U.S. patent application number 11/677590 was filed with the patent office on 2007-08-30 for flashable rooftop solar collector enclosure.
Invention is credited to Paul B. Soucy.
Application Number | 20070199561 11/677590 |
Document ID | / |
Family ID | 38442842 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070199561 |
Kind Code |
A1 |
Soucy; Paul B. |
August 30, 2007 |
FLASHABLE ROOFTOP SOLAR COLLECTOR ENCLOSURE
Abstract
A flashable, rooftop enclosure with a solar radiation
transmissive glazing suitable for holding solar energy collector of
a solar power system includes an insulated base section with
sidewalls which is secured to the roof sheathing and flashed all
around, and a removably attachable glazed top section with full
skirt, that is secured to and over the base unit after the interior
components and connections are made, so as to seal the enclosure,
overlap the flashing, and admit solar radiation. The internal
components may include any or all of photovoltaic and thermal
converters, with electrical and thermal fluid means of removing
energy from the enclosure to respective energy distribution
systems.
Inventors: |
Soucy; Paul B.; (Methuen,
MA) |
Correspondence
Address: |
MAINE & ASMUS
100 MAIN STREET, P O BOX 3445
NASHUA
NH
03061-3445
US
|
Family ID: |
38442842 |
Appl. No.: |
11/677590 |
Filed: |
February 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60776519 |
Feb 24, 2006 |
|
|
|
Current U.S.
Class: |
126/623 |
Current CPC
Class: |
Y02E 10/40 20130101;
F24S 80/40 20180501; F24S 80/30 20180501; F24S 80/70 20180501; Y02B
10/20 20130101 |
Class at
Publication: |
126/623 |
International
Class: |
F24J 2/46 20060101
F24J002/46 |
Claims
1. A flashable, rooftop enclosure for containing solar energy
collector and converter components of a solar power system,
comprising: a rectangular base section having an insulated bottom,
an upward extending sidewall terminating in a sealing top edge, and
means for attachment to an exterior supporting surface whereby a
weatherproof flashing or sealing means may extend from a protective
layer on said supporting surface onto said sidewall; a top section
having a sealing rim structure with a full skirt extending downward
therefrom, said rim structure sealingly enclosing a solar energy
transmissive glazing, said top section sized to fit over said base
section so as to make sealing contact between said sealing rim
structure and said sealing top edge, with said skirt overlapping
said sidewall and flashing or sealing means, thereby forming a
sealed enclosure capped by said glazing and flashed or sealed to
said protective layer; means for removably attaching said top
section to said base section; and means for transferring collected
energy out of said rooftop enclosure to an energy distribution
system;
2. The rooftop enclosure of claim 1, said means for transferring
collected energy out of said rooftop enclosure comprising openings
in said bottom of said base section.
3. The rooftop enclosure of claim 1, said means for transferring
collected energy out of said rooftop enclosure comprising openings
in said sidewall of said base section and corresponding notches in
said skirt of said top section.
4. The rooftop enclosure of claim 1, further comprising a fluid
conduit configured for converting solar radiation to heat and
transferring the heat to a fluid flow therein.
5. The rooftop enclosure of claim 1, further comprising an air duct
configured for converting solar radiation to heat and transferring
the heat to an airflow therein.
6. The rooftop enclosure of claim 1, further comprising at least
one photovoltaic cell.
7. The rooftop enclosure of claim 1, further comprising a reflector
associated with a said solar energy collector and converter
component.
8. The rooftop enclosure of claim 7, said reflector being rotable
on at least one axis.
9. The rooftop enclosure of claim 6, further comprising a cooling
subsystem for said photovoltaic cell.
10. The rooftop enclosure of claim 1, said supporting surface
comprising roof sheathing, said protective layer comprising roof
shingles.
11. The rooftop enclosure of claim 1, said glazing comprising
tempered glass.
12. The rooftop enclosure of claim 1, said sealing top edge
comprising a seal applied to a top edge of said sidewall.
13. The rooftop enclosure of claim 1, said means for removably
attaching said top section to said base section comprising
fasteners.
14. The rooftop enclosure of claim 13, said fasteners being applied
through said skirt into said sidewall.
15. The rooftop enclosure of claim 14, arranged immediately
adjacent another said rooftop enclosure on a said support surface,
said fasteners being applied only to the upper and lower ends of
said top section.
16. A flashable, rooftop enclosure for containing solar energy
collector and converter components of a solar power system,
comprising: a rectangular base section having an insulated bottom,
an upward extending sidewall terminating in a top edge configured
with a seal, means for attachment to the sheathing layer of a
shingled roof whereby flashing may be extended from the roof
shingles onto said sidewall, and openings in the insulated bottom
for circulating a thermal fluid in and out of said base section to
and from an energy distribution system; a top section having a
sealing rim structure with a full skirt extending downward
therefrom, said rim structure sealingly enclosing a panel of
tempered glass, said top section sized to fit over said base
section so as to make sealing contact between said sealing rim
structure and said sealing top edge, with said skirt overlapping
said sidewall and flashing, thereby forming a sealed enclosure
capped by said tempered glass and flashed to said roof shingles;
and means for removably attaching said top section to said base
section.
17. A flashable, rooftop enclosure and solar energy collector,
comprising: a rectangular base section having an insulated bottom,
an upward extending sidewall terminating in a sealing top edge,
means for attachment to an exterior supporting surface whereby a
weatherproof flashing or sealing means may extend from a protective
layer on said supporting surface onto said sidewall, a top section
having a sealing rim structure with a full skirt extending downward
therefrom, said rim structure sealingly enclosing a solar energy
transmissive glazing, said top section sized to fit over said base
section so as to make sealing contact between said sealing rim
structure and said sealing top edge, with said skirt overlapping
said sidewall and flashing or sealing means, thereby forming a
sealed enclosure capped by said glazing and flashed or sealed to
said protective layer; means for removably securing said top
section to said base section; electrical wires extending from said
rooftop enclosure for connection to an electrical energy
distribution system; means for transferring heat energy out of said
rooftop enclosure to a heat energy distribution system; at least
one photovoltaic cell within said sealed enclosure connectible to
said electrical wires; and a temperature control subsystem
configured for maintaining said at least one photovoltaic cell
within a normal operating temperature and connected to said means
for transferring heat energy to at heat distribution system.
18. The rooftop enclosure of claim 17, said temperature control
subsystem comprising a fluid conduit proximate said at least one
photovoltaic cell and configured for transferring heat from said
photovoltaic cell to a fluid flow within said fluid conduit, said
means for transferring heat energy out of said rooftop enclosure to
a heat energy distribution system comprising a fluid flow
circuit.
19. The rooftop enclosure of claim 17, further comprising at least
one reflector associated with said at least one photovoltaic
cell.
20. The rooftop enclosure of claim 19, said at least one reflector
being rotable on at least one axis, said enclosure comprising means
for rotating said at least one reflector thereby affecting the
amount of solar radiation received by said at least one
photovoltaic cell.
Description
PRIORITY CLAIM
[0001] This application claims priority to pending U.S. application
Ser. No. 60/776,519 filed Feb. 24, 2006.
FIELD OF THE INVENTION
[0002] The invention relates to solar collector enclosures, and
more particularly, to a flush mounted and flashable, two part,
solar collector enclosure system that facilitates installation,
maintenance and repair of solar passive, photovoltaic, and hybrid
solar power systems.
BACKGROUND OF THE INVENTION
[0003] Solar energy is universally available. Sunshine striking the
earth on a typical day is estimated to be sufficient to heat
millions of homes, potentially conserving substantial fossil fuel
and corresponding costs.
[0004] In the context of the exploding technology of home and
building construction materials, designs and building techniques,
there has not been much recent development in residential solar
collector design. Although solar energy is abundant, harnessing it
for residential and commercial use is limited by available, cost
effective technology. Numerous active and passive solar collector
systems for residential, commercial and industrial applications
have been designed, installed and otherwise proposed; however,
widespread acceptance of past solar collector systems is restricted
by high initial cost, installation and weather related performance
deficiencies, sometimes complicated operating nuances, unexpected
maintenance issues, and high repair costs. Costly suitable solar
collection materials and fabrication techniques, unattractive
installations, and questionable reliability/repair capability make
their purchase unattractive to many potential users.
[0005] Other problems associated with current solar energy
collectors include their being difficult, expensive or impractical
for fitting or retrofitting to existing structures; bulkiness,
weight, size and unaesthetic appearance; unsuitability for on-site
assembly and installation by building contractors and the
do-it-yourself handyperson; the requirement of a thermal mass,
complicated circulation equipment and other accessories for
operation; compromising of conventional roof structures and
coverings; inflexibility for heating selected spaces; requirements
for a single or possibly multiple glazings, thick insulating
materials, rubber gaskets and other heat loss reduction materials.
The typical collector is large, bulky, difficult to manufacture,
unsuitable for site assembly, difficult to install and thereby
increases overall system cost.
[0006] The difficulties of installation, maintenance and repair is
a subject not much discussed in the prior art. Many years of
experience have indicated that these problems are a significant
contributor to the relatively low level of acceptance. Unitary
collector modules with their single or double glazed panes and
insulated bodies are heavy, difficult or not suitable or intended
to flash to a roof top or other support surface, as well as time
consuming and difficult to access for repairs. Applicant's own
issued patent U.S. Pat. No. 5,596,981, particularly FIGS. 1 and 3,
incorporated herein by reference, illustrates a contemporary design
of a heavy glazing, modular collector that is both heavy and
awkward to install, and time consuming to access for any necessary
repairs. Placing collector modules in banks or arrays in close
proximity adds complexity to the installation and in particular to
access for repairs.
[0007] These problems can lead to a breach of system or roof top
integrity, or damage to the internal components, or abandonment and
replacement of otherwise functional collectors when simple repairs
are needed or attempted. Completed repairs where complex
disassembly and reassembly is required, may result in a failure to
fully restore the solar energy collection system to its original
capability. Clearly a need exists for an improved solar collector
system and installation methodology that overcomes the problems and
limitations associated with the current solar collector modules and
systems.
SUMMARY OF THE INVENTION
[0008] In one aspect, the invention is an improved solar power
collector enclosure for enclosing the collector subassembly of an
air or fluid circulation heating system or photovoltaic or hybrid
solar power system. The enclosure offers significant benefits
relating to system design, installation, and subsequent maintenance
and operations. The basic enclosure unit, which may be ganged
together with like units in various ways as is later described, is
a two part system. The first part is a walled base component which
may be installed on the sheathing of a roof or other mounting
surface and may be flashed or sealingly joined about its perimeter
to the roof shingles or other roof covering system.
[0009] The second part is a glazed and fully skirted top component
sized for easy placement on and over the base component with a
significant overlap of its skirting down over the wall of the base
component and flashing. The top is then secured to the base unit so
as to hold the top in a sealing manner to the base component,
forming a secure, effective and weather-proof enclosure, flush
mounted and flashed to the roof system. The enclosure is easily
opened for and during installation, and later for maintenance and
repairs, for placement and access to collector components and
associated wiring and/or plumbing. The glazing is transparent to a
high degree to solar radiation over a wide spectrum, for optimal
performance of the enclosed collector.
[0010] As is well known, a photovoltaic cell array, or a solar
collector array for a water or air circulated heating system, is
generally mounted in so far as is practical with a direction and
angle of elevation that will optimize the array's exposure to
sunlight. Other variables, including complexity and cost of the
installation and connections to the space being served, as well as
esthetics, are also important considerations, making every
installation design a compromise. Fluid and air circulation type
solar collector modules are typically rectangular with two opposing
edges longer than their adjoining edges, specifically configured in
some cases as for flow of the gas or fluid medium, to have the long
sides running with the pitch angle of the roof or mounting
structure, and the short sides installed as the upper and lower
ends. In some cases and for some installations it may be preferable
to orient rectangular modules with the short sides as the sloping
sides. These and other types and shapes of collectors and
photovoltaic cell arrays, where rectangular includes square, and
other shapes including round and other than rectangular or round,
are candidates for incorporation with and/or enclosed within an
enclosure of the invention.
[0011] In many cases, for practical reasons including cost and ease
of installation, the mounting of an enclosure of the invention is
stationary such as on a rooftop or other fixed structure. In this
respect, the mounting options of the base component of the
invention are flexible. In one aspect it may be mounted directly on
a roof surface as by fasteners through the bottom surface of the
base component into the roof sheathing or by angle brackets joining
the sides of the base component to the sheathing. It may
alternatively be similarly mounted on an elevated surface of
conforming size or a rack assembly or open framework configured
with an appropriate fixed or variable direction and/or slope. For
example the base may be mounted on a pipe rack by attachment of the
underside of the base component to horizontal support pipes
arranged at different heights so as to place the collector at the
desired angle of elevation, or on a raised roof section or false
roof built on an existing roof to provide the correct angle of
elevation for the collectors. The supporting structure may include
a manual or automatic single or multi axis motion system with
appropriate sensors or angular pre-calibration to keep the plane of
the enclosure and the collectors within directed towards the sun
during daylight hours, as is well known in the art.
[0012] The base component has an insulated, substantially planar
bottom side to for heat retention and protection of the surface
upon which it is mounted, and an upwardly extending side wall
around its entire perimeter, that terminates in a generally
upwardly exposed sealing surface. The sidewall may be insulated as
well. The sidewall is at least of sufficient height to accept
conventional step flashing with roofing shingles that expose about
5 inches to the weather, nominally 5 inches or more high. At the
top and bottom and in some installations along the sides there may
be a continuous strip of flashing or waterproof membrane. The
flashing or membrane may or may not be attached or adhered to the
sidewall of the enclosure base so long at it retains its position
and alignment during placement of the enclosure top.
[0013] The interior surfaces of the base component and/or the
absorber plates of the solar collector installed therein, whatever
the type may be, are generally coated, lined, or layered with solar
radiation absorbent material. The base component of the enclosure
may be configured with openings in the bottom, and/or U-shaped
notches in the side walls, within which duct work, tubing or pipes
carrying thermal energy transfer gas or fluid, or control rods, or
wires carrying electrical control signals or power, enter or exit
the base component. Such duct work, tubing, pipes or wires
extending into the enclosure may be configured with unions, joints,
or connectors accessible within the enclosure when opened, for ease
of installation, updating and repair of the solar power collector
subsystem. The top component of the enclosure may be configured
with matching U-shaped notches in its skirt, by which the duct
work, pipes or wires contained at their point of entry or exit from
the enclosure, when it is assembled and sealed.
[0014] The solar collector enclosure of the invention is in some
aspects separable from the solar collector subassembly within, but
not necessarily in all respects. Components of the solar collector
may be incorporated into the base component, and/or the top
component of the enclosure. For example, the glazing of the
enclosure top may also be considered a component of the solar
collector, retaining the heat generated within. Likewise base
component of the enclosure may be integrated in its assembly or
fabrication with the solar power collector, for example as a plenum
or reflector or both, or otherwise configured with fluid carrying
pipes, ducts or passageways where the fluid is directly or
indirectly heated during normal operation of the solar collector.
The base component may be integrated with photovoltaic components,
wiring, and means for cooling or temperature controlling the active
photovoltaic elements, such as metallic, air or fluid channels
configured for conducting high heat away from the photovoltaic
devices. It may also carry reflective elements that focus light on
photovoltaic elements to match the full size of the glazing window
to the functional area of the photovoltaic cells. Likewise, some of
the structure by which these functionalities are accomplished may
be fabricated or assembled as internal or underside attachments to
the enclosure top or its glazing.
[0015] When the base component is installed directly on a roof top
or other support surface which is normally required to be sealed or
shingled to shed rain and snow, flashing or other sealing means may
be extended from the roof surface or roof covering material up onto
the sides, particularly the sloped sides, of the base component
sufficiently far to insure that when the enclosure top is in place,
rain water will normally be diverted away from or around the
enclosure.
[0016] The enclosure top or cover component is configured as an
inverted tray or cover, sized to cover and fully enclose the base
component, including any flashing or sealing means that have been
extended or bent and lapped up onto the side of the base component.
The topside of the cover component is glazed with a transparent or
translucent solar energy admissive material. The frame of the top
within which the glazing is secured, consisting in one aspect of
the rim and the sides, may be fabricated of stock or extruded metal
such as aluminum, such as power-coated, painted or anodized
aluminum, or other material suitable to extended outside exposure
and temperature extremes. The enclosure top is sized to be placed
over and enclose the base component and flashing or sealing
materials fully, with the top sides extending down over the upward
extending sides of the base sides so as to fully envelop the base
component. The interior topside of the top component is brought
into sealing contact with the sealing surface of the base
component, thereby closing the collector enclosure to unwanted air
infiltration. The top is then secured to the base with a minimal
number of fasteners, preferably one at or about each corner,
although more or less may be used. The term fasteners is intended
to be construed broadly, as sufficient to retain the top to the
base in a weatherproof and relatively airtight manner, excepting
intentional or tolerable amounts of air leakage or water
drainage.
[0017] Solar collectors may be installed side by side with little
room in between for sidewall access to fasteners. For this reason,
cover components may be secured to base components by side
accessible latches or fasteners applied only to or through the
exposed top and bottom sides, the upper and lower ends of the top
section; two fasteners at the top and two at the bottom being one
example. Other examples and embodiments may employ fasteners
applied from the top, where side access is irrelevant.
[0018] The box-like structure of the cover component or enclosure
is fabricated with sufficient rigidity to assure that the sealing
contact is maintained around the full perimeter of the collector,
and the fastners may in some cases function like hinges at least to
a limited extent. For example, in some embodiments, one side or end
may be opened for limited access by unlatching or removing
fasteners from all but the opposing side, and elevating the first
side of the enclosure top for access to the interior of the
enclosure. Alternatively, the top can be completely removed for
access to the interior or repair of the top, or replacement of the
top with a new top if necessary or useful as in the case of the
glazing being broken.
[0019] The features and advantages described herein are not
all-inclusive and, in particular, many additional features and
advantages will be apparent to one of ordinary skill in the art in
view of the drawings, specification, and claims. Moreover, it
should be noted that the language used in the specification has
been principally selected for readability and instructional
purposes, and not to limit the scope of the inventive subject
matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an exploded, perspective view of the top and base
or bottom sections of one embodiment of a solar collector
enclosure.
[0021] FIG. 1A is a variant of FIG. 1, with side notches replaced
by through-bottom holes.
[0022] FIGS. 2A and 2B are face and side elevations of a grommet
used for sealing pipe connections passing through the side walls of
the top and bottom sections of FIG. 1.
[0023] FIGS. 2C and 2D are face and side elevations of a grommet
used for sealing pipe connection passing through the bottom side of
the bottom section of FIG. 1A.
[0024] FIG. 3 is a simplified construction schematic end view of a
false roof section for providing a higher angle of presentation of
an array of solar collectors.
[0025] FIG. 4 is a top view of the surface of a false roof or
support surface as in FIG. 3, prepared for installation of solar
collectors.
[0026] FIG. 5 is a simplified plumbing schematic of the return and
supply lines for the installation of FIG. 4.
[0027] FIG. 6 is an end view of the installation of FIGS. 3, 4 and
5 with the base sections installed.
[0028] FIG. 7 is a partial cross section view of one end of a solar
collector enclosure of one embodiment of the invention, showing a
double glazing and details of the sealing contact area, end wall
fastener, and side wall pipe grommet.
[0029] FIG. 7A is a partial cross section view of one end of a
solar collector enclosure of one embodiment of the invention,
showing single glazing and details of the sealing contact area, end
wall fastener using a flanged thin wall insert and backing nut, and
bottom side pipe grommet.
[0030] FIG. 7B is a partial cross section view of one end of a
solar collector enclosure of one embodiment of the invention,
showing details of the sealing contact area and end wall
fastener.
[0031] FIG. 8 is a perspective view of a frame for a bottom section
assembled from extruded material having rib or channel-like
features similar to the extrusions of FIG. 7.
[0032] FIG. 9 is a cross section view of a sealing gasket intended
to seal two suitably-spaced adjacent solar collector modules.
[0033] FIG. 10 is a cross section view of a sealing gasket as
illustrated in FIG. 7A.
[0034] FIGS. 11A and 11B are perspective and side views of a
flanged and threaded thin wall insert and retaining nut for use
with the fasteners of FIGS. 7, 7A and 7B.
DETAILED DESCRIPTION
[0035] Solar collectors for heating systems typically use an energy
transfer medium of gas, fluid or electricity, and may use a
combination of mediums. The embodiments described below are
generally presented in the context of fluid medium solar collectors
but are applicable to collectors using other energy transfer
mediums as well to solar power system employing photovoltaic cells
and arrays. Please note, for purposes of the description that
follows, the term "solar collector" extends, where the context
admits, to some embodiments of the solar collector "enclosure" of
the invention, particularly in solar heating applications where the
primary energy capture mechanism is the circulating of air through
the enclosure as a plenum, or of air or liquid through an energy
absorbing conduit within the enclosure, for solar warming of the
air or liquid as part of a heating circuit extending to a heat
exchanger or space intended to be heated.
[0036] Solar collection systems require means for routing the
energy transfer medium into, through, and out of the collection
system and routed for delivery to the subject facility or device
for dispersion of the collected energy. Multiple collector modules,
of a size that is suited to system design flexibility, ease and
cost of manufacture, and relative ease of installation, are
frequently installed in banks or arrays of side by side collectors
as a system. The array is arranged with a fixed or adjustable
direction and elevation such that the collectors get maximum solar
exposure. The array is sized to meet the overall installation
requirement for peak and average thermal collection capacity.
[0037] An interconnect path between modules is required to provide
an efficient routing of the energy transfer medium. The modules are
typically connected in a parallel arrangement, although series and
series/parallel combinations of module interconnections, as are
well understood in the art, may be used. For air and fluid medium
collectors, this interconnect path is typically configured as inlet
and outlet manifolds of some sort; one running along the top end of
an array of side by side modules, and the other running along the
bottom or lower end.
[0038] Referring to FIG. 1, a simplified illustration of a two part
enclosure for a solar collector module discloses one aspect of the
invention. This embodiment is of a fluid medium collector module
enclosure. Base section 10 is an insulated base component, in the
form of a box or tray with an open top. Top section 20 has a glazed
top side pane enclosed by flange 26 which is further configured
with downward extending sidewalls which are configured with
U-shaped notches 24. The base section 10 is installed to a roof or
rack or other suitable support, with short ends 29 oriented as the
upper and lower ends; the interior components of the module such as
piping and/or ducting are installed, connected and checked; and the
top section then fitted over and attached to the base section in a
fully enclosing manner to complete the enclosure. Other embodiments
may employ grommeted holes in the sidewall of the base section
rather than U-shapes notches, where during installation the
necessary fittings are run through the grommeted holes. The top
section necessarily retains corresponding notches for removable
attachment to the base section with clearance for the one or more
sidewall connections after all plumbing and wiring is
completed.
[0039] The division of the collector module enclosure into
separate, standard size top and base sections facilitates the
installation greatly. Base section 10 is relatively light and
easily handled. Glazed top sections 20 are more easily handled with
less risk of damage after all base sections are installed, and all
the associated interior components of the collector are installed,
connections made, fluid added, and leak checks performed.
Subsequent repairs or alterations are also greatly facilitated by
this arrangement.
[0040] The sides and bottom of base section 10 are made or include
layers of thermal insulating materials. The interior surfaces or
absorber plates placed therein are coated or lined with light
energy absorbent materials such as a black coating, and the
exterior is weatherproof. Various means may be used for attachment
of the base section to a pipe rack, roof top, raised platform or
other mounting structure, as is well understood in the art. Notches
12 and 14 at opposite ends of base section 10 are provided for
fluid piping interconnections between adjacent modules.
[0041] It should be noted that in some embodiments, fluid piping
and/or air or gas ductwork may be routed through the bottom of base
section 10 or the short end walls 29 rather than the long
sidewalls. For example, FIG. 1A illustrates a variation of the
embodiment of FIG. 1, in which side notches are replaced with
through-holes 12 and 14 in the bottom side of base section 10, thus
eliminating the need for pipe openings in the top section.
[0042] Referring to FIGS. 1, 2A and 2B, rubber grommets 30 as
illustrated in FIGS. 2A and 2B are used to close notches 12 and 14
around fluid pipes running out of and between adjacent base
sections 10. Notches may be oversized to accommodate a range of
pipe diameters. Grommet size can be selected to fit the pipe size.
The grommets may be slipped over the ends of pipe lengths during
assembly; or slit so that they can be slipped around a pipe and
manipulated into place within the notch. Two such grommets 30 may
be used in each notch 12 and 14, providing an air gap in between
for further insulative value. Variants of grommets 30 may be fully
as thick as the wall of base component 10. Another variant of
grommet 30 may be a circular grommet as in FIGS. 2C and 2D for use
in the embodiment of FIG. 1A; or a two piece grommet in the form of
a semi-circular lower half grommet or gasket to which is mated a
top half grommet or gasket that fills the remainder of the
notch.
[0043] Referring again to FIG. 1, base section 10 is further
configured with a top edge seal 16 that is substantially continuous
around the perimeter, except for notches 12 and 14 for which
grommets 30 form an equivalent sealing structure and function.
[0044] Top section 20 is of a size calculated to be placed over and
enclose base section 10, with the underside of flange 26 resting on
top edge seal 16 so as to seal the enclosure against infiltration
of outside air that might reduce the efficiency of the collector.
Notches 24 align with notches 12 and 14 to accommodate piping or
other pass-through conduits. Grommets 30 or a variant thereof may
be used to seal notches 24 around the piping or otherwise close the
notch. It should be noted that there is sufficient spacing between
the respective sidewalls of base section 10 and top section 20 to
accommodate and cover flashing or other roofing material or other
sealant that may have been applied to the sidewalls of base section
10 in order to seal or make a rainproof joint with respect to the
rooftop or other support platform to which the base section 10 may
be attached.
[0045] An array of base sections 10 may be installed in a variety
of configurations; side by side installations being most common.
Referring to FIG. 3, a simple pipe rack, raised surface section, or
fully enclosed false roof may be constructed to provide a structure
with a suitable direction and angle of elevation for installation
of the collector array. FIG. 3 illustrates in simplified form a
fully framed false roof section 40 configured for attachment of
collector module base section 10 (not shown) such that the top end
of the collector enclosure top section 20, when complete, overhangs
the peak, facilitating the flashing requirement on this side of the
collector.
[0046] FIG. 4 illustrates preparation of the surface of the false
roof 40 of FIG. 3, with an EPDM rubber sheet 42 applied first,
firring strips 44 applied to support base sections 10, and fluid
line openings 46 (top end) and 48 (lower end) prepared with
silicone gaskets for sealing the fluid pipes that will pass through
the false roof surface connecting to a suitable line or manifold in
the false attic below.
[0047] FIG. 5 illustrates the plumbing associated with FIG. 4,
configured underneath false roof 40. Return line system 52 ties
fluid line openings 46 together, and supply line system 50 ties
fluid line openings 48 together. It should be noted that everywhere
fluid carrying pipes are shown in FIGS. 4 and 5, they may in other
embodiments be air ducts and/or wiring conduits, with energy
transfer or collector sensor or control functions, depending on the
type and complexity of the solar power system and in particular the
type and design of the collectors.
[0048] FIG. 6 is an end view of base sections 10 installed on
firring strips 44, on EPDM rubber sheet 42 on false roof 40. Base
sections 10 in this embodiment have openings in their underside,
rather than notches in the sidewalls, aligned with fluid line
openings 46 and 48 through which fluid lines of the core components
(not shown) will be connected to supply line system 50 and return
line system 52. Rubber or aluminum U-channels 60, spanning the
distance between the sidewalls and extending substantially up the
sidewalls, are installed between adjacent base sections 60 so as to
provide a drainage channel between base sections. Flashing or
sealant 62 is applied to the outer sides of the outer base sections
10 in conjunction with the roofing of false roof 40 so as to
provide a rain proof joint.
[0049] While this embodiment contemplates attachment to firrings
and fluid connections being made through the bottom of the base
sections; other embodiments may use other attachment means and
utilize the notches of the FIG. 1 embodiment for interconnections
of fluid lines, or wire or air conduits between modules. In those
cases, channels 60 and flashing or sealant 62 is modified
accordingly to assure the modules will be sealable when tops are
applied.
[0050] Referring again to FIG. 1, and to partial cross section FIG.
7, a top section 20 (without notches) is placed over each base
section 10 such that each module is sealed by contact of flanges 26
on respective top side seals 16, and such that the sidewalls of top
section 20 enclose the vertical portions of channels 60 and
flashing or sealant 62. Fasteners 64 are then applied at points 28
in the upper and lower endwalls 27 of top sections 20, penetrating
into base sections 10 at points 18 on end walls 29 so as to secure
the top sections to the base sections. There is sufficient rigidity
in both sections to insure that the upper and lower end attachments
maintain the top and base sections in sealing contact with each
other without the need for an extensive line of fasteners along the
sides of each collector. There may in some embodiments be a further
top side bead of sealant or sealing strip applied between adjacent
top sections 20 so as to prevent rain water from penetrating the
space between collector modules.
[0051] FIG. 7A illustrates another variation of the embodiment of
FIG. 7, where a single pane 22 of tempered glass is fitted to
flange 26 with a U-shaped seal 23, and a sealing gasket 16 is also
a U-shaped seal on the top edge of the frame of bottom section 10.
There may be a bead of RTV or equivalent sealing material applied
to seal the exposed edges of seal 23, top and bottom, thereby
further assuring that the glazing to frame junction will remain
water tight for an extended period. Connector 64 uses a flanged,
threaded, thin wall insert 66 and retaining nut 68 to secure top
section 20 to base section 10. Connector 64 may be positioned
higher or lower in endwall 27, or alternatively or in addition in
the sidewalls of base section 10. Grommet 30 is installed in the
bottom or underside of base section 10.
[0052] FIG. 7B illustrates another variation of the embodiment of
FIGS. 7 and 7A, using the same reference numbers. Other variations
and combinations of these features are within the scope of the
invention. It should be noted that speed nuts and other forms of
reinforcement for using fasteners in thin wall applications may be
employed for fastening the top to the base section. Reinforcing
ribs, mounting extensions, and/or hinged latching mechanisms and
the like may also be integrated, attached or configured for
attaching the top to the base section for easy full or partial
disassembly so that the top can be swung upward in a hinged-like
manner from one or either end of the base section, or removed
altogether, for access to the interior components.
[0053] It will be appreciated that other means and types of
fasteners or latching systems may be employed to fasten or latch
the top sections to their respective base sections. But, consistent
with one goal of the invention, the location of required fasteners
in one embodiment of the invention should be restricted to the
upper and lower ends of each module, providing one fastener
proximate each corner for good sealing, and assuring that the
proximity of adjacent modules does not interfere with sidewall
fastener access. The number of fasteners should be minimal, as few
as one fastener in each end being within the scope of these
embodiments, so as to provide quick access for removal of the top
section for maintenance and repair.
[0054] Other embodiments may have a minimal number of side or top
accessible fasteners or latches, either tool-operated or manually
actuated, as few as one on each end or one on each of four sides of
the top section, for quick removal of the top section from the base
section.
[0055] The top may comprise one or more glazings, which may be
tempered glass or plastic of suitable composition. The glazing may
or may not be planar; For example, there may be a dome shaped
glazing providing greater volume and/or clearance for the
collection elements within the enclosure.
[0056] The enclosure may contain active elements such as air
dampers, fluid valves, electrical switches, motorized or manually
movable reflectors, process sensors, and/or microprocessors or
computers. The internal elements of each enclosure or collector may
contain or be configured for wired or wireless communication and
remote control. There may be lights or light emitting elements
within or mounted on the enclosures that provide functional or
decorative illumination of internal components or indicate process
conditions, or simply highlight the enclosures through their
glazings from a distance during periods of darkness.
[0057] Among the many further examples of the invention is a
flashable, rooftop enclosure for containing solar energy collector
and converter components of a solar power system. The enclosure
consists of a rectangular base section having an insulated bottom,
and an upward extending sidewall terminating in a sealing top edge.
There are a variety of common means for attachment of the base
section to an exterior supporting surface such as a roof, as
described elsewhere in this disclosure, whereby weatherproof
flashing or sealing may extend from a protective layer of shingles
or other roof covering to the sidewall.
[0058] There is also a top section having a sealing rim structure
with a full skirt extending downward. The rim structure sealingly
encloses a solar energy transmissive glazing. The top section is
sized to fit over the base section so as to make sealing contact
between the sealing rim structure and the sealing top edge, with
the skirt overlapping the sidewall and the flashing or sealing,
thereby forming a sealed enclosure capped by the glazing and
flashed or sealed to the protective layer. There may be any of many
common means or unique means for removably securing or attaching
the top section to the base section, some of which have been
described herein. The rooftop enclosure will have one or a
combination of common or unique means for transferring collected
energy out of the enclosure to one or more energy distribution
systems, such as has been further described herein.
[0059] The rooftop enclosure may contain an array or module of
interconnected photovoltaic cells, or at least one photovoltaic
cell, and may have associated circuitry by which the electrical
output is managed and delivered to an electrical energy
distribution system. There may be a reflector or reflector array
associated with the photovoltaic array or module, not shown here
but all as is well understood in the art. The reflector and/or the
reflector and photo array may be adjustable such as rotable about
at least one axis, for optimizing the solar efficiency of the cell,
not shown here but well understood in the art, and contained within
an enclosure of the invention.
[0060] There may be a cooling or temperature control subsystem in
the enclosure, associated with the photovoltaic cell, module or
array, whereby the efficiency of the photovoltaic elements is
optimized. The subsystem may include fluid ducts connected to a
thermal fluid flow circuit. The fluid may be air or liquid such as
glycol or water or other fluids commonly used for such purposes.
The heat energy absorbed by the subsystem may be conducted out of
the enclosure and to a heat energy distribution system.
[0061] The foregoing description of embodiments of the invention
has been presented for the purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Many modifications and
variations are possible in light of this disclosure. It is intended
that the scope of the invention be limited not by this detailed
description, but rather by the claims appended hereto.
* * * * *