U.S. patent application number 13/339759 was filed with the patent office on 2012-07-05 for solar panel modules having structural properties.
This patent application is currently assigned to SolarChange LLC. Invention is credited to Peter Elrick Cummings.
Application Number | 20120167492 13/339759 |
Document ID | / |
Family ID | 46379488 |
Filed Date | 2012-07-05 |
United States Patent
Application |
20120167492 |
Kind Code |
A1 |
Cummings; Peter Elrick |
July 5, 2012 |
Solar Panel Modules Having Structural Properties
Abstract
A load-bearing solar panel module is integrated into a building
roofing structure. The solar panel is comprised of a structural
encasement that includes two lateral structural rails, and at least
three perpendicular intersecting cross beams disposed there
between. The structural encasement of the module exhibits
load-bearing properties when integrated into a roofing structure of
a residential or commercial building which approximate those of a
traditional roofing structure. The solar panel module further
includes at least one of a plurality of solar photovoltaic cells
and a plurality of thermal vacuum tubes disposed within the
structural encasement, and between an outer glass plate and an
inner insulation assembly.
Inventors: |
Cummings; Peter Elrick;
(Fairfield, CT) |
Assignee: |
SolarChange LLC
Bridgeport
CT
|
Family ID: |
46379488 |
Appl. No.: |
13/339759 |
Filed: |
December 29, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61427948 |
Dec 29, 2010 |
|
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Current U.S.
Class: |
52/173.3 |
Current CPC
Class: |
Y02B 10/70 20130101;
Y02E 10/44 20130101; F24S 20/67 20180501; F24S 80/54 20180501; Y02E
10/40 20130101; H01L 31/0543 20141201; H01L 31/048 20130101; H02S
40/44 20141201; F24S 10/45 20180501; Y02B 10/10 20130101; H01L
31/0547 20141201; Y02E 10/52 20130101; Y02B 10/20 20130101; F24S
20/25 20180501; Y02E 10/60 20130101 |
Class at
Publication: |
52/173.3 |
International
Class: |
E04D 13/18 20060101
E04D013/18 |
Claims
1. A load-bearing solar panel module for integration with a
building roofing structure comprising: a first extruded structural
rail; a second extruded structural rail aligned parallel to the
first extruded structural rail; a first extruded cross beam coupled
to a first end of each of the first and second extruded structural
rails, wherein the first extruded cross beam is aligned
perpendicular to and between such first and second extruded
structural rails; a second extruded cross beam coupled to a second
end of each of the first and second extruded structural rails,
wherein the second extruded cross beam is aligned perpendicular to
and between such first and second extruded structural rails; at
least one middle component aligned perpendicular to and coupled to
each of the first and second extruded structural rails between the
first end and the second end of the first and second extruded
structural rails; wherein the first and second extruded structural
rails and first and second extruded cross beams and at least one
middle component are coupled together into a structural encasement
such that the solar panel module exhibits load-bearing properties
when integrated into a building roofing structure; and at least one
of a plurality of solar photovoltaic cells and a plurality of
thermal vacuum tubes disposed within the structural encasement.
2. The load-bearing solar panel module of claim 1, wherein the
first and second extruded structural rails form the lateral sides
of the solar panel module.
3. The load-bearing solar panel module of claim 1, wherein the
structural encasement comprising the first and second extruded
structural rails, first and second extruded cross beams and at
least one middle component is configured to exhibit load-bearing
properties approximating a standard roofing structure for a
commercial or residential building.
4. The load-bearing solar panel module of claim 1, wherein the
solar panel module is integrated into the building roofing
structure such that the solar panel module is parallel to an
external surface of said roofing structure.
5. The load-bearing solar panel module of claim 4, wherein the
solar panel module is integrated into the building roofing
structure such that the solar panel module lies within the same
plane as the external surface of said roofing structure.
6. The load-bearing solar panel module of claim 1, wherein the
solar panel module is further defined by an outer glass plate and
an inner insulation assembly, between which the structural
encasement is situated.
7. The load-bearing solar panel module of claim 1, wherein the
solar panel module is configured to be one of a plurality of solar
panel modules which are integrated into the building roofing
structure.
8. A building roofing structure comprised of a plurality of
load-bearing solar panel modules which are integral with the
building roofing structure, and wherein each of said plurality of
load-bearing solar panel comprises: a first extruded structural
rail; a second extruded structural rail aligned parallel to the
first extruded structural rail; a first extruded cross beam coupled
to a first end of each of the first and second extruded structural
rails, wherein the first extruded cross beam is aligned
perpendicular to and between such first and second extruded
structural rails; a second extruded cross beam coupled to a second
end of each of the first and second extruded structural rails,
wherein the second extruded cross beam is aligned perpendicular to
and between such first and second extruded structural rails; at
least one middle component aligned perpendicular to and coupled to
each of the first and second extruded structural rails between the
first end and the second end of the first and second extruded
structural rails; wherein the first and second extruded structural
rails and first and second extruded cross beams and at least one
middle component are coupled together into a structural encasement
such that the solar panel module exhibits load-bearing properties
when integrated into the building roofing structure; and at least
one of a plurality of solar photovoltaic cells and a plurality of
thermal vacuum tubes disposed within the structural encasement.
9. The residential roofing structure of claim 8, wherein the first
and second extruded structural rails form the lateral sides of the
solar panel module.
10. The residential roofing structure of claim 8, wherein the
structural encasement comprising the first and second extruded
structural rails, first and second extruded cross beams and at
least one middle component is configured to exhibit load-bearing
properties approximating a standard roof structure for a commercial
or residential building.
11. The residential roofing structure of claim 8, wherein the solar
panel module is integrated into the building roofing structure such
that the solar panel module is parallel to an external surface of
said building roofing structure.
12. The residential roofing structure of claim 11, wherein the
solar panel module is integrated into the building roofing
structure such that the solar panel module lies within the same
plane as the external surface of said building roofing
structure.
13. The residential roofing structure of claim 8, wherein the solar
panel module is further defined by an outer glass plate and an
inner insulation assembly, between which the structural encasement
is situated.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/427,948, filed on Dec. 29, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates to solar panel modules, and
more particularly a novel solar panel module configured to be
usable as a load-bearing structural member for a residence or
commercial building.
BACKGROUND
[0003] Traditional solar or photovoltaic panels are not integrated
into the roof's structure and instead must be affixed to the
exterior of a building's roofing structure. To many, this is not
aesthetically desirable. Additionally, since traditional,
non-integrated solar or photovoltaic panels cannot otherwise
contribute in a load-bearing fashion to the roofing structure, the
material roofing costs are not offset by the use of such solar
paneling. Moreover, the cost of adding traditional solar
photovoltaic or thermal solutions to a building's roofing structure
also has hidden costs associated with the additional engineering of
the roof cavity to make sure that the structure of the roof can
handle the new loads being imposed onto the original engineering of
the roof framing (snow loads, snow drifting, wind and wind up
lift). Still additional drawbacks associated with traditional,
non-integrated solar or photovoltaic panels include having to
uninstall such panels whenever the building needs to be re-roofed,
for example, or when the panels reach their natural technological
end of life, e.g., 17-20 years. Thus, there is a need in the art
for solar panel modules configured as load-bearing structural
roofing members which are both more aesthetically and economically
desirable by virtue of being integral with the roof.
SUMMARY OF THE INVENTION
[0004] Disclosed and claimed herein is a load-bearing solar panel
module for integration with a building roofing structure which
includes a first extruded structural rail and a second extruded
structural rail aligned parallel to the first extruded structural
rail. The solar panel module further includes a first extruded
cross beam coupled to a first end of each of the first and second
extruded structural rails, such that the first extruded cross beam
is aligned perpendicular to and between such first and second
extruded structural rails. In addition, a second extruded cross
beam is coupled to a second end of each of the first and second
extruded structural rails, such that the second extruded cross beam
is also aligned perpendicular to and between such first and second
extruded structural rails.
[0005] The solar panel module further includes at least one middle
component aligned perpendicular to and coupled to each of the first
and second extruded structural rails and between the first end and
the second end of the first and second extruded structural rails.
The solar panel module is configured such that the first and second
extruded structural rails, the first and second extruded cross
beams and the at least one middle component are coupled together
into a structural encasement which exhibits load-bearing properties
when integrated into a roofing structure of a commercial or
residential building. Finally, the solar panel module includes at
least one of a plurality of solar photovoltaic cells and a
plurality of thermal vacuum tubes disposed within the above
structural encasement.
[0006] Other aspects, features, and techniques of the invention
will be apparent to one skilled in the relevant art in view of the
following description of the exemplary embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The features, objects, and advantages of the present
invention will become more apparent from the detailed description
set forth below when taken in conjunction with the drawings in
which like reference characters identify correspondingly
throughout, and wherein:
[0008] FIG. 1 illustrates an exploded view showing the individual
components of a solar panel module configured in accordance with
the principles of the invention;
[0009] FIG. 2 illustrates an assembled view of the solar panel
module of FIG. 1; and
[0010] FIG. 3 illustrates another example of a thermal vacuum tube
assembly usable in combination with the solar panel module of FIGS.
1 and 2.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Overview of the Disclosure
[0011] Disclosed herein is a prefabricated structural solar roof
panel module, configured to function as a load-bearing structural
member of the roofing structure of a residence or commercial
building. In certain embodiments, the solar panel modules disclosed
herein are capable of generating electric power for general power
usage and hot water for air conditioning and space heating.
[0012] One aspect of the invention is to provide a novel
prefabricated solar panel module that substantially enhances the
building structural soundness by virtue of being integral with the
overall structural system of the building, while at the same time
providing for an efficient renewable source of energy. A panel
module so configured may save time, labor, and costs of roof
installation by accurate spaced alignment, with the built-in
rafter/rails providing the main structural strength and stiffness.
To that end, the solar panels may preferably be designed and built
to meet the requirements for structural loadings, as specified in
the International Building Code (IBC) and/or the International
Residential Code (IRC), including the ability to handle snow loads,
wind and wind uplift.
[0013] By virtue of being integral with the roofing structure, the
novel solar panel module disclosed and claimed herein effectively
replaces traditional construction methods and materials used to
complete a building's roofing structure. As such, the cost
associated with the presently disclosed novel solar panel module to
be installed into the cavity of a roof as a load-bearing structural
component may be roughly equal to the same cost associated with
building out the same roof cavity using traditional framing
material and the labor costs.
[0014] Still another aspect of the novel solar panel modules
disclosed and claimed herein is that they are fully upgradable, as
technology evolves, without having to be un-installed, and that
they have an expected life that approximates that of a typical
residential or commercial roof structure.
[0015] It should further be appreciated that the novel solar panel
modules disclosed and claimed herein may be customized on a
regional or customer-specific basis for purposes of hurricane
resistance and snow load allowances. Additionally, the novel solar
panel modules disclosed and claimed herein may be customized for
local climate to be fully thermal or fully photovoltaic based on
HVAC needs of the installer, all while satisfying all load-bearing
requirements, e.g., IBC and IRC requirements.
[0016] As used herein, the terms "a" or "an" shall mean one or more
than one. The term "plurality" shall mean two or more than two. The
term "another" is defined as a second or more. The terms
"including" and/or "having" are open ended (e.g., comprising).
Reference throughout this document to "one embodiment", "certain
embodiments", "an embodiment" or similar term means that a
particular feature, structure, or characteristic described in
connection with the embodiment is included in at least one
embodiment of the present invention. Thus, the appearances of such
phrases in various places throughout this specification are not
necessarily all referring to the same embodiment. Furthermore, the
particular features, structures, or characteristics may be combined
in any suitable manner on one or more embodiments without
limitation. The term "or" as used herein is to be interpreted as
inclusive or meaning any one or any combination. Therefore, "A, B
or C" means "any of the following: A; B; C; A and B; A and C; B and
C; A, B and C". An exception to this definition will occur only
when a combination of elements, functions, steps or acts are in
some way inherently mutually exclusive.
Description of an Exemplary Embodiments
[0017] Referring now to FIG. 1, depicted is an exploded view of a
solar panel module 100, configured as a hybrid photovoltaic and
solar-thermal panel in which both photovoltaic cells and an array
of thermal pipe vacuum tube solar thermal collectors may be
integrated into a residential or commercial roofing structure.
However, it should be appreciated that in other embodiments, the
solar panel module 100 may be configured as only a
solar-photovoltaic system or as a solar-thermal system, rather than
a hybrid system of both.
[0018] As shown, the panel module comprises various individual
components which contribute to both its energy producing and
load-bearing properties. In particular, the panel comprises a first
extruded structural rail 105 (depicted as the female component) and
a second extruded structural rail 110 (depicted as the male
component). In the embodiment of FIG. 1, the first and second
extruded structural rails 105 and 110 form the two longitudinal
sides of the module 100. The first and second extruded structural
rails 105 and 110 may be preferably fabricated from sheet metal
material, such as zinc coated steel sheet or aluminum having a
minimum thickness, e.g., 1/8 inch. The thickness of the material
used to fabricate the extruded structural rails 105 and 110 may be
a function of the strength of the material used and the IBC or IRC
requirements for the particular building to be constructed.
[0019] Module 100 further comprises a first extruded cross beam
115a and a second extruded cross beam 115b, which serve as end
enclosures for the module 100 in its assembled form. The first and
second extruded cross beams 115a and 115b are oriented essentially
perpendicular to the first and second extruded structural rails 105
and 110. Disposed between the first and second extruded cross beams
115a and 115b, and also oriented essentially perpendicular to the
first and second extruded structural rails 105 and 110, is a middle
component 120. The first and second extruded cross beams 115a and
115b, together with the middle component 120, function to provide
lateral stability to the module assembly. As with the first and
second extruded structural rails 105 and 110, the first and second
extruded cross beams 115a and 115b and middle component 120 may be
fabricated from sheet metal material, such as zinc coated steel
sheet or aluminum having a minimum thickness, e.g., 1/8 inch, where
the thickness of the material used is a function of both the
properties of the material itself and the IBC or IRC requirements
for the particular building to be constructed.
[0020] Continuing to refer to FIG. 1, module 100 may further
comprise certain insulation-related components, such as a
polystyrene insulation component 125, which may be situated between
two stone fiberboard panels 130a and 130b. An insulation
subassembly comprised of the polystyrene insulation component 125
and fiberboard panels 130a and 130b, together with an APA plywood
sheathing (exposure 1) 135, may be used to provide the insulation
requirement for the roof, and the finish surface for the underside
of the roof.
[0021] Disposed above the insulation subassembly may be a
sun-heated vacuum tube subassembly comprised of a metal reflector
140, a tube stabilizer/support component 145, thermal vacuum tubes
150, and a manifold 155. The metal reflector is configured to
improve the system's ability to capture heat energy by focusing
more direct and ambient sunlight onto the vacuum tubes 150, while
the tube stabilizer/support component 145 supports one end of the
vacuum tubes 150 within the first and second extruded structural
rails 105 and 110. A manifold 155 is provided on the opposite end
of the vacuum tubes 150 as a means to facilitate the flowing of the
heated water to an external tank or water distribution system (not
shown). In this fashion, the solar irradiance on the vacuum tubes
150 may heat the water contained within the manifold 155 such that
the water in the manifold 155 may reach temperatures between
155.degree. F. and 195.degree. F., and may preferably reach a
temperature of approximately 195.degree. F.
[0022] Since the embodiment of FIG. 1 depicts the solar panel
module 100 as a hybrid photovoltaic and solar-thermal panel, it is
further depicted as including a hybrid solar can 160 which houses
one or more solar cell strings (not shown). Additionally, the
hybrid solar can 160 may further comprise a diurnal tracking
system, such as the system disclosed and claimed in U.S.
Publication No. 2010/0275902, entitled "Photovoltaic and Thermal
Energy System." In particular, and as disclosed in U.S. Publication
No. 2010/0275902, the hybrid solar can 160 may be configured to
track the sun throughout the day in order to maximize the amount of
power generated by the system.
[0023] Rather than allowing the elevated temperatures of and around
the solar cell string to degrade the efficiency of the system, as
would typically occur, heat may be drawn away from the cells by
using a cold water inflow 165 and a hot water outflow 170 for
piping cold and hot water, respectively. In particular, the cold
water inflow 165 is configured to pipe cold/cool water to cool the
solar cell assembly, while the hot water outflow 170 removes the
resulting heated water for potential use in a separate power
generation system and/or for hot water consumption.
[0024] Finally, a single-ply tempered glass plate 175 may be used
to cover the module 100 to protect the module 100 from the
environment, while still allowing sun rays to reach both the vacuum
tubes 150 and the solar photovoltaic cells (not shown) within the
hybrid solar can 160. The assembled module 100 may then be
integrated into the roofing structure of a building during the
original construction process and in place of the standard roofing
materials which would otherwise be used to form the roof.
[0025] It should also be appreciated that, while the module 100 of
FIG. 1 has been depicted as a hybrid photovoltaic and solar-thermal
panel having both photovoltaic cells and an array of heat pipe
(thermal) vacuum tubes, the solar panel module 100 may
alternatively be configured as only a solar-photovoltaic system or
as a solar-thermal system, rather than a hybrid system of both.
However, in such cases the module 100 would exhibit the same
load-bearing properties described above, and as required to meet
any IBC or IRC requirements.
[0026] Referring now to FIG. 2, depicted is an assembled view of
the solar panel module 100 of FIG. 1. In particular, FIG. 2 shows
the assembled solar panel module 200 having both a solar portion
210 and a thermal portion 220. As described above with reference to
FIG. 1, the solar portion 210 may be comprised of a hybrid solar
can 230 which houses one or more solar cell string(s) 240, and
which uses water piping 250 to remove heat from the area around the
cell string(s) 240. The thermal portion 220 contains the heat
transfer components referenced above, including vacuum tubes
260.
[0027] The solar portion 210 and the thermal portion 220 are then
housed in an extruded, structural encasement comprised of first and
second extruded cross beams 270a and 270b, along with middle
component 280a, all situated between and perpendicular to first and
second extruded structural rails 290a and 290b which form the two
longitudinal sides of the module 200. Additionally, it should be
appreciated that the module 200 may also include a secondary middle
component 280b in the event additional lateral strength is
required.
[0028] As described above with reference to FIG. 2, the components
which form the extruded, structural encasement of the module 200
may preferably be fabricated from sheet metal material, such as
zinc coated steel sheet or aluminum having a minimum thickness,
e.g., 1/8 inch, which is a function of both the strength of the
material used and the IBC or IRC requirements for the particular
building to be constructed.
[0029] It should be appreciated that the above-described components
may be connected using various approaches, including, for example,
interlocking joints, blind fasteners, snap-fit joints, and
conventional screws. Additional connectors may be provided at both
the eave and the ridge to secure the solar panel modules to each
other and/or to make them integral with the structural roofing
system. For aesthetic purposes, it may be preferable for the
modules 200 to be connected together and to the roofing system so
as to form an essentially flush exterior.
[0030] Numerous variations to the above-identified components are
similarly within the scope of the invention. For example, FIG. 3
shows a vacuum tube arrangement 300 which, rather than utilizing
the ten-tube configuration of FIGS. 1 and 2, instead utilizes 13
tubes having a close spacing, e.g., spacing 310. In certain
embodiments, spacing 310 may be approximately equal to the outside
diameter of the vacuum tubes plus approximately 1/8 inch. In any
event, this closer spacing may allow the replacement of the
corrugated metal reflector (e.g., reflector 140 of FIG. 1) with the
sheet of flat reflective aluminum 320, as shown in FIG. 3.
Moreover, since the module is preferably sealed, the aluminum need
not be anodized. The closer spacing may also eliminate the need to
use rubber grommets. With wider spacing, such as the case with
FIGS. 1 and 2, rubber grommets may be needed to hold the vacuum
tubes in place.
[0031] It should further be appreciated that closer spacing between
the vacuum tubes may also minimize the lost solar irradiance that
would otherwise pass between the tubes. The rear flat reflector 320
of FIG. 3 may direct the remaining solar irradiance that passes
through the narrower gap to the sides and rear of the tube
absorbers.
[0032] While certain exemplary embodiments have been described and
shown in the accompanying drawings, it is to be understood that
such embodiments are merely illustrative of and not restrictive on
the broad invention, and that this invention not be limited to the
specific constructions and arrangements shown and described, since
various other modifications may occur to those ordinarily skilled
in the art.
* * * * *