Connector assemblies for connecting panels

In one embodiment, a connector assembly comprises: a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

TECHNICAL FIELD

The present disclosure generally relates to connectors and collectors for connecting panels.

BACKGROUND

In the construction of naturally lit structures, such as greenhouses, pool enclosures, solar roof collectors (e.g., photovoltaic modules), stadiums and sunrooms, glass panel roofs have been employed to allow natural light to shine therein. The glass panels themselves can be mounted in frame-like enclosures that are capable of providing a watertight seal around the glass panel and provide a means for securing the panel to a structure. These frame-like enclosures also provide for modular glass roofing systems that can be assembled together to form the roof.

Glass panel roofing systems generally provide good light transmission and versatility. However, the initial and subsequent costs associated with these systems limits their application and overall market acceptance. The initial expenses associated with glass panel roofing systems comprise the cost of the glass panels themselves as well as the cost of the structure, or structural reinforcements, that are employed to support the high weight of the glass. After these initial expenses, operating costs associated with the inherently poor insulating ability of the glass panels can result in higher heating expenses for the owner. Yet further, glass panels are susceptible to damage caused by impact or shifts in the support structure (e.g., settling), which can result in high maintenance costs. This is especially concerning for horticultural applications wherein profit margins for greenhouses can be substantially impacted due to these expenditures.

As a result, multiwall polymeric panels (e.g., polycarbonate) have been produced that exhibit improved impact resistance, ductility, insulative properties, and comprise less weight than comparatively sized glass panels. As a result, these characteristics reduce operational and maintenance expenses. Polymeric panels can also be formed as solid panels. Solid panels are solid plastic between their front and rear faces, and are useful where high impact resistance, high clarity, and/or the ability to thermoform the panel is desired. Multiwall panels have voids between their front and rear faces, e.g., the panel may be extruded as a honeycomb with an array of passages extending along the extruded length of the panel. Multiwall panels are useful where a high insulation value, lightweight, and easy installation, are desired.

For ease of design and assembly, multiwall panels can be produced in modular systems. The modular systems comprise multiwall panels with integral panel connectors, wherein the panel connector assemblies are employed to join the panels together and/or secure the panels to a structure on which they are employed. Standard panels can also be used, which are formed continuously and uniformly, i.e., they are extruded slabs and are cut to size and installed in the same manner as glass. These standard panels require a frame or the like to hold them in place.

Modular panels are advantageous for their extreme ease of installation, but are disadvantageous owing to their limited versatility in that modular panels cannot be cut to a desired size if such cutting involves loss of a connecting edge, because the modular panel will no longer be readily connectable to other panels at the cut edge. As a result, if a panel with an unusual or non-standard width is desired, a new extrusion die must be commissioned, at great expense, so as to be able to extrude panels of the desired width, and having the desired connecting edges. Further, modular panels are naturally limited to use with modular panels having complementary attachment structure (i.e., a tongue-and-groove panel will connect to other tongue-and-groove panels having the same tongue/groove configuration, but will not connect to standing seam panels). Standing seam generally refers to a panel with an integrated side collector adjoined to another panel with the use of a connection system. Thus, greater flexibility in the size of the modular panels, without the requirement for expensive equipment and retooling, and the ability to connect to a variety of panels is desired.

Additionally, modular panels can be subject to high wind loads depending upon the structure and location on which they are installed, and must be able to withstand certain live loads (e.g., wind loads) and static loads (e.g., snow loads) in order to satisfy various building codes (e.g., be able to support 3 feet (0.9 meter) of wet snow and/or be able to withstand wind loads of 80 miles per hour (mph) to 280 mph (130 kilometers per hour (kph) to 450 kph)). Wind loads can create negative forces which can pull a modular panel off its supports and thus, lead to premature failure of the modular panel. An improved connector assembly that can withstand high wind loads and not allow a panel to be pulled from its supports is continually desired.

BRIEF DESCRIPTION

Disclosed, in various embodiments, are side collectors and connector assemblies comprising a clip and methods for connecting panels with the side collectors and/or connector assemblies comprising clips, and panels using the side collectors and/or connector assemblies comprising clips.

In one embodiment, a connector assembly comprises: a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, a side collector comprises: a connector engagement region comprising a head having a size and geometry to mate with a panel connector; a panel engagement region comprising a receiving area having an energy director extending into the receiving area, and having a size to attach onto an end of the panel; and a clip engagement region comprising an opening, and having a size to accommodate an extension on a side of an engagement of a clip.

In one embodiment, a panel assembly comprises: a connector assembly, comprising a connector; a pair of side collectors, each comprising a connector engagement region; and a panel engagement region comprising a receiving area; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension protruding from a side of the clip, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement; a panel located in each panel engagement region; and wherein the connector is mated with the connector engagement region of the side collectors so as to hold ends of the panels together.

In one embodiment, a method of making a panel assembly, comprises: attaching a first panel to a second panel with a connector assembly, wherein the connector assembly comprises a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, a method of making a photovoltaic module assembly comprises: attaching a first photovoltaic module to a second photovoltaic module with a connector assembly, wherein the connector assembly comprises a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, an assembly comprises: a connector comprising two cavities defined by flexible walls, wherein each of the cavities has a geometry and is configured to mate with connector engagement regions from a pair of side collectors; a header located between the two cavities; and a first slot on a side of the connector and between the cavities, wherein the first slot has a size and geometry to receive an end of a panel without a side collector, wherein the cavities enable two sets of panels to be stacked and connected with the connector; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the stem diverges to a receiver located on an end of the stem opposite the base, wherein the engagement has an extension projecting from a side of the engagement, wherein a panel engagement region on the side collectors comprises an opening in a joint wall on a side of the panel engagement region opposite a receiving area, wherein the opening is configured to receive the extension of the engagement.

DETAILED DESCRIPTION

Disclosed herein are various embodiments of connector assemblies, e.g., connector(s) and collector(s), and clip(s). The connectors can attach to a support via the clip, where the clip can comprise an extension protruding from an edge of a cross-member. The extension can, when used to attach multiple panels together, assist in keeping the panels attached to one another when a load is applied. In other words, the extension can assist in keeping the panel assembly intact by effective resistance to positive and negative wind load force, thereby preventing separation of the panels. The clips disclosed herein comprising an extension can hold the connector assembly together at higher wind loads than clips not comprising an extension. The connectors can also be single or double sided; e.g., can be capable of engaging one or two sets of collectors, and optionally of engaging the ends of one or two additional panels with no collectors. The collectors can be integral with the panel (formed as part of the panel, e.g., as a single, unitary component), or separate from the panel as an independent component. If the collector is a separate component, many different width panels (e.g., measured in the X direction) can be used with the same collector and connector. Additionally, many different thicknesses (measured in the Y direction) and/or different width panels can be used with the same connector by using different, separate collectors. Various designs can be included to attach other components, including, but not limited to, for example, photovoltaic panels having frames designed to accept connectors (e.g., standing seam connectors) for ease of assembly. Additionally, the clips can be designed to enable the panels to be level when assembled (in the Y direction). The clips can also be designed to engage with the panels so as to not allow separation between the panel and the clip in the X direction when subjected to a load. Optionally, a single clip design can be used with several collector or integrated collector designs.

The connector assemblies generally comprise a connector, a side collector, and a clip for attaching panels together. The connectors and collectors are designed as mating pairs with one acting as the male and the other as the female connector. In many of the embodiments illustrated in the Figures, the connector is illustrated as the female component, while the collector is illustrated as the male component. It is noted that this is merely for illustration and ease of discussion. The opposite configuration is also covered herein and contemplated hereby, wherein the connector is the male component and the collector is the female component (e.g., seeFIG. 27). Therefore, the discussion of the cavity for the connector and the connector engagement region for the collector can readily be reversed and is hereby understood.

The connector can be designed with a cavity that has a size and shape to mate with a pair of side collectors (from adjacent panels) in order to hold the panels together. The specific size and shape of the cavity is dependent upon the size and shape of the side collectors. Desirably, the connector securely attaches to the panels, over the side collectors. In other words, the size of the cavity can be about equal to the size of the side collectors such that when the connector is assembled onto the side collector, physical contact between the outer surface of the side collector and the inner surface of the cavity is attained (e.g., over greater than or equal to 80% of the outer surface of the collector). It is noted that when a clip is utilized having an engagement (e.g., cross-member24inFIG. 1, receiver52inFIG. 17) that will be located between the connector and the collector, the size of the collector inner surface is sufficient to enable the engagement to be located between the connector and collector. For ease of installation and minimization of the use of fasteners, the connectors can be designed to snap-fit onto the collectors (e.g., seeFIG. 4), to slide onto the collectors from an end of the panel (e.g., seeFIG. 26), and/or to otherwise attach. It is contemplated, however, that a sliding mechanism can also be used to attach the connectors to the collectors.

It is noted that the connector is complementary to the combination of collectors to which it connects. However, both collectors do not need to be identical. Different collectors can be used on each panel so long as the connector is designed to receive that combination of collectors.

Further, panels using the side collector(s) (and/or connectors) disclosed herein can have all of their edges—not just two opposing edges—bearing attachment structures. (SeeFIG. 36) For example, panels for a wall might bear edge connectors with standing seams where the horizontal panel edges are to be joined and edge connectors with tongue and groove attachments where the vertical panel edges are to be joined.

For example, referring toFIGS. 1-4, the connector100has a cavity (interior portion102) with a size and shape complementary to two side collectors210arranged adjacent to one another such that the collector assembly (two adjacent side collectors) can be inserted into the cavity102. For example, such that the peaks216and slopes218of the adjacent side collectors form a valley that receives the connector protrusion120. Similarly, complementary flange104and ledge220of the connector100and side collector210, respectively, can be in physical contact when the connector is attached to the panels.

Some embodiments of the connectors100are “double” connectors, i.e., they have cavities102on two opposite sides for receiving pairs of side collectors (e.g., seeFIG. 16). In these embodiments, a cavity102is located on each side of the header134. Each of these cavities102comprises the flanges104to engage the ledges220of the side collectors210(e.g., seeFIG. 2). As with the other connectors100, for example as illustrated inFIG. 3, each cavity102of the double connectors are configured to mate with a specific pair of side collectors210and therefore has a complementary inner geometry that matches the outer geometry of the side collectors (or, as is mentioned above wherein the connector is the male element, the connector will have a complementary outer geometry to match the inner geometry of the collector, wherein the collector will extend from the end of the panel). For example, as illustrated inFIG. 16, wing(s)36can be present that mate with receiver(s)52extending from stem22on the clip10. As is clear from the exemplary embodiments illustrated in the figures, each of the connectors in the double connector does not have to be identical. A combination of different connectors can be used. As can be seen fromFIG. 16, the connector can have different shaped cavities102that are configured to receive the same shaped pairs of side collectors. It is also contemplated that different shaped pairs of collectors can be received in each cavity that is shaped accordingly. Here, the difference in shape is to enable the additional receipt into one of the cavities, the clip engagement (e.g., cross-member(s)24and/or receiver(s)52).

In addition to different cavity geometries, the connectors can comprise different outer geometries, thereby enabling them to receive additional panel(s), e.g., panel(s) that do not have a side collector. Optionally, slot(s) (e.g., slots150,152) can be formed between the cavities102(see e.g.,FIG. 16). The size and geometry of these slot(s) is dependent upon the thickness of the panel(s) intended to be inserted into the slot(s). Note, it can be desirable to only have slot(s) on the side(s) of the double connector intended to receive additional panels. The presence of a panel in the slot stabilizes the sides154,156of the double connector, preventing flexing of the side(s) after installation of the panel. In other words, while the side collectors210are inserted into the cavities102, the sides154,156(accordingly), of the double connector, are forced outward, causing the edges158,160(accordingly) defining the slot(s) to move into the slot. Once the flange104passes the end of the slide region214to the ledge220, the sides154,156move back out of the slot(s)150,152. Hence, if a snap-fit arrangement is employed, the side collectors are inserted into the double connector prior to the insertion of the additional panels. Furthermore, if a fastener is employed, the set of side collectors located between the connector and the support are inserted first to enable the attachment of the fastener302to arm30. Then the second set of side collectors are inserted into the open cavity102prior to the insertion of the additional panel(s). The additional panels can have a thickness that enables a compression fit in the slot, e.g., without damaging the end of the panel. Such a fit will prevent inadvertent removal of the panel from the slot and will stabilize the sides154,156against movement upon the application of force to the panels.

As is illustrated inFIG. 18and mentioned above, the end of the panels (without collectors) can be inserted into the slot(s). This creates an arrangement, in the Y direction (see coordinate system labeled inFIG. 18), of panels with collectors (e.g., first set of panels), gap (e.g., fluid gap such as air), panels without collector, gap (e.g., fluid gap such as air), panels with collectors (second set of panels). Since the sizes of the slots are different, different thickness panels are located on each side of the double collector. In embodiments that employ the double connector, a clip can optionally be employed to provide attachment of the first set of panels to a support300. In addition, the clip may further comprise member(s)38configured to receive fastener(s)302. Hence, one or both of the connectors of the double connector can be configured to receive fastener(s) to enable further securement of the connectors (and hence the panels) to the support300. In other words, in addition to the snap connection via the side collectors of the first set of panels, the retention of the connectors can be further enhanced via direct attachment of the header of the double connector to the member(s)38of the clip10via the use of connecting member276.

Some further exemplary embodiments of additional connectors are set forth inFIGS. 10,20, and24. These embodiments further illustrate that the specific size and geometry of the connector is only limited by the size and geometry of the side collectors and clip to which it will be connected. Also, as is clear with respect to the panels and the side collectors, the connectors can optionally comprise various combinations of ribs162(e.g., horizontal, vertical, diagonal, and any combination thereof) as is desired, e.g., for additional structural integrity (e.g., seeFIGS. 3 and 16). Any rib arrangement is based upon desired structural integrity for the particular connector, based upon where the connector will be employed and the loads it will experience.

The side collector(s) are located at the end of the panel, wherein adjacent side collectors (from adjacent panels) form the seam between the panels to be connected. As noted above, the side collectors can have various designs that are complementary to the design of the connector and clip so as to enable the collectors (male portion; connector engagement region222with a head234) to mate with the connector (female portion; cavity102) (or collectors (female portion) to mate with the connector (male portion)), e.g., seeFIG. 23andFIG. 24.

The specific geometry of the collectors are dependent upon the geometry of the connector to which they will be mated. Some exemplary geometries are illustrated inFIGS. 2,9,19, and23. As can be seen in these figures, the collectors can optionally comprise rib(s)226(e.g., vertical, horizontal, and/or diagonal to enhance the structural integrity of the collector. It is also noted that the density of the ribs (number of ribs per unit area), can be greater than the density of the ribs in the panel (if the collector is separate) or in the remainder of the panel (if the collector is integral). Diagonal ribs, for example, can be used along with vertical ribs and horizontal ribs in the area adjacent the panel engagement region224. In this embodiment vertical ribs and horizontal ribs are employed throughout the side collector, with diagonal ribs only located in the area adjacent the panel engagement region224(e.g., no diagonal ribs are used in the connector engagement region).

As noted, the side collectors can be an integral part of the panel (e.g., seeFIG. 2), or a separate component (e.g., seeFIG. 19), e.g., a side collector formed separate from the panel and later attached to the panels (e.g., after manufacturing of the panel is complete). Non-integral side collectors, such as tongue and groove, base and cap, and standing seam side collectors are advantageous in that panel sizes (e.g., length, width, height, and/or thickness) are not limited by sizes that are already produced because of cost issues associated with creating, testing, and validating a new die system to produce the desired size. With non-integral side collectors, any size and combination of panels and/or sheets can be used, since the side collectors are produced separate from the sheet and attached at a later time (e.g., at or close to the job site). Additionally, different shape side collectors can be used to attach different panels of a system (e.g., roof) together. This enables the side collectors and connectors to be customized for the particular location and desired properties (e.g., to enhance structural integrity, sound dampening, and/or light transmission, etc.) Non-integral side collectors are additionally advantageous in that they essentially convert a standard panel (e.g., a planar panel with no side collector) into a modular panel. These side collectors can have a structure configured to wrap around an edge of a panel, (e.g., a U-shape) and be sized to receive the thickness(s) of the panel(s) to be fit therein. These side collector(s) can be welded (e.g., ultrasonically and/or thermally), chemically attached (e.g., chemically bonded or glued), and/or mechanically attached (e.g., screwed, bolted, riveted, etc.) and/or otherwise affixed to the panel(s).

As discussed above, the side collectors have a complementary design to the connectors so as to enable mating thereof. In many embodiments, these components can be snap-fit together. Hence, the side collector210comprises an area that enables the connector to readily move over the surface of the side collector, such that when a force is exerted on the connector toward the side collector, the sides156of the connector flex outward, away from the cavity102(seeFIGS. 2-4). This enables the connector engagement region222to enter the cavity102until the flange104contacts the ledge220, thereby allowing the sides156to move back toward the cavity102.

Alternatively, in the various embodiments, if flexing of the sides156of the connector is not possible and/or not desirable, the connector can be disposed onto the collector by placing the side collectors of two panes adjacent to one another. The connector and collectors can be moved together (e.g., in the Z direction), sliding the connector and collectors together (e.g., sliding the connector engagement region222into the cavity102).

When the collector is a separate element from the panel, it comprises a panel engagement region224(seeFIGS. 9,10,19, and23). The height of the panel engagement region224is sufficient to enable an end of a panel to be inserted therein (e.g., is sized to receive the thickness(es) of the panel(s) to be fit therein (seeFIGS. 22 and 26)). Depending upon the design of the collector, the receiving area232can be defined by the connector engagement portion222, collector arm(s)230, and/or rib(s)226. For example, inFIG. 19, the receiving area232is defined by the connector engagement portion222and arm230. InFIG. 23, the panel engagement region224has an arm230, but the receiving area232is defined by the connector engagement portion222and horizontal rib226. InFIGS. 9 and 10, the receiving area232is defined by arms230. In some designs, the arms230extend outward, e.g., from the connector engaging area (seeFIGS. 8-10,27, and28), e.g., such that the panel engagement region comprises a body portion262which is located adjacent to the connector engaging region (seeFIGS. 8 and 9) and arm(s)230extending from the body portion262, forming receiving area232for attachment onto an edge of a panel. In other embodiments, the arms230are located in alignment with the connector engaging region (seeFIGS. 19, and23), e.g., such that the panel engagement region is located adjacent the connector engaging region (e.g., the panel engagement region is formed by the arms230(which may be multiwalled), and no body portion).

Within the panel engagement region224can be energy director(s)228extending into the receiving area232. These energy directors can be configured to engage an outer surface (e.g., surface208ofFIG. 12) of the panel to which the collector will be attached. The energy directors can aide in grasping and retaining the panel in the panel engagement region224of receiving area232and/or can redirect energy received by the collector and/or panel (e.g., during welding (e.g., ultrasonic welding, laser welding, and/or thermal welding) together of the collector and panel) into the ribs198of the panel (see e.g.,FIG. 2). Therefore, desirably, some or all of the energy directors228are located in the receiving area232so as to align with vertical ribs (e.g., ribs extending in the Y direction) in the panel when the panel is inserted into the panel engagement region224. The energy director(s) can be located on one or both horizontal surfaces (surfaces extending in the X direction) in the receiving area232. To inhibit the arms from detaching from the panel, and/or to avoid moisture, air, and/or insect infiltration, an energy director can be located at the end of each arm246(e.g.,FIG. 28). Furthermore, it was discovered that the strongest bond between an attachment member and a multiwall panel came about when an energy director was positioned directly over a vertical rib in a multiwall structure. Energy director(s) can be used on the vertical surface as inFIG. 19when the panel has a closed end (e.g., is not open to the individual ribs), and has horizontal ribs or when the panel is a solid panel.

The number of energy director(s) employed can be different on each horizontal surface (and optionally the vertical surface), and can vary depending upon the length of the horizontal surfaces, the amount of vertical rib(s), if any, (and, if on the vertical surface, the amount of horizontal ribs) in the panel, and/or the amount of force that will be exerted onto the collector and/or panel when they are assembled together. For example, in the case of the multiwall panel, greater than or equal to 2 energy directors are generally employed on each horizontal surface, specifically, greater than or equal to 4, more specifically, greater than or equal to 5, and yet more specifically, greater than or equal to 8. Although any geometry can be employed for the energy director228, a generally triangular geometry is employed, e.g., an isosceles triangle extending into receiving area (such as from the arm(s)230). The height of the energy director (e.g., the distance the energy director extends from arm230into receiving area232) can vary. Generally the height is less than or equal to 5 mm (millimeters), specifically, 0.25 mm to 2 mm, more specifically, 0.5 to 1 mm.

The energy directors can be formed as an integral part of the collector (i.e., an extension from arm230, not an attachment to arm230). Furthermore, to enhance compatibility between the collector and the panel, the energy director(s) can be formed from the same type of material as the panel, or can be a composition comprising the same type of material as the panel. For example if the panel is a polycarbonate panel, the energy director(s) can be polycarbonate, or a composition comprising polycarbonate, such as a polycarbonate and ABS.

Not to be limited by theory, it is believed that, e.g., during ultrasonic welding the energy directors pinpoint the energy of the vibrating ultrasonic horn to a small area between the side collector and panel (apex of the triangle) causing the energy director to melt and subsequently fuse the side collector and panel together. Without the energy directors, the ultrasonic horn would vibrate, heat, and compress a large unmelted side collector into the panel, crushing a multiwall panel or creating a very weak bond with a solid panel. In addition or alternative to the welding, the side collectors210can also be attached to the panel by laser welding, by chemical, and/or mechanical methods (e.g., gluing, chemical bonding, fastener(s), and combinations comprising at least one of the foregoing).

Bonding a separate side collector to a panel can comprise inserting the edge of the panel into the receiving area of the side collector until the edge contacts the vertical wall and/or the panel cannot be inserted any further and creating relative motion between an ultrasonic welding horn and the arms of the side collector so as to melt the energy director(s) and form a bond between the arm and the panel surface.

To address thermal expansion of the panels, the side collectors can have a joint side with an angled wall (e.g., angled from the connector engagement region toward the receiving area) such that, when assembled, the joint walls254form a joint (e.g., space252) having a decreasing width from the base258toward the point264(seeFIG. 10). In other words, the joint wall can be non-perpendicular, as determined with respect to the arm230. The joint walls form a space having a converging diameter from the base258toward the connector engagement region222, and optionally all the way to the point264adjacent the end of the joint wall254opposite the base258. The size of the space formed by the adjacent walls should be sufficient to enable the thermal expansion of the panels to which the side collectors are attached. Essentially, as the panels thermally expand, they would exert a force on the side collectors, causing the side collectors to move toward each other. As the side collectors move toward one another, the width (as measured in the X direction), of the space decreases. The space can have a width (as measured in the X direction, and in the relaxed state (i.e., when no force is applied due to thermally expanding panels)), at the base258, of greater than or equal to 1 mm, specifically, 2 mm to 10 mm, and more specifically, 2.5 mm to 5 mm.

Alternatively, or in addition to the joint252, a spacer250can be located between adjacent joint walls254. The spacer can comprise a flexible material that can be compressed by expanding panels, e.g., a foam or elastomeric material (seeFIG. 8). The spacer can have a sufficient size and compressibility to allow for the thermal expansion of the panels. For example, the spacer can have a thickness (measured in the X direction and in the non-compressed state) of greater than or equal to 1 mm, specifically, 2 mm to 10 mm, and more specifically, 4 mm to 8 mm.

When the side collector is to be used with an alignment clip that will not engage the outer surface of the side collector and/or the connector, the side collector has an opening212to receive the cross-member24of the clip10(e.g., seeFIGS. 2 and 10). This opening is located in the joint wall254adjacent the receiving area232.

As is mentioned, a clip can be employed with the connector and collectors. Different types of clips are possible. For example, the clip can be an alignment clip (e.g., seeFIG. 1), and/or a combination alignment clip and engagement clip (e.g.,FIGS. 17,21, and25). Hence, the clip can comprise an alignment region that is designed to align the adjacent panels such that when the panels are attached together, they are level. For example, inFIG. 1, the clip10is illustrated as comprising a cross-member24at one end of stem22and a base18at the other end. The base18can have a foot28, side(s)12,14, leg(s)16, area20, and/or support(s)26, e.g., the base can form a “u” shape (e.g., with a side14, leg16, and arm30(seeFIGS. 2 and 21), or with legs16and foot28(seeFIG. 25)). For example, as is illustrated inFIGS. 1,4, and21, the base can comprise sides12,14(extending in the Y directing away from the engagement) defining area20, with arm30extending from the side14to leg16(which extends in the Y direction toward the engagement). The foot28can extend away from stem22in one or both directions, e.g., forming a L-shaped foot or a T-shape (seeFIGS. 1,17,21, and25), with the stem, respectively. The T-shaped stem allows even alignment of the assembled panels since both of the adjacent panels are held the same distance from the support. However, the L-shaped foot only extends along one panel and hence does not support the panels evenly when assembled (e.g., the panels will be offset by the thickness of the foot28).

Building codes often require panel and connector assemblies be able to withstand wind loads of 80 mph to 280 mph (130 kph to 450 kph) without failing. Such wind loads can create a “negative wind load” that can pull a roof or wall from its supports with forces of 16 pounds per square foot (lb/ft2) to 200 lb/ft2(about 766 Pascals (Pa) to about 9576 Pa). A potential failure mode can be observed in connector assemblies exposed to such wind loads in that the panels can separate from one another at the attachment point due to deflection and subsequent release of the clip from the attachment point. The clip10inFIG. 1can be modified to incorporate features that can help prevent the separation of adjoining panels and thus, prevent subsequent release from the attachment point and failure of the connector and panel assembly.

For example, referring now toFIG. 5, which is a cross-sectional view of the cross-member24and stem22of clip10, the various design features to aid in preventing disassembly during wind loading are illustrated.FIGS. 6 and 7also illustrate various designs of clip10incorporating the design features described herein. For example, as illustrated inFIG. 5, the cross-member24can comprise extensions44,46that are configured to engage with the opening212in side collector210to assist prevention of separation of the panels, e.g., to prevent separation of panels200,202as illustrated inFIG. 4when facing a wind load (e.g., a negative wind load). Cross-member24can, itself, be designed so that the extension is a lip44on either or both sides of the cross-member24(e.g., first side48and/or second side50). As illustrated inFIG. 5, the lip44can protrude upward and/or downward from either side48and50of cross-member24. One embodiment of a clip10comprising a lip44protruding downward from cross-member24is illustrated inFIG. 7; another possible design is illustrated inFIG. 11. In embodiments where lip44is present, the opening212in side collector210can, optionally, be modified as shown inFIG. 12, i.e., opening212can be modified to accommodate (i.e., compliment or match) the lip44. InFIG. 11, another embodiment of clip10is illustrated having a lip extending from the second side of the cross-member24to engage with an opening212in a side collector210.

Cross-member24can also, alternatively, or in addition to lip44have protrusion46protruding therefrom on either or both sides48,50upward or downward as illustrated inFIG. 5.FIG. 6illustrates a clip10with protrusion46extending downward from cross-member24. Protrusion46can be configured to penetrate into the side collector210in the area of the opening212, creating a gripping effect and being able to prevent disassembly of the connector assembly70.FIG. 7illustrates an embodiment where a clip can also, optionally, comprise protrusion46extending from the foot28of the clip10with a lip extending from the second side50of the cross-member24so that lip44and protrusion46face one another. For example, as illustrated inFIG. 7, the protrusion46can be pointed inward for ease of assembly and to make disassembly more difficult. It is contemplated, however, that the protrusion46can be oriented in any direction that will provide the desired panel retention when a force is applied. It is to be understood that any combination of lip44and protrusion46can be included in any of the embodiments disclosed herein.

FIG. 12illustrates a connector assembly70with a cross-member24having lip44that is not under a load, whileFIG. 13illustrates the same, but under a negative wind load. InFIG. 12, arm30can be used to attach the clip10, and hence, panels200,202to a support structure40using a fastener302having a fastener head304. Exemplary fasteners include a bolt, screw, nail, rivet, nut, peg, glue, two-sided tape, as well as combinations comprising at least one of the foregoing. Exemplary supports include a beam (e.g., purlin, I-beam, rectangular beam, etc.), piling, wall, a rafter, post, header, pillar, roof truss, as well as combinations comprising at least one of the foregoing. As illustrated inFIG. 12, the clip can comprise multiple legs16and supports26that can provide design flexibility while providing solutions for various applicable building codes and can also support panels200,202and can maintain level spacing between panels200,202.

As can be seen inFIG. 13, when under a negative wind load, there can be uplift in the Y direction (see coordinate system illustrated inFIG. 18) of the connector assembly70, but the lip44is able to engage with opening212in the side collector210to prevent side collectors210and thus, panels200and202from separating from one another. (e.g., resist X direction separation). For example, when the panel200,202experiences a negative wind load, the panel200,202can be pulled so that only the clip10holds the panel to the structure. The lip44effectively creates a mechanical stop preventing the panels from detaching.FIG. 13additionally illustrates that the panel engagement region224can, optionally, comprise energy directors228as described in more detail with respect toFIG. 28.

If the opening212of the side collector210is not modified to match with the lip44of the clip10, the lip44can still function to hold the side collectors210and panels200,202together due to increased concentrated pressure of the lip44. The material of the side collector210will yield to the lip44and the lip44can penetrate into the side collector210in the area of the opening212, creating a gripping effect (e.g., mechanical stop) to assist the connector assembly70from disassembling when under load.

Insertion of the clip10with the lip44can be accomplished by ensuring the thickness (h) of the clip10is less than opening212in the side collector210(see e.g.,FIGS. 11 and 12). It is contemplated that the clip10can be slid in from either or both ends of the panels which are to be interconnected, which would allow for a constricted or even force fit between the thickness (h) of the clip and the opening212in the side collector210. Additionally, it is contemplated that the clip10could be forced into the opening212from the side of the panel if the thickness of the clip10was larger than the opening212.

As illustrated inFIGS. 12 and 13, the tolerance between the thickness and height of the opening212in the collector72and the thickness (h) and height (t) of the lip44(see e.g.,FIG. 11) can create a floating effect in the connector assembly70that can provide allowances for thermal expansion as well as the ability to slide the panels along the clip after assembly. Alternatively, or in addition to, a zero tolerance situation can occur in which the ability to slide the panel is restricted and the clips can be slid onto the panel from an end of the panel and moved into place before securing from a side or bottom of the clip.FIG. 37illustrates a clip60that can be used in this embodiment where the clip comprises a cross-member24having a lip44with a foot28connected to a side14with a landing62extending therefrom.

Turning again now toFIG. 12, when the clip10is assembled onto panels200,202, arm30on the clip10can be used to attach the clip10and thus, panels200,202to a support structure40using fastener302. Exemplary fasteners include a bolt, screw, nail, rivet, nut, peg, glue, two-sided tape, as well as combinations comprising at least one of the foregoing. Exemplary supports include a beam (e.g., purlin, I-beam, rectangular beam, etc.), piling, wall, a rafter, post, header, pillar, roof truss, as well as combinations comprising at least one of the foregoing.

FIG. 14is an embodiment of a panel (e.g., LEXAN* THERMOCLICK) panel where the panel is modified to accommodate a clip10having the design illustrated in FIG.11. Similarly,FIG. 15is an embodiment where a clip10having the design illustrated inFIG. 11is connected to panels having a lap joint connection68.

When the clip10is assembled onto adjacent panels200,202(seeFIG. 4), side12is adjacent the first panel200, while side14is adjacent the second panel202. Arm30(FIG. 1) can be used to attach the clip10, and hence the panels200,202, to a support300using fastener(s)302. Similarly, when an arm30is not present, fastener(s)302can be attached to the support300through the foot28(seeFIG. 17). Exemplary fasteners include a bolt, screw, nail, rivet, nut, peg, glue, two-sided tape, as well as combinations comprising at least one of the foregoing. Exemplary supports include a beam (e.g., purlin, I-beam, rectangular beam, etc.), piling, wall, a rafter, post, header, pillar, roof truss, as well as combinations comprising at least one of the foregoing.

In order to prevent the panels200,202from being unlevel due to the presence of the fastener302, the side(s)12,14, and/or leg(s)16have a length “l”, and/or the solid area20has a thickness, that is greater than or equal to the height “h” that the fastener head304extends from the linear portion22(e.g., stem22) toward the panels. If there is a difference in the thickness of the panels (in the Y direction), the side(s)12,14, and/or leg(s)16have a length “l”, and/or the solid area20has a thickness (as is appropriate), to compensate for the difference in the panels' thicknesses, such that, when the panels, connector, and clip are assembled together, the outer surface208of the panels are level with one another; they are aligned. In other words, the side(s)12,14, and/or leg(s)16have different length “l”, and/or the solid area20has a different thickness, wherein the difference in the length/thickness is equal to the difference in the panels' thicknesses.

Further structural integrity can be attained in the clip via the use of an optional extension from the leg(s)16and/or sides12,14, e.g., support26. Lateral extension(s) (e.g., support)26(e.g., seeFIGS. 1,11,17,21, and25) can be employed with the various embodiments of the clip, wherein the lateral extension(s) can extend toward and/or away from the adjacent panel to which the clip is connected. For example, the lateral extension(s) can extend toward and/or away from the stem22(in the X direction). These extension(s) can provide support to the panel as well as can inhibit air, water, and/or insect infiltration.

At the end of the stem22opposite the foot28is an engagement that can be located in an opening in the side collector and/or can contact a surface of the side collector. Exemplary engagements include a cross-member24(seeFIGS. 1 and 21), receiver(s)52(seeFIG. 17), and/or support structure40(seeFIG. 12). In various embodiments, the engagement can have a generally T-shape (e.g., the cross-member24is located perpendicular to the stem22), and/or can be arcuate (e.g., extending from the stem22in a manner complementary to the shape of the side collector slide region214(e.g.,FIG. 17receiver52in combination withFIG. 16). Stated another way, a receiver(s)52can diverge from the stem22at an end opposite the base18. Hence, the engagement can be configured to be located in an opening in the side collector (seeFIGS. 2 and 4, opening212in side collector210), or can, when assembled, be located between the side collector (e.g., the slide region214) and the connector (e.g., the inner surface122(see e.g.,FIG. 3) (see alsoFIG. 26, receiver(s)52contacting surface (slide region)214). When the engagement is configured to be located in the opening212, the stem has a length that is less than the height of the receiving area (e.g., both measured in the Y direction). In other words, the stem has a length that is less than the thickness of the panel that will be received in the receiving area232(see e.g.,FIG. 10).

As illustrated inFIGS. 21 and 22, cross-member24can comprise an extension (e.g., protrusion46) on the second side50of the cross-member24which will engage with the panels200,202ofFIG. 22to assist in preventing panel separation when a load is applied to the assembly.FIGS. 25 and 26illustrate yet another embodiment where extensions can be present on cross-member24(e.g., on the first side48and/or on the second side50). For example, as illustrated inFIGS. 25 and 26, protrusion46can be located on cross-member24. It is contemplated, however, that lip44could also be present on cross-member24, as well as any combination of lip44and protrusion46.

The cross-member24can extend out from the stem22in the “X” plane (e.g., seeFIGS. 1,11,21, and25), in one or both directions (e.g., positive and negative) and the distance in each direction can be the same or different. Similarly, one or more wings can extend from the stem22along the “X” plane, in one or both directions, with the length of the wings being the same or different (seeFIG. 17). Larger wing widths can provide higher wind loads. The desired width of the wings (e.g., from the end of one wing to the end of the other wing), is therefore dependent upon the intended application and desired structural integrity. Wing spans of up to and exceeding 50 mm can be employed, specifically spans of 5 mm to 40 mm, and more specifically spans of 10 mm to 30 mm.

With respect to the angle at which the cross member24and lip44extend from the stem22, it is also determined based upon desired structural integrity and the desired shape of the side collector to which the clip will connect. The cross-members can extend from the stem at an angle θ of 85° to 95°, with an angle of 90° desirable to enable higher loadings. An angle θ of more than 90° reduces load potential while an angle θ of less than 90 inhibits assembly of the panels and the clip, and can hinder assembly. The wings are generally curved and extend from the stem22at an angle θ of 100° to 155°, specifically, 35° to 75°, and more specifically, 40° to 50°. For example, clips having an angle θ of 90° have a loading capacity of 100 lb/ft2(4,788 Pa), while at an angle of 135°, the clip (comprising the same material and thickness), has a loading capacity of less than 80 lb/ft2(3,830 Pa).

The length of the clip (i.e., in the Z direction, see coordinate system illustrated inFIG. 18) is also dependent upon desired structural integrity (e.g., wind load resistance). When maximum wind load resistance is desired, the clip length is equal to the length of the panel. When less resistance is needed, the clip can have a length that is less than or equal to 50% of the length of the panel, specifically less than or equal to 25% of the length of the panel, and more specifically, less than or equal to 10% of the length of the panel. For example, the clip length can be less than or equal to 24 inches (61 centimeters (cm)), specifically, less than or equal to 12 inches (30.5 cm), more specifically, less than or equal to 6 inches (15.2 cm), yet more specifically, less than or equal to 3 inches (7.6 cm), and even less than or equal to 2 inches (5.1 cm).

In addition to the cross-member(s)24and/or receiver(s)52, the engagement can further comprise member(s)38. The member(s)38are configured to receive a portion of the connector and/or fastener(s) (e.g., to receive protrusion120into region42defined by member(s)38; seeFIGS. 20 and 21; and/or to receive fastener302(seeFIG. 12)). Therefore, the member(s)38can optionally be threaded, and/or comprise an adhesive or bonding agent, e.g., to facilitate retention between the clip and the connector. In addition to the member, support structure40may extend outward from the member and to the wing to provide additional structural integrity to the member (seeFIG. 17). The geometry of the support structure is preferably complementary (e.g., the negative) of the geometry of the portion of the connector and/or collector to which it will be adjacent when assembled.

The stem22extends from a base18(e.g., from the foot28) to the engagement. Therefore, if the engagement is configured to be located in the opening212, the stem22will have a length that is less than the thickness of the panel, while if the engagement is configured to physically contact the surface of the side collector, the stem22will have a length that is greater than or equal to the thickness of the panel (measured in the Y plane).

Referring toFIG. 27, this figure is intended to show that the above configurations can be reversed such that the connector is the male element and the side collectors form the female element to enable mating of these components. In this exemplary embodiment, when the side collectors are assembled together, the joint walls274form the cavity272. As with the other embodiments, any complementary mating engagement can be employed, such as snap-fit, tongue-and-groove, etc. The connector can further be attached to one or both of the side collectors with a clip10and fastener302. As can be seen from the figure, this arrangement enables a small profile since there is a minimum amount of connector and no side collector, extending away from the panels. The distance that the support166of the side collector extends away from the side collector210is dependent upon the size of the panels and the clips. For example, the support166can have a thickness (measured in the Y direction), that is less than or equal to 30% of the thickness of the panel (measured in the Y direction), specifically, less than or equal to 20%, and even less than or equal to 10%. In some embodiments, the support has a thickness of less than or equal to 40 mm, specifically, less than or equal to 30 mm, and more specifically, less than or equal to 20 mm, and even less than or equal to 10 mm.

Referring toFIG. 28, exemplary embodiments illustrating connector assemblies that use the side collectors to hold the panels together without the need for connectors. In these embodiments, mating pairs of side collectors have complementary geometries (e.g., tongue-and-groove (FIG. 28)). In these embodiments, the side collectors do not have mirror geometries with each other (e.g., as is illustrated in many of the other figures. They have complementary, mating geometries that enable the two side collectors to fixedly mate (e.g., to hold together so as separate only when intentionally disassembled). In many embodiments of these side collectors, and even of the above connector/side collector groups, the elements permanently mate (e.g., once the elements are assembled they cannot be disassembled without breaking one or more of the components).

The connector, side collector, and clip can, independent of the other elements, comprise any material that gives the desired properties (e.g., light transmission, insulation, strength, durability, and/or impact resistance, etc.). For example, they can each independently comprise a metal (e.g., aluminum), a polymeric material (e.g., acrylic, polycarbonate, etc.), or combinations comprising at least one of the foregoing. For example, the clip can comprise aluminum (e.g., 6000 series aluminum such as aluminum 6061; 7000 series aluminum such as aluminum 7108 or aluminum 7055; stainless; and other metals that will allow the clip to provide the desired wind load protection to the connector assembly as well as combinations comprising at least one of the foregoing. Panels, side collectors, and/or connectors can optionally, independently, be solid or hollow (e.g., multiwall, for example comprising support structures, such as ribs). If the ribs are present, the density and configuration (straight, angled, parallel, perpendicular, etc.) of the ribs, is merely dependent upon the desired structural integrity and transmissivity of the particular element. For the side collectors and connectors, the ribs can have a thickness of up to 1 mm, specifically, 0.25 to 0.75 mm, and more specifically, 0.35 to 0.6 mm. In some embodiments, the diagonal ribs have a greater thickness than the parallel and/or perpendicular ribs (wherein parallel and perpendicular are determined in relation to the X direction). Diagonal ribs are ribs that are neither parallel nor perpendicular. In other words diagonal ribs not parallel or perpendicular to the panel outer surface when the element (collector or connector) is attached to the panel. Diagonal ribs provide improved stiffness in all directions compared to vertical and horizontal ribs. Ribs, particularly diagonal ribs, can be used to tune the degree of stiffness (e.g., flexibility of the elements). Desirably, the connector engagement region of the side collector is stiff (rigid such that it does not flex or bend when being assembled with the connector), while the connector has flexible sides156(e.g.,FIG. 16) to enable it to be assembled over the side collector.

If multiwall panels are used, any number of layers or sheets can be used, with any combination of support structures being contemplated for use. Owing to the connector assemblies (e.g., to the separate side collectors), one can choose a panel having any desired thickness, structure (multiwall or solid), color, width/length, and shape, and adapt its edges to bear edge connectors having the desired attachment structure, and affix it to other panels having edge connectors with complementary attachment structure. Standard panel thicknesses are 4, 4.5, 6, 8, 10, 16, 20, 25, 32, 35, 40, 45 and 50 mm, and further, different varieties of multiwall panels are available, generally having 2 to 10 layers, specifically, 2 to 6 layers (e.g., with 1 to 5 cells across the panel thickness). Also, the cavities can have a variety of internal structures (rectangular passages, triangular passages, etc.). For example, the panels can be solid, hollow, or a combination thereof (e.g., can be multiwall panels wherein cavities of the panels are hollow and may optionally be filled, e.g., comprise a gas, a fluid, and/or a solid, depending on the desired properties of the structure (e.g., soundproof, heat transmission, light transmission, weight, etc.).

Furthermore, conceivably, due to the flexibility attained with the side collectors, radically different panels (e.g., a 4 mm solid panel and a 32 mm multiwall panel) can be fit together, so long as the panels were each fit with side collectors having complementary attachment structures. For example, the panel can be a functional panel such as a photovoltaic panel designed to be a portion of the structure with the structural integrity of solid, hollow, or filled panels. For example, the panels can optionally be arranged so that there is a space between adjacent stacked panels (e.g., seeFIG. 18) or without space between the adjacent stacked panels and the panels can be solid, hollow (which, for example, could be useful for cooling functional panels generating and/or absorbing heat), and/or filled (with a fluid such as a liquid, gel, and/or gas), with a variety of rib configurations (e.g., seeFIG. 18). Other functional panels can include, but are not limited to skylight inserts, infrared absorbing and/or reflecting structures, solar water heaters, electrical roof fans, plastic fan blades driven by heat convection, etc. For example, as illustrated inFIGS. 39 and 40, a double sided connector and clip can be assembled with a photovoltaic panel500in slot150,152(seeFIG. 16).FIG. 36illustrates an example of a photovoltaic panel500. The double side connector and clip are the same as previously discussed with respect toFIGS. 16 to 18.FIG. 40illustrates an embodiment where a flexible photovoltaic panel502can be bonded to a multiwall sheet or to a standing seam and inserted into slot150, while another panel504can, optionally, be inserted into slot152, whileFIG. 39illustrates an embodiment where a photovoltaic panel500can be directed inserted into slot152or where the photovoltaic panel500can, optionally, be bonded to a solid or multiwall sheet and inserted into slot152and another panel506can, optionally, be inserted into slot150.

Once the side collector is attached to the panel (or if it is integral) assembly of the panels with the connector assembly can comprise inserting a clip into the side collector (e.g., where it engages the rectangular cut out). In other words, sliding the cross-member into the opening in the side collector. The clip can then be fastened to the support. A second panel, with side collector attached, can be slid up against the first panel so that the two touch or are in close proximity and so that the side collector of the second panel engages the clip. Finally, the connector is attached to the extended legs of the side collectors (i.e., to the connector engagement region) to secure everything together.

The connector(s), collectors, and clips can be formed using various techniques, such as extrusion (e.g., a metal/plastic co-extrusion (i.e., pultruded metal with encapsulated metal parts with plastic), a plastic coextrusion with a cap layer (e.g., for ultraviolet protection, and so forth)). Metal pultrusion with encapsulated metal parts with plastic can be used to attain enhanced rigidity to withstand very high forces such as hurricane force winds. The metal could be incorporated in the area(s) of the plastic. For example, referring toFIGS. 41 and 42, the metal260(e.g., coextruded metal) could be coextruded with the plastic to provide enhanced structural integrity to the arms230, opening212, and/or part or all of the joint side of the collector (e.g., from the bottom to the opening212). In some embodiments, the metal is coextruded in the area of one or both arms, and/or along the base258, and/or along the joint wall254. The metal can extend up the joint wall254along the entire body portion, and/or from the base258up to and/or through the opening212(if present). In some embodiments, the metal is coextruded along the base and joint wall, but not along the arms.

An advantage of the methods disclosed herein is that bonding secondary elements (e.g., collectors) to either multiwall or solid sheet products relying on adhesive systems are messy and have an extensive manual element. Ultrasonic welding techniques without energy directors employed in the past resulted in poor bond strength and/or crushed multiwall panels. Other mechanical fastening or heat welding techniques resulted in surface blemishes or other unsightly marks on the materials surface. The technique disclosed herein includes a bonding technique which provides for an intimate bond between similar materials making up the panel and the attachment. The use of the energy directors can facilitate the bond between the attachment elements (the side collector and the panel, the connector and the side collector, etc. (e.g., standing seam leg, tongue or groove attachment, snap attachment, etc.)). It was discovered that the inclusion of these energy directors enables the use of ultrasonic welding without crushing the multiwall panel or creating a weak bond between two flat polymer surfaces.

Also referring toFIGS. 41 and 42, optionally, the side collector(s) and/or connectors can have barrier elements to enable water, air, and/or bug infiltration resistance. These barrier elements can comprise a ridge and a valley, wherein the mating ridge and valley are rounded components. For example, they can form greater than or equal to 40% of a circle, specifically, greater than or equal to 50% (e.g., can form a semicircle). Exemplary barrier elements are illustrated inFIGS. 41 and 42, wherein the barrier valley242onFIG. 41is configured to mate with the barrier ridge244onFIG. 42. As is illustrated, the barrier valley242can be located on the connector engagement region222, adjacent to the panel engagement region224, e.g., in contact therewith.

The various connectors, collectors, and assemblies disclosed herein address the issue of needing expensive aluminum extrusions for connectors. The present assemblies, utilizing various configurations (e.g., mechanical stops and/or extensions) to prevent panel separation can provide enough strength to withstand hurricane force (e.g., 200 mph (322 kilometers per hour (kph)) winds with the use of plastic connector and collectors, (or the side collectors when no connector is used). The combination of the profile structure and the clips that connects the panels to support (e.g., rafter, etc.) has been modeled to provide enough strength to withstand these high loads.

Additionally, with the separate side collectors, substantial reduction in shipping costs can be attained. Since the panels do not include the side collectors, they can be packaged in a much smaller area, thereby allowing shipping of greater than or equal to 40% more product in the same space.

The connectors, collectors, clips, and assemblies thereof as described herein are further illustrated by the following non-limiting examples.

EXAMPLES

In this example, panels were tested on a 4 foot (ft) by 6 ft box (1.2 meters (m) to 1.8 m) for the ability of the clips and panel assemblies to handle a load. A clip having the design illustrated inFIG. 38, with a flat cross-member was tested and compared to a clip having the design illustrated inFIG. 11and a panel as illustrated inFIG. 12, with the height of the extensions equal to 0.035 inches (0.889 millimeters (mm)). The panels as tested had a 5 wall X structure. Various configurations were tested as shown inFIG. 30. Comparative Sample 1 (C1) was a connector assembly having a 3 inch (in, 7.6 centimeters (cm)) center bolt clip with a flat cross-member having the design illustrated inFIG. 38; Comparative Sample 2 (C2) was the same as C1 but had a flush mount; Comparative Sample 3 (C3) was also the same as C1, but had a hanging ¾ inch mount; and Comparative Sample 4 (C4) was also the same as C1, but had a steel spacer.FIG. 30illustrates the deflection (measured in inches) versus pressured (measured in pounds per square foot (lb/ft2)) for the various clip designs and mount.

As can be seen fromFIG. 30, it was surprising to discover that a lip having a height of only 0.035 inch (0.889 mm) resulted in a substantial increase in the ability of panels to handle a load. Specifically, the load increased from a maximum of 160 lb/ft2(7,656 Pa) before break for Comparative Samples 1 to 4 (C1 to C4) without the lip to 325 lb/ft2(15,550 Pa) for Sample 1 having the lip as herein described. As shown inFIG. 30, Sample 1 did not break, i.e., the clip was able to prevent panel separation. For example, the ability of the panel to handle a load without separation can be increased by greater than or equal to 25%, specifically, greater than or equal to 30%, more specifically, greater than or equal to 35%, even more specifically, greater than or equal to 40%, and yet more specifically, greater than or equal to 50%.

Comparative Samples C5 and C6 illustrate further results of wind load testing where a panel with a connector assembly having the design illustrated inFIG. 29was tested for wind load handling capabilities and compared to a panel having the connector assembly design illustrated inFIG. 38. A wind load of 200 mph (322 kph) is indicated by line310inFIG. 31. As can be seen fromFIG. 31, at wind loads of greater than or equal to 200 mph (kph), Comparative Sample 5 (C5) and Comparative Sample 6 (C6) had increasing deflection where C5 failed at a pressure of about 180 lb/ft2(8,618 Pa) and C6 failed at a pressure of about 140 lb/ft2(6,703 Pa), where failing refers to the panel separation and/or clip bending. This example demonstrates that without the clip design with a lip as described herein, the panel assemblies could separate and fail under wind loading greater than or equal to 200 mph (322 kph).

In this example, panels having the connector assembly design illustrated inFIG. 38andFIG. 12were tested and compared at various wind loads. The panels as tested had a 5 wall X structure. Comparative Samples C7 and C8 (FIG. 33) had the connector assembly design illustrated inFIG. 38, while all the other samples inFIGS. 32,34, and35had the connector assembly design illustrated inFIG. 12. Table 1 lists the data observed from the wind load testing of Samples 2 to 5, while Table 2 lists the data observed from the wind load testing of Comparative Samples C7 and C8. Tables 3 and 4 list the data observed from the wind load testing of Samples 6 to 11.FIGS. 32,33,34, and35graphically illustrate the results, withFIG. 33belonging to the Comparative Samples andFIGS. 32,34, and35belonging to the samples having the design illustrated inFIG. 12. Wind speed is measured in mph and deflection is measured in inches (in).

The results in Table 2, specifically, C7 can be compared to Sample 10 in Table 4 and will be discussed in further detail. C7 had a larger batten and side collector than other samples, so it was able to sustain a higher wind load than other samples because the larger batten and side collector added stiffness to the panel.

Table 3 lists the data from testing 4 foot (1.2 m) wide panels andFIG. 34illustrates the results. Samples 6 to 8 have the connector assembly and clip design illustrated inFIG. 12. As can be seen from Table 3 andFIG. 34, as the purlin spacing increases, the wind speed and load that the connector assembly can resist is reduced. Additionally, the mode of failure changed from the samples tested in Table 2 compared to those in Tables 1, 3 and 4. For example, the failure mode for the samples in Table 2 was due to the panel slipping off the clip, while the failure mode in Table 3 was due to failure of the clip, demonstrating that a stronger clip can potentially allow for even high wind speeds to be withstood than those tested. The failure mode for the samples in Table 1 was tearing of the clip through the panel, which demonstrates the maximum load the panel can sustain.

Table 4 illustrates data for Samples 9 to 11, where Sample 9 had a full length, 18 foot (5.5 m) long clip and Samples 10 and 11 had a 3 inch (7.6 cm) long clip. Full length clip refers to a clip having the design illustrated inFIG. 11and extending the full length of the panel, i.e., 18 feet (5.5 m), while the clip used in Samples 10 and 11 also have the design inFIG. 11, but had a length of 3 inches (7.6 cm). As can be seen in Table 4 and correspondingFIG. 35, the full clip can handle higher wind loads as compared to a clip having a length of 3 inches (7.6 cm). For example, the full clip (i.e., 18 foot (5.5 m)) can handle wind loads greater than or equal to 200 mph (322 kph), specifically greater than or equal to 225 mph (362 kph), and even more specifically, greater than or equal to 240 mph (386 kph) before failing, while the 3 inch (7.6 cm) clip can handle wind loads greater than or equal to 150 mph (240 kph), specifically, greater than or equal to 175 mph (282 kph), and even more specifically, greater than or equal to 185 mph (298 kph).

As mentioned, C7 in Table 2 can be compared to Sample 10 in Table 4. C7 illustrates a higher load than that of Sample 10 because C7 had a batten and side collector, having the design illustrated inFIG. 28, that was twice the size of the batten and side collector of Sample 10, having the design illustrated inFIG. 12. The larger batten and side collector size added to the stiffness and load capacity of C7. Despite the increased load, the failure mode of sliding off the clip showed that a higher potential load can possibly be achieved through modification of the clip and panel interface. For example, in Sample 10, the failure mode was failure of the clip due to fracture, which is another indication that a higher potential load can possible be obtained through a modification of the clip to a material with a higher strength. Comparing Sample 11 to C7 and C8 demonstrates that the combination of strengthening the clip and creating a mechanical stop at the interface between the panel and the clip can provide high wind load capability with a lower profile batten and side collector design. Sample 11 had a 4 foot purlin spacing and exceeded the results of Sample 10 with a 3 foot purling spacing. It can possible for an assembly with the design of Sample 11 to have equivalent wind load handling capability with a batten and side collector design that is half the size of that used in C7. For example, extrapolating the results of Sample 11 to a 3 foot purlin spacing yields a value between 210 and 250 mph, which would be approximately equal to that of C7.

It is contemplated that the connector assemblies disclosed herein can be used in the construction of naturally lit structures such as greenhouses, pool enclosures, solar roof collectors (e.g., photovoltaic modules), stadiums and sunrooms, glass panel roofs, and combinations comprising at least one of the foregoing. For example, the connector assemblies can be used to attach photovoltaic modules together. Photovoltaic modules are generally an assembly of the various components of the module, including a first layer, a fluid layer, a second layer, junction box, cables, micro-inverter, etc. (seeFIG. 36illustrating a photovoltaic module500). The connector assemblies described herein can be used to hold photovoltaic modules together to create a solar panel. A method of making a solar panel is also contemplated where the method can comprise attaching a photovoltaic module to another photovoltaic module with any of the designs of the connector assemblies described herein to create a solar panel.

The connector assemblies comprising the various designs of the clip with either the lip or protrusion can be capable of withstanding a higher wind speed and load than connector assemblies with a clip having a flat cross-member. Such a design can enable the connector assemblies to be used in applications where high wind loads (e.g., greater than or equal to 200 mph (322 kph)) can be encountered.

In one embodiment, a connector assembly comprises: a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, a side collector comprises: a connector engagement region comprising a head having a size and geometry to mate with a panel connector; a panel engagement region comprising a receiving area having an energy director extending into the receiving area, and having a size to attach onto an end of the panel; and a clip engagement region comprising an opening, and having a size to accommodate an extension on a side of an engagement of a clip.

In one embodiment, a panel assembly comprises: a connector assembly, comprising a connector; a pair of side collectors, each comprising a connector engagement region; and a panel engagement region comprising a receiving area; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension protruding from a side of the clip, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement; a panel located in each panel engagement region; and wherein the connector is mated with the connector engagement region of the side collectors so as to hold ends of the panels together.

In one embodiment, a method of making a panel assembly, comprises: attaching a first panel to a second panel with a connector assembly, wherein the connector assembly comprises a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, a method of making a photovoltaic module assembly comprises: attaching a first photovoltaic module to a second photovoltaic module with a connector assembly, wherein the connector assembly comprises a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.

In one embodiment, an assembly comprises: a connector comprising two cavities defined by flexible walls, wherein each of the cavities has a geometry and is configured to mate with connector engagement regions from a pair of side collectors; a header located between the two cavities; and a first slot on a side of the connector and between the cavities, wherein the first slot has a size and geometry to receive an end of a panel without a side collector, wherein the cavities enable two sets of panels to be stacked and connected with the connector; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the stem diverges to a receiver located on an end of the stem opposite the base, wherein the engagement has an extension projecting from a side of the engagement, wherein a panel engagement region on the side collectors comprises an opening in a joint wall on a side of the panel engagement region opposite a receiving area, wherein the opening is configured to receive the extension of the engagement.

In the various embodiments, (i) the opening of the side collector comprises a complimentary geometry to the extension of the engagement, wherein the opening and the extension engage with one another and/or (ii) the extension penetrates into the opening of the panel engagement region; and/or (iii) the base comprises elements that, when assembled with the connector, collector, and panels, the panels will be level; and/or (iv) the base comprises a section formed by a side, area, and a leg, and wherein the side and leg have a length/that is greater than a height of a fastener head, wherein the area extends from the side to another side; and/or (v) the extension comprises a lip projecting from a side of the engagement and/or comprises a protrusion extending from a side of the engagement; and/or (vi) wherein adjacent panels are connected by a mating geometry selected from the group consisting of tongue and groove and snap fit; and/or (vii) wherein adjacent panels are connected by a lap joint; and/or (viii) a photovoltaic panel is located in the first slot; and/or (ix) the connector further comprises a second slot on another side of the connector opposite the first slot and between the cavities, wherein the second slot has a size and geometry to receive an end of another panel without a side collector; and/or (x) another photovoltaic panel is located in the second slot; and/or (xi) the clip further comprises members located on a receiver of the clip; and/or (xii) the header is configured to receive a connecting member that attaches the connector to members of the clip.