U.S. patent application number 12/961195 was filed with the patent office on 2011-03-31 for operating a building integrated photovoltaic conversion system implemented with integrated control management units.
Invention is credited to Joe Brescia.
Application Number | 20110073156 12/961195 |
Document ID | / |
Family ID | 42036191 |
Filed Date | 2011-03-31 |
United States Patent
Application |
20110073156 |
Kind Code |
A1 |
Brescia; Joe |
March 31, 2011 |
Operating A Building Integrated Photovoltaic Conversion System
Implemented With Integrated Control Management Units
Abstract
A power generating system is manufactured and operated within an
exterior shell or facade of a building structure. The system
components--energy generating devices (which can be photovoltaic),
control units and associated power/signal wiring are incorporated
and operated within individual unitized curtain wall units making
up the facade
Inventors: |
Brescia; Joe; (Alameda,
CA) |
Family ID: |
42036191 |
Appl. No.: |
12/961195 |
Filed: |
December 6, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12564671 |
Sep 22, 2009 |
7847181 |
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12961195 |
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12564609 |
Sep 22, 2009 |
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12564671 |
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12564627 |
Sep 22, 2009 |
7845126 |
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12564609 |
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12564664 |
Sep 22, 2009 |
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12564627 |
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12564686 |
Sep 22, 2009 |
7845127 |
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12564664 |
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12564732 |
Sep 22, 2009 |
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12564686 |
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12564740 |
Sep 22, 2009 |
7845128 |
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12564732 |
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12564748 |
Sep 22, 2009 |
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12564740 |
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12564761 |
Sep 22, 2009 |
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12564748 |
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12564768 |
Sep 22, 2009 |
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12564761 |
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12564774 |
Sep 22, 2009 |
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12564768 |
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12564783 |
Sep 22, 2009 |
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12564774 |
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61099437 |
Sep 23, 2008 |
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61114410 |
Nov 13, 2008 |
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Current U.S.
Class: |
136/244 ;
29/897.3 |
Current CPC
Class: |
E04B 2/885 20130101;
E04B 2/96 20130101; Y02B 10/10 20130101; Y02B 10/12 20130101; Y02B
10/14 20130101; Y02A 30/60 20180101; Y02E 10/50 20130101; H02S
20/26 20141201; Y02A 30/62 20180101; Y10S 136/291 20130101; H01L
31/02021 20130101; Y10T 29/49629 20150115; E04B 2/88 20130101; Y10T
29/49623 20150115; H02S 40/32 20141201; H02S 40/34 20141201; E04B
2/967 20130101 |
Class at
Publication: |
136/244 ;
29/897.3 |
International
Class: |
H01L 31/042 20060101
H01L031/042; B21D 47/00 20060101 B21D047/00 |
Claims
1. A method of operating a building integrated power generating
system comprising: providing a plurality of unitized curtain wall
elements defining at least a portion of an exterior shell for a
building structure; wherein said unitized curtain wall elements are
hung from and situated in front of the building structure;
operating a plurality of energy conversion devices integrated and
contained within said plurality of unitized curtain wall elements;
each of said plurality of energy conversion devices being coupled
to an associated power control module that is mounted directly
thereon and is adapted to optimize and report on a power output of
a respective one of such plurality of energy conversion devices;
wherein a plurality of associated power control modules for said
plurality of energy conversion devices are also integrated and
contained within said unitized curtain wall elements; operating a
management unit coupled to a plurality of associated power control
modules and also integrated and contained within said unitized
curtain wall elements, which management unit is adapted to process
said report and control an array of energy conversion devices;
wherein the power generating system is operated within said
plurality of unitized curtain wall elements.
2. The method of claim 1 wherein said plurality of energy
conversion devices can be selectively activated or de-activated by
said corresponding power control modules on an individual basis or
a floor by floor basis.
3. The method of claim 2, wherein said plurality of energy
conversion devices are photovoltaic devices and can be selectively
activated or de-activated based on shading, cleaning and/or
scheduled maintenance.
4. The method of claim 1 wherein said power control module receives
power and signals from an energy conversion device both by physical
connection and wireless connection.
5. The method of claim 1 wherein said power control module is
physically attached to and/or a part of a photovoltaic module
containing a solar energy conversion device.
6. The method of claim 1 wherein said power control module is
coupled to a management unit adapted to control an entire array of
energy conversion devices.
7. The method of claim 6 wherein said management unit is coupled to
an automated DC disconnect adapted to activate and deactivate an
entire array of energy conversion devices.
8. The method of claim 7 wherein said management unit is coupled to
a remote server adapted to monitor said array.
9. The method of claim 1 wherein said unitized curtain wall
elements are interconnected in a continuous grid entirely within
said exterior shell.
10. The method of claim 9 wherein said continuous grid extends
across an entire floor.
11. A method of making a building integrated photovoltaic power
generating system comprising: providing a plurality of
interconnected unitized curtain wall units defining at least a
portion of an exterior shell for a building structure; wherein said
unitized curtain wall units are hung from and situated in front of
the building structure; each of said plurality of interconnected
unitized curtain wall units having an integrated photovoltaic
energy conversion device contained therein; providing a control
module associated with and coupled to each integrated photovoltaic
energy conversion device, which control module is adapted to
optimize and report on a power output of such photovoltaic energy
conversion device within a solar power generating array; said
control module also being integrated and contained within said
interconnected unitized curtain wall units and including electrical
wiring for transmitting power and reporting information output from
an associated integrated photovoltaic energy conversion device of
said solar power generating array; providing a management unit
coupled to a plurality of said control modules and also integrated
and contained within said unitized curtain wall elements, which
management unit is adapted to process said reporting information
and optimize an output of said solar power generating array.
12. The method of claim 11 wherein said unitized curtain wall units
are interconnected in a two dimensional continuous grid entirely
within said exterior shell.
13. The method of claim 11 wherein said control modules mitigate
effects of shading on said integrated photovoltaic energy
conversion device.
14. The method of claim 11 wherein said control modules are
attached directly to said associated integrated photovoltaic energy
conversion device.
15. The method of claim 11 wherein said control modules are mounted
within a wireway or raceway integrated within said unitized curtain
wall units.
16. The method of claim 11 wherein at least some input/output
control signals from said control modules are communicated
wirelessly between such control module and said integrated
photovoltaic energy device.
17. The method of claim 11 wherein said power output is returned to
a utility grid.
18. The method of claim 11 wherein at least a portion of said power
output is used to power outlets and/or mechanical systems in the
building structure.
19. The method of claim 11 wherein the system is compliant with
Underwriters Laboratories (UL) requirements and does not require
additional UL certification or inspection prior to operation.
Description
RELATED APPLICATION DATA
[0001] The present application claims priority to and is a
continuation of application Ser. No. 12/564,671, now U.S. Pat. No.
7,847,181, which in turn claims the benefit under 35 U.S.C.
.sctn.119(e) of the priority date of Provisional Application Ser.
No. 61/099,437 filed Sep. 23, 2008 and Provisional Application Ser.
No. 61/114,410 filed Nov. 13, 2008, all which are hereby
incorporated by reference. The present application is further
related to and is a continuation of the following additional
applications, all of which are incorporated by reference herein:
[0002] Building Integrated Power Generating System; Ser. No.
12/564,609 (attorney docket number 2009-1); [0003] UL Compliant
Building Integrated Photovoltaic Conversion System; Ser. No.
12/564,627 (attorney docket number 2009-2) now U.S. Pat. No.
7,845,126; [0004] Method of Operating Building Integrated
Photovoltaic Conversion System; Ser. No. 12/564,664 (attorney
docket number 2009-3); [0005] Building Integrated Photovoltaic
Conversion System Implemented In Both Vision and Spandrel Areas;
Ser. No. 12/564,686 (attorney docket number 2009-5) now U.S. Pat.
No. 7,845,127 [0006] Unitized Curtain Wall Module Adapted for
Integrated Photovoltaic Conversion Module; Ser. No. 12/564,732
(attorney docket number 2009-6); [0007] Unitized Building
Integrated Photovoltaic Conversion Module; Ser. No. 12/564,740
(attorney docket number 2009-7) now U.S. Pat. No. 7,845,128; [0008]
Unitized Building Integrated Photovoltaic Conversion Module Adapted
With Electrical Isolation and Grounding; Ser. No. 12/564,748
(attorney docket number 2009-8); [0009] Unitized Building
Integrated Photovoltaic Conversion Module Adapted With Electrical
Conduits; Ser. No. 12/564,761 (attorney docket number 2009-9);
[0010] Integrated Electrical Conduit for Solar PV System; Ser. No.
12/564,768 (attorney docket number 2009-10); [0011] Electrical
Raceway for Building Integrated Solar PV System; Ser. No.
12/564,774 (attorney docket number 2009-11); [0012] Method of
Assembling Building Integrated Photovoltaic Conversion System; Ser.
No. 12/564,783 (attorney docket number 2009-12).
FIELD OF THE INVENTION
[0013] The present invention relates to making and operating power
generating systems integrated within building facade or exterior
shell structures, and more specifically to BIPV systems which
include integrated control and management modules for optimizing
power.
BACKGROUND
[0014] It has been long been considered desirable to integrate
photovoltaic (or PV) devices and systems into commercial and
residential buildings. To date, however, such systems have been
generally limited to conventional roof-top based systems which have
limited photovoltaic capability and little aesthetic appeal.
Conventional roof-top based systems are limited in photovoltaic
capability because, among other reasons, the modules which make up
these conventional systems are connected in series which
effectively lowers the productivity of the entire system to that of
the least productive of the modules. Conventional roof-top based
systems also depend upon racking systems which do not afford a
practical method to integrate photovoltaic elements into a vertical
building face in an attractive and safe manner. Shading by building
elements, equipment, and other constraints severely limit the area
available for PV deployment.
[0015] Clearly it would be desirable to incorporate PV devices in a
larger area of a building structure, and in a more visually
appealing fashion. In a recent attempt at such an endeavor, a
building in New York City incorporated PV elements in vertical
facade assemblies that were actually physically separate from the
main structure, and configured as artistic elements. The project
was in fact a failure due to the inability of the system designer
to overcome regulatory restrictions on the incorporation of
electrical elements into this type of structure. Thus, while the
panels are still attached to the side of the building, they have
not been utilized to generate useful PV power.
[0016] "Unitized" curtain wall systems are those which can be
preassembled and glazed as units (i.e., the glass or other surface
material installed) off site and progressively installed section by
section on a building. One advantage of the unitized curtain wall
approach is that the labor is performed in an off site, controlled,
manufacturing environment. Unitized systems are suitable for mid to
large projects, i.e. high-rise buildings (four stories or more),
those with significant repetition of their components, and/or
projects in locations that have higher seismic design requirements.
Frame units for unitized curtain walls are typically configured as
one module (glazing or glass unit) wide by one story in height.
These pre-glazed frames are typically placed on bunks consisting of
about 6 units each and hoisted by a tower crane to their respective
floors where they are installed, often by utilizing a small mobile
hoist from the floor above.
[0017] The unitized curtain wall systems also typically include a
pressure equalized rain screen, which counteracts the forces that
cause water infiltration, such as surface tension, capillary
action, gravity, kinetic energy, and pressure differential.
Unitized curtain wall systems are in wide spread use and gaining
commercial popularity across for the country because of their ease
of integration, reasonable cost, schedule-friendly capabilities and
aesthetic beauty and high performance.
[0018] Photovoltaic modular panels have been integrated into
curtain wall glass for building integrated photovoltaics, as seen
in U.S. Publication Serial No. 2008/0163918 incorporated by
reference herein. Nonetheless the design described is optimized
only for amorphous type solar cells, and is not conducive to ease
of construction because it is not configured for efficient
inter-modular connection. Nor does such design compensate for
shading, a problem that severely impairs the performance of
conventional series-connected solar panels particularly in
articulated applications like building enclosures. As is well
known, in conventional PV approaches shading degrades the
performance and power output (or yield) of the shaded module or
unit. When shading falls on one or more of the conventional
series-connected solar panels, the series connected modules degrade
in overall performance to that of the lowest yield in the string.
Finally the prior art also fails to address the lack of overall
Underwriters Laboratory certification or UL approval. UL
certification of the framing system is an essential element to
enable PV projects to be approved under applicable building and
safety regulations, and thus is a key element to enable widespread
adoption. Many commercially available modules are UL Approved to UL
1703, but no framing systems related to Building Integrated
Photovoltaics (UL Category QHZQ) are commercially available today
WO 2006/123335 incorporated by reference herein suffers from
similar deficiencies, in that inter-module connections (in
particular those between each individual solar module and those
adjacent left and right) are depicted in great detail. However,
this system is connected in series, without individual module
management. In addition, the array construction method lacks
inter-module conduits or passages suitable for routing wiring.
Moreover, the modules are connected to each other only in a lateral
(left and right) fashion; there is no teaching of vertical
connection. For this reason any vertical connections must be
accommodated through additional structures, such as tracks, tubes
or strips that are not integrated into the curtain wall framing
members. U.S. Pat. No. 6,646,196 incorporated by reference herein
shows a similar set up, and suffers similar deficiencies. These
additional runs add cost and complexity to installation, reduce
operational efficiency, raise maintenance costs and complexity, and
potentially increase susceptibility to failure.
SUMMARY OF THE INVENTION
[0019] An object of the present invention, therefore, is to reduce
and/or overcome the aforementioned limitations of the prior
art.
[0020] A first aspect of the invention concerns a building
integrated power generating system;
[0021] Another aspect of the invention concerns a building
integrated power generating system that is UL/regulatory
compliant;
[0022] A further aspect concerns integrating control management
units into such power generating system;
[0023] Yet another aspect concerns a building integrated power
generating system that is implemented in both vision and spandrel
areas of a building facade;
[0024] Other aspects include unitized curtain wall units that are
adapted for photovoltaic energy conversion modules;
[0025] Still other aspects cover electrical isolation, electrical
conduits and grounding features of such unitized curtain wall units
and associated building integrated power generating systems;
[0026] Another aspect of the invention covers integrated
wireways/raceways used with the unitized curtain wall units;
[0027] Further aspects concern methods of assembling/manufacturing
such unitized curtain wall units and building integrated
photovoltaic conversion systems;
[0028] Other aspects include methods of operating the conversion
modules, the control modules, and an entire power generating array
integrated within a building shell;
[0029] Finally, other aspects of the inventions will be apparent to
those skilled in the art from the detailed disclosure that
follows.
[0030] It will be understood from the Detailed Description that the
inventions can be implemented in a multitude of different
embodiments. Furthermore, it will be readily appreciated by skilled
artisans that such different embodiments will likely include only
one or more of the aforementioned aspects or objects of the present
inventions. Thus, the absence of one or more of such
characteristics in any particular embodiment should not be
construed as limiting the scope of the present inventions. While
described in the context of a power generating array within a
building facade, it will be apparent to those skilled in the art
that the present teachings could be used in any number of
applications.
DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is an illustration of a preferred embodiment of a
photovoltaic power generating system implemented within an exterior
shell or facade of a building structure;
[0032] FIG. 2 shows a cutaway section of the building structure
along the direction shown in FIG. 1 designated with a bubble and
the numeric notation 2, to illustrate further details and the
spatial relationship of components of the preferred solar power
generating system;
[0033] FIG. 3 shows a cutaway section of the building structure
along the direction shown in FIG. 1 designated with a bubble and
the numeric notation 3, to illustrate further details and the
spatial relationship of components of the preferred solar power
generating system;
[0034] FIG. 4 shows a cutaway section of the building structure
along the direction shown in FIG. 1 designated with a bubble and
the numeric notation 4, to illustrate further details and the
spatial relationship of components of the preferred solar power
generating system;
[0035] FIG. 5 shows a cutaway section of the building structure
along the direction shown in FIG. 1 designated with a bubble and
the numeric notation 5, to illustrate further details and the
spatial relationship of components of the preferred solar power
generating system;
[0036] FIG. 6 is a block diagram of the main electrical components
employed in the preferred solar power generating system;
[0037] FIG. 7 is a flowchart depicting a preferred process used to
assemble embodiments of the solar power generating system;
[0038] FIGS. 8A and 8B show another perspective of the curtain wall
units along the direction shown in FIG. 1 designated with a bubble
and the numeric notation 8, to illustrate further details and the
spatial relationship of components of the preferred solar power
generating system.
DETAILED DESCRIPTION
[0039] The present invention preferably incorporates mono and/or
poly silicon crystalline cells used for converting solar energy
into electrical energy, such as those offered by Suntech Power
Holdings Co. Ltd. (Suntech) directly into standardized curtain wall
products, such as those offered by Architectural Glass and Aluminum
Co, Inc (AGA) of Alameda Calif. The AGA curtain wall products are
well-known durable exterior facades. The end result is a solar
power generation system that also, much in the same manner as
conventional curtain wall, functionally and aesthetically encloses
a building.
[0040] By incorporating solar energy directly in the construction
process for a building, the cost of implementing such green
capability is greatly reduced. The cost of operating such buildings
also goes down dramatically as a result of net energy savings by
reducing the need for lighting using Daylighting Techniques and by
controlling the solar heat gain and envelope U-value to reduce the
energy needed for heating, ventilation and air-conditioning systems
(HVAC).
[0041] The invention also has applicability, however, to
retrofitting/re-cladding existing buildings to include solar
capability, particularly when such structures include mechanical
screening surrounding their rooftop. The invention can be used in
such instances to both beautify and increase the functionality of
such otherwise unaesthetic and nonfunctional architectural
features.
Unitized Curtain Walls
[0042] Before delving into the specifics of the present invention,
it is useful to describe and understand the characteristics of
unitized curtain walls. Unitized curtain walls are an extremely
popular form of building facade used throughout the world.
[0043] The main defining characteristic of unitized curtain walls
are that they are substantially (and usually entirely) preassembled
off site in units and, after transport to the project site, hung or
fastened onto on the building's structural slab edges. The unitized
curtain wall does not typically function as a structural support
element for the building. The final installation of these
pre-assembled units into the integrated whole results in a
"unitized" curtain wall system.
[0044] Off-site pre-assembly of the units is far preferable to
onsite because operations can be done far more efficiently--at a
dedicated facility by skilled personnel--with much lower cost and
with higher speed and throughput. Off-site assembly also leads to
higher quality work with better seals, stronger bonds, and fewer
errors, and further enables assembly bench testing prior to
transportation and installation.
[0045] In contrast conventional stick built curtain wall systems
require that the aluminum or metal frames for the glazing be
field-assembled at the jobsite according to the specific
architectural requirement. The labor for such solutions is costly,
and the quality of such an installation is difficult to control
from one unit to the next. Moreover, because stick built curtain
wall frames are not manufactured in a controlled factory
environment, before they can be UL certified, they must be field
inspected, one by one, for approval. Such one by one field
inspection is less preferable than the present invention, because
the one by one approach consumes longer time and runs the risk that
inspection, even after the expense of transport and assembly on
site, will fail to result in certification. Prior building
integrated PV curtain walls, such as that mentioned in New York
City above, suffered these very failures.
[0046] Unlike stick built approaches, curtain wall unitized panels
are typically prefabricated as standardized 4'-8'
width.times.10'-15' height units made up of different cladding
materials (stone, painted aluminum, glass, opaque-glass, etc.)
depending on the desired aesthetic/look the Architect is trying to
achieve. A common form factor is five feet wide by thirteen and a
half feet tall. The shop pre-assembly of the different materials
into a unit, among other things, allows for: [0047] better quality
control of the finished product (both the units themselves and the
overall curtain wall system) and, [0048] easy (and thus rapid)
installation on site, as each unitized panel `mates` with the one
above, with the one below and with the ones to either side of it,
thereby adding support, and achieving continuity and integrity for
the overall wall once completed. [0049] Decreased duration on job
site, thus leading to improved and more efficient construction
schedules [0050] minimized packaging because the unitized
pre-assembled units may be transported to the site with less
packaging and waste than stick built, thus promoting environmental
goals for reducing and recycling of jobsite packaging.
[0051] A unitized curtain wall unit is typically made up of the
following major parts/components: [0052] Framing Members: these
capture and support the different cladding or glazing materials
desired and frame them into a unit which is manageable and
conveniently sized for final installation. The framing is typically
rectangular (although other shapes could be used) with vertical
framing elements and horizontal framing elements. Framing members
may be comprised of any materials known in the art, including,
aluminum, steel, fiberglass or other composite materials. The
vertical framing elements (sometimes called Thullions'), of each
unit `mates` with the units adjacent, thereby providing support to
the adjacent units and achieving continuity of the wall system once
completely installed. The primary horizontal framing elements
(sometimes called the `stack joints`) at the top and bottom of the
unit also mate with the units above and below, similarly providing
support to the adjacent unit and the entire wall and achieving
continuity of the wall system once completely installed.
Preferably, each unitized curtain wall unit also includes one or
more intermediate horizontal members. These intermediate horizontal
members are typically used to hold or mount and provide support to
pieces of glazing or cladding. For example, the glazing below might
be transparent or vision glass, while that above might be PV
material. In unitized curtain wall, these framing members are
pre-assembled in the factory. The pre-assembled frame thus forms
the skeleton of the unit which will, after completion of the
pre-assembly as described below, be transported to the building
site for installation. [0053] Support Structure/Brackets: are used
to fix/connect each of the curtain wall units to the edge of the
building's floor-slab. In addition to providing the structural
support for the wall, these brackets provide the ability to take up
variation in the building's construction (typically +/-2 to 4
inches) and exactly align each of the units with one another
(typically within +/-1/8 to 1/4 of an inch) to achieve the
continuity required and the aesthetic alignment desired. Typically,
the support structures/brackets are composed of two mating
components. One of these is pre-assembled into the unitized frame
at the factory. The other mating component of the support
structure/brackets is typically fastened to the building's
floor-slab onsite. In this manner, the installation on site can be
achieved with convenient attachment of the mating components.
[0054] Sealant/Gaskets: physically connect and isolate the cladding
or glazing materials to the framing members. The sealant/gaskets
effectively affix the cladding materials to the framing members,
providing a waterproof seal. The sealant/gasket material is
typically semi-flexible to accommodate minor movement of the frame
relative to the cladding material. This isolation of movement is
particularly important for PV, glass, or stone as they can break
due to their brittle nature, but also important with other thin,
opaque materials due to their tendency to buckle producing an
undesirable aesthetic. In the building integrated PV application,
it is preferable to incorporate UL approved materials designed
specifically for this purpose to assure System UL Compliance. In
the building integrated PV application, the sealants and gaskets
also serve to electrically insulate PV from framing in many
applications. The sealant and gaskets are pre-assembled to the
frames and glazing as part of the pre-assembly. [0055] Glazing or
Cladding: the material which forms the aesthetic and structural
exterior of the final unitized curtain wall. Different cladding
materials (stone, painted aluminum, glass, opaque-glass, etc.) may
be utilized depending on the desired aesthetic/look. The glazing or
cladding is attached to the unitized curtain wall frame members
during pre-assembly. [0056] Vision Material: the transparent glazed
area of the unit located in the zone(s) through which occupants
view out or through which daylight is to be admitted to the
building interior. This zone is typically the entire width of the
curtain wall unit/panel.times.18''-40'' above the floor to the
underside of the ceiling. The vision material is also pre-assembled
into the unit in the factory. [0057] Spandrel Area: In a building
with more than one floor the term spandrel is also used to indicate
the space between the top of the window in one story and the sill
of the window in the story above. The term is typically employed
when there is a sculpted panel or other decorative element in this
space, or when the space between the windows is filled with opaque
or translucent glass, in this case called spandrel glass. Further,
many opaque or translucent materials can be used, including any of
a number of form factors of energy conversion devices. The glazing
or cladding for the spandrel area is attached to the unitized
curtain wall frame members during pre-assembly.
[0058] It will be understood by those skilled in the art that this
is a simplified description, and not intended to be an exhaustive
list. The components may vary from those described. Moreover not
every curtain wall unit will require such components, and some
units may in fact use other components without deviating from the
spirit of the present teachings and techniques.
[0059] The labor and assembly process associated with curtain wall
units is also divided into separate phases which allows for more
optimized costing associated with the various activities and better
predictability of scheduling.
[0060] Fabrication Labor: typically includes all the labor involved
in making or cutting/shaping each of the constituent framing and
support parts of the curtain wall unit and then pre-assembling all
the parts into the pre-assembled units designed for installation at
the particular project. Since the curtain wall units are assembled
typically in a dedicated facility, consistency and quality can be
better controlled and optimized.
[0061] Installation Labor: typically includes the labor involved in
attaching the support brackets/structures to the building, laying
out, hoisting, and hanging the curtain wall units on the building,
mating and aligning all the units and taking up tolerances,
completing the necessary electrical connections, adding final
seals, insulation and any interior finish trim that needs to be
coordinated with finish material (like ceilings or sheetrock) that
are typically provided by others. Because the on-site assembly
method of the unitized curtain wall units is effectively identical
and because all of the units have a common method for mating and
attachment, the skill sets of the assemblers can be standardized
and more easily controlled as well.
Unitized PV Curtain Walls
[0062] The present invention aims to enable unitized curtain wall
systems to deliver energy production capability--more specifically
photovoltaic functionality similar to a rooftop PV installation.
That is, a system that primarily functions to generate electricity
from solar power once the entire set of parts are assembled, and
also performs the same aesthetic cladding function as prior art
curtain wall systems. The difference here, of course, is that the
power generation must be as compatible as possible with the
requirements of a PV curtain wall unit, including resistance and
compliance with various regulations concerning
heat/conductive/insulation properties, air/water infiltration, wind
load resistance and seismic considerations.
[0063] To accomplish this, a photovoltaic (PV) curtain wall unit
includes the following (in addition to some or all of the standard
components noted earlier):
[0064] Photovoltaic Panels: for a wall-system application, these
are preferably glazable PV panels--and so can be thought of as a
direct material replacement for the opaque glazed spandrel and/or
vision material in the curtain wall unit--although there are some
differences between these materials that are accommodated/designed
for as shown in the present embodiments. Other types of
panels/energy conversion devices can of course be used, and in this
respect the invention is effectively panel-device agnostic. Varying
cell density, photovoltaic materials, opacity, and aesthetic look
can be adjusted as needed to meet the desired appearance,
aesthetics and requirements.
[0065] Inverters/module management units/controls: these typically
convert and optimize electricity generated by PV panels into grid
compliant power. Preferably, the inverters/module management
units/controls are provided locally and individually, at each
curtain wall unit, to allow the PV wall system to more efficiently
generate electricity from solar power. As mentioned, there is
frequently greater variability in light exposure from one portion
of a vertical building surface to another than there is on a
typical rooftop installation. As a result, for BIPV applications,
it is preferable that local controls account for self or site
shading of each individual wall unit/panel and eliminate or reduce
the otherwise typical impact from shading in which one shaded
unit/module degrades the performance of the entire string of
modules in the affected series. Shading can result from shadows
cast by trees, other buildings, dust accumulation, and even birds,
planes, and window cleaners. These conditions occur frequently on
vertical curtain wall environments, and it is therefore important
that the integrated PV curtain wall system include necessary
controls and methods to mitigate and/or avoid this deleterious
impact. In addition, these inverter/control elements should be
easily accessible for maintenance and yet preferably be hidden from
view of the occupants of the space as well as from viewers of the
building exterior for both safety and aesthetic purposes. Finally,
it preferable that of the above components should be rated UL or
equivalent, and outdoor rated to accommodate for building
construction conditions.
[0066] Wiring: wiring is preferably accommodated to carry power
(and preferably control signals, where necessary) all the way from
the PV panels to the grid without adding additional architectural
complexity. Ideally, the wiring will be effectively invisible in
the installation condition. In the preferred embodiment means are
provided from each PV panel, through the curtain wall unit, to
transport the generated electricity in a safe and controlled way
through the entire wall array and ultimately to the interior of the
building. Similar to the needs of the local inverter/controls, the
wiring in a curtain wall system should preferably be done
efficiently (i.e., preferably few wires for a long array run helps
limit the size of the code required raceway (or other required
wiring passage)), in an aesthetically pleasing manner (which, in a
curtain wall system typically means hidden from view) while being
protected from damage and accessible for maintenance. It will be
appreciated that in other power generating applications involving
other energy conversion devices, other types of tubing/conduits,
etc., can be employed to transport other energy related materials,
including heated/cooled fluids, etc. between modules and other
parts of a circulation system within a building structure.
[0067] Accordingly, unlike previous applications of PV technology
on a vertical wall, each PV curtain wall unit of the present
invention can be sold, delivered and installed as a complete unit.
Each PV curtain wall unit is preferably preassembled off site and
transported to the building as a prefabricated module, allowing
this new application to not only be simply, quickly hung on the
building, but also, as panels, wiring, inverters and controls have
also been prefabricated into a series of connected code-rated
raceways attached to or formed by the unit framing, each unit can
be simply, quickly and efficiently connected, coupled or plugged as
needed into its neighboring units.
[0068] In an electrical generation system each unit is preferably
linked to a common grounding mechanism using methods well known in
the art.
[0069] As described above, one main purpose of the invention is to
provide a photovoltaic power from a unitized curtain wall system.
The units assembled according to the teaching of the invention will
preferably be connected or linked in a manner that accumulates the
electricity generated by each unit in the manner described above.
The electricity so accumulated is connected to the building's
primary electrical system and grid tied as appropriate, using
methods known in the art. It is possible that the electricity in
the system may be harnessed to run existing mechanical systems
within the building envelope such as shading devices, window
treatments, or blinds. This implementation thus allows a solar
energy system to be installed as part of a building facade with the
same ease and minimal additional labor cost.
SPECIFIC DETAILS OF PREFERRED EMBODIMENT
[0070] In a conventional rooftop system, PV panels, wiring,
controls, rack/support, etc. are all assembled on site and then
plugged into the inverter/storage mechanisms. In the case of a
preferred unitized PV curtain wall as described herein the PV
curtain wall units are preferably each `plug and play`--each unit
mates into and is electrically coupled to its adjacent unit to form
the solar array. In turn, the solar array is electrically connected
into the balance of the building electrical system. In this respect
therefore, the inventions better achieve the functionality of a
conventional rooftop system, but do so on the vertical sides of the
building. Because a typical high rise building has 7-12 times
greater wall than rooftop space, the present invention allows far
greater harvest of solar energy.
[0071] In a preferred embodiment the invention is used preferably
in cladding at least a substantial vertical portion of a building
structure 100 as seen in a partial elevation drawing in FIG. 1. The
degree to which PV and non-PV curtain wall units are included and
interconnected within a cladding can be tailored as needed for any
particular site requirements and system goals. Please note that the
elements shown in the figure are not intended to denote specific
sizes or ratios, as it expected that the invention will take many
different forms, sizes, and form factors in different types of
installations. Moreover although the discussion herein is presented
primarily in the context of a commercial structure, it is expected
that embodiments can be used on virtually any other type or variety
of structures, including residential structures, parking
structures, other non-habitable structures, hospitals, airport
terminals, train station terminals, sea port terminals, government
buildings and even within transportation systems such as elevated
rails, bridges, and other structures offering suitable solar
exposure. Furthermore while shown as part of an exterior of the
building, the cladding could be extended to other interior areas of
a structure as well, such as may be found in an atrium, a
courtyard, etc.
[0072] A preferred unitized curtain wall structure covering a
building facade includes a number of separate curtain wall elements
105 preferably constituted of aluminum, although it will be
understood that other suitable materials may be used, such as
steel, fiberglass, or other composite materials. In this instance
the curtain wall structure is shown as a combination of vision
areas and spandrel areas, but it will appreciated that these could
be separate components or utilized in varying combinations. The
curtain wall units 105 can be configured as desired to extend
across multiple stories in a continuous strip of spandrel and
vision areas. While the elements 105 are shown as separate
components it will be appreciated that larger "units" in the form
of multiple curtain wall elements could be assembled off-site in
some instances.
[0073] The curtain wall elements 105 are further adapted to
preferably include a photovoltaic (PV) module 120 and/or other
energy conversion device. Such devices could include capability for
converting other forms of electromagnetic energy, potential energy,
kinetic energy, thermal energy and/or chemical energy including
photochemical energy. For example, thermionic, piezoelectric and/or
mechanical devices could be integrated for harnessing
heat/wind/rain energy). Other examples will be apparent to those
skilled in the art, and it is expected that other conversion
devices will be adapted for use with the present invention. Because
of their physical structure the curtain wall elements 105 can be
easily adapted (mechanically/physically) to house/integrate
different types of such conversion devices (which tend to be
smaller than such elements) using the principles set out herein. It
will be understood that the conversion devices can be spatially
arranged as part of the curtain wall elements in any convenient
fashion appropriate for the particular installation. Furthermore as
shown in FIG. 1, it is possible that some elements 105 may include
conversion devices, while others may not, again depending on system
requirements and goals.
[0074] In addition, in some instances well-known solar thermal
energy collectors/plates could be embedded instead or in addition
within the curtain wall elements for heating a conductible fluid,
air or some other medium for transporting heat energy. Other
well-known solar thermal support elements such as mirrors, lenses
and other concentrators (not shown) could be used of course to
increase the heat concentration, and conventional heat storage
devices (not shown) can be incorporated to store heat energy.
[0075] The PV module used in the preferred embodiment can be any
one of a variety of virtually any commercially available PV module,
including preferably a crystalline solar cell/module offered by
Suntech Power. The PV module can include any number of conveniently
and conventionally interconnected individual solar cell devices,
such as described in the aforementioned prior art references. As is
known in the art, the photovoltaic technology utilized by the PV
module may be based on any suitable photovoltaic conversion
technology, including for example, thin film, dye tinted, fullerene
based, polycrystalline, or monocrystalline. The specifics of the
solar cell/module (or other energy conversion device) are not
material to the present invention; however regardless of their
specific photovoltaic conversion technology the PV modules must be
suitable to physically integrate them within the unitized curtain
wall units. Accordingly, a wide variety of existing and
contemplated technologies can be accommodated, thus making the
invention PV module "agnostic," which further enhances the
commercial potential for the invention.
[0076] Conventional vision material or, in this case, glass panels
115 are also shown in FIG. 1. As described, these glass panels can
be configured to have more than one panel along the vertical axis
of the unit. In this configuration, the glass panels will be
separated by intermediate horizontal framing members. Further,
while the PV module 120 is shown in FIG. 1 in the vision area of
the building structure 100, it can alternatively be integrated into
spandrel areas or as part of a spandrel based module 110, or in any
number of combinations of such areas based on system requirements
and design aesthetics.
[0077] A linked solar array or assembly of PV curtain wall elements
105, 105', 105'' etc. is thus shown mated together, cladding or
enclosing a structure, preferably extending both horizontally and
vertically across multiple floors. The elements 105 are preferably
sized to be compatible with conventional building elements to
further increase their integration potential. This arrangement is
also useful for increasing the overall solar energy potential
coverage for up to nearly 100% of the wall area of a structure. In
contrast, typical rooftop systems only allow for a limited
percentage of an overall surface area.
[0078] FIG. 2 shows a cutaway section of the building structure 100
along the vertical axis/direction shown in FIG. 1 designated with a
bubble and the numeric notation 2. In this figure the structure of
the curtain wall units (such as 105, 105' and 105'' which are
otherwise identical) is further elaborated, including the
relationship of the BIPV module 110 to the other components. In
general, the typical components of curtain wall framing members on
a BIPV curtain wall unit 105'' are largely the same in concept as
conventional curtain wall framing members. However there are
specific and significant differences that allow PV Panels to be
used in place of other conventional infill material as explained
below.
[0079] Specifically, as seen in FIG. 2, the PV module 110 (located
in a spandrel area as depicted in FIG. 1) is preferably mounted
within an extra deep glazing pocket 125 shown generally with cross
hatching for emphasis. The extra deep glazing pocket 125 is
preferably part of a topmost horizontal framing member 150 in the
spandrel area. This framing member 150 is also distinct from
conventional designs in that it preferably allows extra space in
the glazing pocket 125 for an edge mounted junction box for the PV
module 110 and the PV Leads 140 that come out of the PV module.
[0080] The framing members of the preferred embodiment are unique
in that they form both vertical and horizontal conduits/channels
for inter-module connectivity, including preferably, power lines,
control signal lines, and reporting lines. In some applications as
noted earlier it may be desirable to transport other fluids,
gasses, etc. to and between modules using appropriate channels.
Further, in some applications the desired control and reporting
information flowing to and from the PV module 110 may be
transported using wiring or wireless technology, thus obviating the
need for the separate control signal and reporting lines.
[0081] The curtain wall units 105 are engineered using conventional
techniques so that they are adequately resistant to water, pressure
and other physical influences that might be attendant to a
particular locale. Those skilled in the art will appreciate that
the specific physical implementation can be varied from site to
site in accordance with local building code, geological and weather
based parameters.
[0082] Framing member 150 further preferably includes an opening
allowing the PV leads 140 (or other flexible conduit/piping for
transporting fluids/gasses) to be routed to a management module or
control circuit 135 preferably situated in a power/control raceway
130. Again, to the extent other types of materials are transported,
the opening can be varied accordingly.
[0083] Power/control raceway 130 is preferably attached to the
solar array after installation of the curtain wall units on the
building using any of the techniques known in the art. Nonetheless
it can be preassembled as well in some instances. The management
module 135 is preferably a unit designed for individual and group
control of PV modules such as sold by TIGO Energy under the name
Energy.TM. Module Maximizer-EP (MM-EP) and/or modules as described
in US Patent Publication Nos. 20080097655 and 20090120485
incorporated by reference herein. There are many other power
topologies accommodated, including but not limited to, Enphase,
Solar Edge, Solar Magic, or Enecsys. The management module can be
used to selectively monitor, troubleshoot, activate or de-activate
portions of a building's solar array system, including on a side by
side, floor by floor, or individual basis such as might be needed
for accommodating window cleaning or maintenance as examples.
[0084] The management module is part of a control circuit that
preferably optimizes power output of each module that it is
connected to, and delivers module-level data for operational
management and performance monitoring and/or control. The TIGO unit
in particular uses dynamic module balancing which manages the
energy harvest and sends information for reporting and control. The
modules can be connected in a variety of known methods, depending
on system needs.
[0085] The benefits of such module specific
control/transmission/communication within a building structure is
that they allow for greater efficiency in power collection and more
effective elimination of prior art losses caused by shading by
other external elements (trees, other buildings, dirt, etc.) and
inherent mismatches in PV modules. These problems have heretofore
greatly limited efficiencies of solar arrays in horizontal,
vertical, or inclined configurations, particularly in densely built
areas. Furthermore since such management modules 135 are UL rated
to UL 1741, they can be used in preferred embodiments of the
invention in which an entire solar array for a building is
effectively compliant as constructed with UL (and other safety
organization, such as Canadian Standards Association (CSA),
InterTec North America (ETL), Tuv Rheinlan (TUV)) requirements
because it consists of elements which are each previously
certified.
[0086] The other advantage of the preferred TIGO management module
is the improved safety of the solar array during operation. In
particular, during an emergency, for example, the high voltage
wiring in the preferred embodiment can be shut off, thus preventing
accumulation of voltage and limiting voltage exposure to the
open-circuit voltage (Voc) of a single module 110, generally no
more than a normally non lethal level of approximately 60V. More
advantageously this function can be activated with a safety button
or via a remote management console or a network such as the
Internet (not shown) for maximum flexibility. This function can
also be tied into the buildings existing safety system so it can be
automatically activated in the case of an emergency. Consequently
the system can be installed, maintained or approached by personnel
(including fire or other emergency personnel) without exposure to
voltage levels which, in some topologies of conventional arrays
typically exceed 400 volts during peak operation.
[0087] Finally, because each PV module 110 can be controlled
individually by the management modules, it is possible to link and
interconnect longer runs of PV modules that span more than one face
of the building. While the present description presents the TIGO
unit as an example it should be understood that the invention is
not limited to any particular control module.
[0088] While the management modules 135 are shown within the
power/control raceway 130, it is expected that future generations
of integration modules will continue to shrink in size and
therefore can be placed in a variety of locations. For example it
will be apparent that they can be located in other areas of the
curtain wall element 105'', including directly on the PV module 110
or directly within the framing members, the wiring channels, or
potentially embedded in PV Modules 110. However, it should be noted
that there is a benefit in most cases to locating the management
modules within the power/control raceways because in this way, the
signal lines are better isolated and easily routed between pairs of
adjacent management modules.
[0089] The opening for the PV module leads 140 preferably includes
a grommet 145 on the inboard vertical surface of the horizontal
framing member 150. This allows for the PV module leads (or other
conduits, tubes, etc.) 140 to exit the framing member 150 and enter
the power/control raceway 130 in a safe and secure fashion, and in
a manner that resists aging, corrosion, and damage from movement
that may be cause by earthquakes, wind, etc. Skilled artisans will
appreciate that the additional space shown within framing member
150 that is not used in the embodiment shown in FIG. 2, could be
used in some applications to route electrical wiring or alternative
form factors of management module 135. Again also in other
embodiments of the invention (using other forms of conversion
devices or solar heat collectors) additional tubing, conduits,
etc., could be routed within this part of the framing members and
used to transport heat energy in the form of a conductible fluid,
gas, air, etc. to other areas of the building structure.
[0090] Again, one preferred aspect of the present invention is to
ensure UL and/or CSA/TUV/ETL compliance. The curtain wall units 105
and power/control raceways 130 of the preferred embodiment further
serve such aim by including the capacity to handle regulatory rated
cabling, and with mountings (i.e., appropriate hole sizing,
grommets and other tethering/tying mechanism) and cable
runs/shielding that allow for appropriate separation of different
types of signal cables, such as high and low power lines, that are
also designed to satisfy applicable regulations.
[0091] Note as shown in FIG. 1 the floor level in the preferred
embodiment is somewhat below the bottom of the horizontal framing
member 150, but, this can be altered as desired in any particular
installation. Power/control raceway 130 is also preferably designed
to be UL-compliant, reducing duration of work on site, construction
costs certification expense and commission expenditures. To this
end the raceway may be comprised of materials well-known in the
art.
[0092] The rest of the curtain wall unit 105'' is shown with
conventional vision material elements 115, and various gaskets--for
example, wedge gasket 165, and bed gasket 170, to help in securing
and isolating the PV module 110 from the curtain wall unit 105'.
Note that these same types of gaskets are also shown but not
annotated specifically in the deep glazing pocket region 125. The
gaskets are preferably comprised of materials that are UL rated for
this purpose and may vary from installation to installation.
[0093] FIG. 3 shows a plan view of a curtain wall along the
horizontal axis/direction shown in FIG. 1 with the annotation/label
having a circle with the number three (3). This perspective is
shown between two adjacent curtain wall units 105' and 105.''
[0094] In particular it can be seen that the PV modules 110 are
preferably insulated and isolated by a set of gaskets 165, 170 as
noted before in FIG. 2. As is known in the art, the use of such
gaskets accommodates normal material expansions/contractions, and
allows for flexibility and movement of the panels, such as needed
for wind, seismic and other disturbances. While gaskets are
illustrated as the isolating mechanism in the preferred embodiment
(including for electrical isolation), it will be noted that other
materials could be used, including structural silicones or VHB
tape, such as that sold by 3M (Minnesota Mining and Manufacturing)
without parting from the scope of the invention.
[0095] The main feature of FIG. 3 is a vertical framing member 155,
the top of which is shown in this plan view. This framing member,
like the horizontal framing member 150 noted earlier, is preferably
formed from the spaces created in the mating or coupling of the
individual curtain wall units 105, and preferably without requiring
additional separate structures or materials. As with its
counterpart this member has additional space that can be used to
accommodate other types of conduits as needed by particular energy
conversion devices.
[0096] An additional structure, namely an integral vertical wiring
management clip 160 is also included as part of the curtain wall
unit 105''. This clip effectively behaves as a vertical conduit to
accept, manage and integrate the power and signal cables from PV
modules 110, allowing them to be interconnected in a vertical
orientation as well. Thus, as seen in FIG. 1, the PV modules 120 in
a vision area can be coupled directly to PV modules 110 in a
spandrel area, or even to other modules in a spandrel area below
vision area 120, and so on. The use of both vertical and horizontal
wire accepting frame members allows for PV modules to be connected
in a checkerboard fashion, both in the vertical and horizontal
direction, to form a larger array across the face of the building
structure and even across separate faces of the building
structure.
[0097] Note that the shape and form of the clip 160 is illustrated
in the preferred embodiment as a solid rectangular box structure in
FIG. 3, but any number of variants could be used to accommodate the
power/signal cables. Additional conduits could also be incorporated
(including on the opposite curtain wall element 105') as desired
for any application. While the conduits are shown in a closed
configuration (which permits easy threading/routing of the cables)
it will be apparent that other structures could be used. For
example the wiring may also be prefabricated or built into the
curtain wall unit 105, (for example along the edge of the vertical
framing member). Such wiring would preferably connect with an
electrical coupler to PV module leads 140. At the other end of the
framing member a corresponding electrical coupler could be used to
connect to the leads from a second PV module, or, alternatively, to
leads extending to a management module 135. Any number of similar
variants are possible, and the invention is not limited in this
respect.
[0098] As with the other elements of the curtain wall unit 105''
the vertical wiring management clip 160 is preferably constructed
in a UL compliant manner to permit installation of the units
without additional regulatory approval or accompanying delays.
[0099] FIG. 4 is a plan view again along the horizontal direction
shown in FIG. 1 with the bubble label containing the number 4. This
figure is a cut-away and illustrates more of the details of the
power/control raceway 130 used in preferred embodiments of the
present invention(s).
[0100] The power/control raceway 130 is another feature unique to
the present invention. Though similar in function to existing
technology, the power/control raceway 130 is unique in that it may
also be used for multiple purposes: as a conduit to carry the
management module-management module cabling 165 (or other
tubing/conduits), to contain management module 135, and to serve as
an interior architectural trim piece. While not shown in FIG. 4,
the power/control raceway also preferably includes a grommeted hole
and access for a connector on the underside (bottom) as seen in
FIG. 2 for receiving the leads 140 from the PV modules. Again the
location of the connector is not critical, and the cabling/coupling
is expected to be accomplished in any number of different ways.
[0101] Returning to FIG. 4 the power/control raceway 130 is
preferably formed separately in a predetermined length and then
integrated as an assembly on part of the backside of a curtain wall
unit 105 after unit installation on the structure. This enables
each curtain wall unit 105 to effectively act as a unitized
building block for constructing a solar array when integrated with
the power/control raceway 130 as part of a building facade without
additional supporting elements. In some embodiments the
power/control raceway can be implemented in a similar manner in the
vertical direction.
[0102] The power/control raceway 130, as with the other curtain
wall elements, is in the preferred embodiment is to be rated for
Underwrites Laboratories (UL) or similar organization compliance
and is made of aluminum or some other cost effective materials.
[0103] The management modules 135 are located in the power/control
raceway 130 and manage/control/communicate with the individual PV
modules. These management modules preferably optimize power output
per each PV module and exchange operational management and
performance monitoring data, allowing remote
manipulation/management of the array.
[0104] The PV module leads 140 are coupled between the PV modules
and the management modules to transmit generated power and
communicate other status information to and from the modules. It
will be understood that the particular coupling, wiring, etc., is
expected to vary between different types PV modules or energy
conversion devices.
[0105] Management module to module cabling 165 carries the
accumulated power to a management unit 680 (See FIG. 6). The
management unit is preferably a TIGO Energy.TM. Maximizer
Management Unit (MMU) that manages the whole assembly by processing
the individual and aggregated information from the PV modules. In a
preferred embodiment, the management unit is capable of managing an
entire set of management modules 635 for a building and/or an
array. The management unit communicates between the management
modules 635 and an Inverter 690 which is a modified typical
component of any solar power generation system. Inverter 690
inverts DC to AC as known in the art. The management unit (680)
preferably controls the management modules in real time and sends
data to a remote server 695 in order to allow on or offsite
monitoring of light, temperature, electricity production and other
parameters and provides the resulting information as needed. Again
the monitoring system architecture will be a function of the
particular energy generation mechanism selected, and it is expected
that other variants of the above will be used with different energy
conversion systems.
[0106] Returning to FIG. 4, this also shows a bonding jumper 175,
which is used to connect the individual curtain wall elements to
each other, and, eventually, to a ground potential such as the
steel frame, or other conventional common grounding element in the
building electrical system (not shown). In the preferred embodiment
grounding is accomplished by any of the means known in the art.
[0107] Note that a portion of the vertical framing members 155 can
be seen in FIG. 4 as well. The routing of PV module leads 140 into
such framing members is also shown in more detail in FIG. 5. FIG. 5
shows a cross section of the building in FIG. 1, along the bubble
annotated with the number five (5). As shown in FIG. 5, the PV
module leads 140 preferably extend from the top of a PV module 180;
they are routed through grommet 145, and then into the horizontal
framing member 150; and then they are routed to the vertical
framing member 155, and thus can be transported (up or down)
through the vertical wiring management clip 160.
[0108] FIGS. 8A and 8B show another perspective view of the
mullions formed by a pair of adjacent curtain wall elements 105.
The additional space 190 formed within the mullion is usable as
noted earlier for other array elements as needed. All other labeled
elements are the same as like numbered items discussed in earlier
figures.
[0109] An electrical diagram showing the main preferred components
of a solar power generation system is shown in FIG. 6. In this
figure, like numbered elements are intended to correspond to their
counterparts in prior figures unless otherwise noted.
[0110] As seen in FIG. 6 an array of PV modules 610/620 are
preferably coupled to each other through the management module 635.
The connections between the PV modules and the management modules
are preferably done through the PV leads 640 that are routed both
vertically and horizontally through framing members 650 and 655
respectively as noted earlier. The management modules 635 are
themselves preferably connected through cabling 665, and eventually
to a management unit 680 as noted above. The wiring for these
connections, are preferably done with power/control raceways 630
that are integrated with the curtain wall units 605.
[0111] In the preferred embodiment, management unit 680 is in turn
preferably coupled to a DC disconnect 685. As noted above, DC
disconnect may preferably be activated either manually or
electronically to isolate power to the output of the individual PV
module. The output of this DC disconnect is preferably coupled to
an inverter 690 which converts the DC generated voltage into an AC
voltage in a well-known manner. Note that the management unit 680
is shown outside of the curtain wall unit 105, but it could be
included within that unit without departing from the scope of the
present invention.
[0112] The preferred embodiment includes a monitoring system 692
can be used to evaluate the performance of the individual PV
modules 610 through interrogation of their respective management
modules 635. The monitoring system includes conventional computing
equipment and software for coordinating data exchanges,
calculations, etc., with the management unit and management modules
as is known in the art. Preferably the computing system is a server
that is Internet accessible for remote access.
[0113] The output of the array is preferably connected to the
building electrical system, typically in the main distribution
area, where it can be used to offset consumption of electrical
power or feed power into the utility grid. In some instances the
array can offer other DC and AC outlets for charging electrical
devices, transportation vehicles, etc. The form of the output,
including voltage levels, current levels, etc., can be tailored as
needed for any particular application. Furthermore if desired a
conventional electrical storage system 691 can be employed in some
cases to provide back-up power if desired. Again it will be
understood that the support elements for a particular power
generation system will vary according to the energy conversion
devices used, and FIG. 6 is merely depicting the typical elements
that would be used in a solar to electrical conversion system.
[0114] FIG. 7 is a flowchart illustrating the general steps
employed in a preferred PV solar system assembly process. At step
710, the curtain wall elements 105 are preferably hung on a
building structure in a manner effectively identical to that used
in conventional curtain wall systems with the differences described
above.
[0115] At steps 715 and 720 the PV module leads are then preferably
routed both horizontally and vertically as needed through framing
members 150 and 155 respectively integrated within the curtain wall
units 105. This allows for flexible interconnection of adjacent PV
modules in the solar array.
[0116] During step 725 the PV module leads 140 are preferably
connected to management modules 135 through connectors contained in
horizontal framing member 150. At step 730 the individual
management modules are also preferably electrically coupled
together using the management-module-to-management module cabling
165 in the power/control raceway 130.
[0117] The grounding can be achieved during any one or more of the
above steps in the manner known in the art. At this point the
entire assembly, consisting of unitized curtain wall elements
interconnected to form a solar array, is also completely safe and
preferably UL compliant.
[0118] At step 735 the integration module 135 outputs are
preferably connected to one or more management unit 680 as
described earlier. At step 740, the electrical power can then be
conveniently transferred to the building electrical distribution
system, or made available through other outputs for other
applications (charging). It will be apparent the above steps do not
have to be performed in the sequence noted, and that the actual
assembly process will likely include other obvious variants of the
above.
[0119] To summarize, it can be seen that the invention implements a
new type of PV capable curtain wall unit that has been specifically
designed and engineered to be a power generator, but accomplishes a
dual purpose: to enclose the building aesthetically as part of the
outermost exterior shell enveloping the bulk of the building
facade. Summing up, in the preferred embodiment, this is achieved
by, among other things: [0120] extra deep glazing pockets
incorporated in curtain wall units [0121] adapting the framing
members to include UL and other compliant conduits, channels and
raceways for wiring [0122] housing control and management
mechanisms locally, in each unit [0123] Including control needed to
eliminate the deleterious effect of on-site/orientation shaded unit
from others [0124] electrically isolating the PV modules with the
use of code compliant sealants and gaskets [0125] the addition of
ports and isolating grommets to facilitate electrical connections
and contain control mechanisms in the framing members [0126]
framing members with flexible parts/sleeves to accommodate movement
(for example in response to a seismic events) without damage to the
electrical wiring
[0127] As such, virtually all of the components of conventional
curtain wall units are adapted to deliver solar generated power as
part of a PV system which is constituted substantially within an
exterior aesthetic shell.
UL Compliance/Other Third Party Organizations
[0128] Unlike prior art systems, preferred embodiments of the
invention thus efficiently achieve UL compliance as built because:
[0129] each unit is grounded; [0130] wiring and associated control
devices are housed in a pre-certified raceway (for example, inner
cavities of the framing members); and [0131] electrical isolation
is provided between the PV panels and their framing/surrounding
elements (via the sealants and gaskets--that are manufactured from
code-rated materials).
Retrofits:
[0132] Embodiments of the invention can also be used for an
existing building or structure which can be retrofitted or re-clad
to incorporate other variants of the invention. Moreover in some
instances, the PV modules can be integrated into curtain wall units
in an array suitable for mounting on mechanical screening or other
vertical faces (not shown) typically found on a building or
structure. By utilizing such previously unproductive space, the
invention can add value to existing properties by making them more
cost-effective, attractive to environmentally conscious tenants,
and so on.
[0133] As alluded to above the present invention can also be used
with additional PV enhancement devices, such as solar
concentrators, solar trackers (active and passive) and the like
(not shown). Particularly in the spandrel areas, where appearance
is not as critical, the integration of solar concentrators/trackers
within the curtain wall elements could be used to greatly increase
the collection of solar flux, by altering a radiation path to make
it more incident to the elements, or adjusting the orientation of
the elements themselves.
[0134] While not explicitly shown or described herein, the details
of the various software routines, executable code, firmware, etc.,
required to effectuate the functionality discussed above in the
management modules, management units and monitoring systems are not
material to the present invention, and may be implemented in any
number of ways known to those skilled in the art. Such code,
routines, etc. may be stored in any number of forms of machine
readable media.
[0135] The above descriptions are intended as merely illustrative
embodiments of the proposed inventions. It is understood that the
protection afforded the present invention also comprehends and
extends to embodiments different from those above, but which fall
within the scope of the present claims.
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