin hanger 60 which may be employed according to the present disclosure to attach a purlin 14 to beam 8 of the structure. The hanger may be formed from a metal sheet. It is cut and folded to define a first planar section 62 for attachment to a purlin and a second planar section 64, perpendicular to the first, for attachment to the beam.

Figures 29 to 36 relate to an assembly for coupling together two adjacent sheets of material, which may be PV panels for example. Panels 70 and 72 are arranged in a common plane and adjacent edges 74 and 76 are coupled together by an assembly 78.

The assembly comprises a fixing clamp 80 for attachment to a support rail 82. The fixing clamp and support rail each have a constant cross-section and are elongated along respective longitudinal axes. Each extends along the entire length of each panel edge. The fixing clamp has a central section 84 and two laterally extending members 86 and 88 located on opposite sides of the central portion. Each laterally extending member includes a planar member 90, 92 at its distal end for engagement with an adjacent sheet or panel.

The central section 84 is adapted to receive a fastener. For example, it may comprise two parallel planar members 86. The opposing surfaces of the planar members may define grooves or other structures for engagement with a threaded fastener such as a screw.

The support rail has a mid-section 94 for receiving a fastener to fasten it to the fixing clamp, and two laterally extending side portions 96,98 on either side of the midsection. Each side portion, in combination with the sidewall of the mid-section defines a channel or gutter 100,102 in order to catch and transport away any rainwater passing between the two panels.

A planar member 104, 106 is formed at distal end of a respective side portion for engagement with the underside of a respective panel. Two edge protectors 108, 110 are provided which extend around the edges of respective panels. An upper portion of each edge protector is sandwiched between a planar member of fixing clamp on the panel and the lower portion of each edge protector is sandwiched between the support rail and the panel. The assembly is installed by inserting a fastener through the support rail into the fixing clamp which draws them together, with the edge protectors sealing the junctions between the fixing clamp and support rail on the one hand and the panels on the other.

The mid-section of the support rail made define a channel 112 on its underside for engagement with a fastener to attach it to a supporting structure.

A panel gasket 114 is also shown in Figures 30 and 32 for attaching one panel edge directly to another.

The central section of the fixing clamp and mid-section of the support rail may be slidably engaged with each other. They slide relative to each other in a transverse direction with respect to the longitudinal axes of the clamp and rail. The mid-section of the support rail may define a pair of parallel planar members for slidably receiving planar members 86 of the fixing clamp. This arrangement serves to guide fixing clamp towards the support rail as they are drawn together by a fastener during installation. In addition, as illustrated by Figures 33 and 34, this slidable arrangement enables the assembly to accommodate different panel widths. In Figure 33, the assembly accommodates a panel having a width "a", whilst in Figure 34, the assembly accommodates a panel having a larger width "b", with the clamp and rail further apart.

Figures 35 and 36 illustrate a modified version of the assembly depicted in Figures 33 and 34. It includes a mid-section extender mounted on the distal end of the midsection 94 of the support rail. In the arrangement of Figure 35, the extender facilitates accommodation of a panel having a width "c", which is greater than width "b". The configuration of Figure 36 is arranged with the clamp and rail still further apart to accommodate a panel having a width "d", greater than width "c".

From the present disclosure, many other modifications and variations will be apparent to persons skilled in the art. Such modifications and variations may involve other features which are already known in the art and which may be used instead of or in addition to features already disclosed herein. It should be understood that the scope of the disclosure of the present application includes any and every novel feature or combination of features disclosed herein either explicitly or implicitly and together with all such modifications and variations, whether or not relating to the main inventive concepts disclosed herein and whether or not they mitigate any or all of the same technical problems as the main inventive concepts. The applicants hereby give notice that patent claims may be formulated to such features and/or combinations of such features during prosecution of the present application or any further application derived or claiming priority therefrom.