U.S. patent application number 14/361424 was filed with the patent office on 2014-12-04 for photovoltaic systems.
The applicant listed for this patent is Zinniatek Limited. Invention is credited to Andrew Leo Haynes, Pengcheng Liu, Sing Kiong Nguang, Ashton Cyril Partridge.
Application Number | 20140352760 14/361424 |
Document ID | / |
Family ID | 48535821 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140352760 |
Kind Code |
A1 |
Haynes; Andrew Leo ; et
al. |
December 4, 2014 |
PHOTOVOLTAIC SYSTEMS
Abstract
This invention relates to photovoltaic (PV) unit adapted to
provide wireless power transfer output comprising one or more
photovoltaic cells that generate electrical output, and at least
one wireless power transfer transmitter coupled to transfer the
electrical output via wireless power transfer. Such a PV unit can
be provided in combination with a roofing, cladding or siding
module. Such a module comprises an underlapping region and an
exposed region of an adjacent module when installed on a building
surface; and an outer surface and an under surface, wherein the
under surface of the underlapping region is profiled to define a
pathway for air flow between the module and the building
surface.
Inventors: |
Haynes; Andrew Leo;
(Redbeach, NZ) ; Partridge; Ashton Cyril;
(Stanmore Bay, NZ) ; Liu; Pengcheng; (Mt Albert,
NZ) ; Nguang; Sing Kiong; (Royal Oak, NZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Zinniatek Limited |
Rosedale, Auckland |
|
NZ |
|
|
Family ID: |
48535821 |
Appl. No.: |
14/361424 |
Filed: |
November 30, 2012 |
PCT Filed: |
November 30, 2012 |
PCT NO: |
PCT/NZ2012/000222 |
371 Date: |
May 29, 2014 |
Current U.S.
Class: |
136/246 ;
136/244 |
Current CPC
Class: |
F24S 25/61 20180501;
H02J 50/30 20160201; Y02E 10/56 20130101; H02J 5/005 20130101; H02J
50/05 20160201; H02S 20/25 20141201; H02S 20/26 20141201; F24S
20/67 20180501; H02J 2300/22 20200101; H02S 20/23 20141201; Y02B
10/70 20130101; H02J 2300/24 20200101; H02J 50/12 20160201; H02J
3/381 20130101; Y02E 10/60 20130101; F24S 25/40 20180501; H01L
31/0521 20130101; Y02B 10/20 20130101; H02J 3/383 20130101; Y02B
10/10 20130101; H02S 40/44 20141201 |
Class at
Publication: |
136/246 ;
136/244 |
International
Class: |
H01L 31/02 20060101
H01L031/02; H01L 31/048 20060101 H01L031/048; H01L 31/052 20060101
H01L031/052 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 30, 2011 |
AU |
2011904975 |
Nov 30, 2011 |
NZ |
596793 |
Claims
1. A photovoltaic unit adapted to provide wireless power transfer
output comprising: one or more photovoltaic cells that generate
electrical output, at least one wireless power transfer transmitter
coupled to transfer the electrical output via wireless power
transfer.
2. A photovoltaic unit according to claim 1 wherein the
photovoltaic unit is for installation on a roof or a substrate
panel to serve as a roofing product.
3. A photovoltaic unit according to claim 1 wherein the electrical
output is transferred via wireless power transfer to a load and/or
output conductor.
4. A photovoltaic unit according to claim 1 wherein the wireless
power transfer is via capacitive coupling whereby the wireless
power transfer transmitter forms a capacitor with a wireless power
transfer receiver coupled to (or for coupling to) the load and/or
output conductor.
5. A photovoltaic unit according to claim 4 wherein the wireless
power transfer transmitter comprises a capacitor plate.
6. A photovoltaic unit according to claim 5 wherein the capacitor
plate has surface texturing.
7. A photovoltaic unit according to claim 6 wherein the surface
texturing is nanoscopic and/or microscopic surface texturing.
8. A photovoltaic unit according to claim 1 wherein there are two
or more photovoltaic cells coupled together to generate the
electrical output, wherein the photovoltaic cells are coupled
together using wireless power transfer.
9. Two or more photovoltaic units coupled together to generate
electrical output, each according to claim 1 wherein the
photovoltaic cells are coupled together using wireless power
transfer.
10. A roof or roofing component comprising a photovoltaic unit
according to claim 1.
11. A roof or roofing component according to claim 10 further
comprising at least one wireless power transfer receiver coupled to
(or for coupling to) a load or output conductor for receiving
electrical output from the wireless power transfer transmitter.
12. A roof or roofing component according to claim 10 or 11 wherein
the wireless power transfer is via capacitive coupling whereby the
wireless power transfer transmitter forms a capacitor with the
wireless power transfer receiver coupled to (or for coupling to)
the load and/or output conductor.
13. A roof or roofing component according to claim 10 or 11 wherein
the wireless power transfer transmitter comprises a capacitor
plate.
14. A roof or roofing component according to claim 13 wherein the
capacitor plate has surface texturing.
15. A roof or roofing component according to claim 14 wherein the
surface texturing is nanoscopic and/or microscopic surface
texturing.
16. A photovoltaic unit according to claim 1 for installation on a
roofing, cladding, or siding module comprising: an underlapping
region and an exposed region, wherein the underlapping region is
adapted to be substantially covered by the exposed region of an
adjacent module when installed on a building surface; and an outer
surface and an under surface, wherein the under surface of the
underlapping region is profiled to define a pathway for air flow
between the module and the building surface.
17. A photovoltaic unit according to claim 1 for installation on a
roofing, cladding, or siding module comprising a plurality of
formed surfaces moulded from one or more polymeric materials,
wherein each of the formed surfaces comprise three dimensional
surface features, and wherein the formed surfaces are joined
without weld lines or injection moulding points.
18. A photovoltaic unit according to claim 1 for installation a
roofing, cladding, or siding assembly comprising a plurality of
partially-overlapping modules that substantially covers a building
surface, wherein each module comprises: an underlapping region and
an exposed region, wherein the underlapping region is adapted to be
substantially covered by the exposed region of an adjacent module
when installed on a building surface and the exposed region is
adapted to be substantially exposed when installed on a building
surface; an outer surface and an under surface, wherein the under
surface of the underlapping region is profiled to define a pathway
for air flow between the module and the building surface.
19. A photovoltaic unit according to claim 1 for installation on a
system for removing or recovering thermal energy from a building
surface, the system comprising: a building surface; a roofing,
cladding, or siding assembly comprising a plurality of
partially-overlapping modules that substantially covers the
building surface, wherein each module comprises an underlapping
region and an exposed region, wherein the underlapping region is
adapted to be substantially covered by the exposed region of an
adjacent module when installed on a building surface and the
exposed region is adapted to be substantially exposed when
installed on a building surface; an outer surface and an under
surface, wherein the under surface of the underlapping region is
profiled to define a pathway for air flow between the module and
the building surface; and a fan adapted to induce the air flow.
20. A photovoltaic unit according to claim 1 for installation on a
system for generating electricity and recovering or removing
thermal energy from a building surface, the system comprising a
building surface; a roofing, cladding, or siding assembly
comprising a plurality of partially-overlapping modules that
substantially covers the building surface, wherein each module
comprises an underlapping region and an exposed region, wherein the
underlapping region is adapted to be substantially covered by the
exposed region of an adjacent module when installed on a building
surface; and an outer surface and an under surface, wherein the
under surface of the underlapping region is profiled to define a
pathway for air flow between the module and the building surface,
and wherein the outer surface of the exposed region comprises one
or more photovoltaic
Description
FIELD OF THE INVENTION
[0001] The present invention relates to photovoltaic (PV) systems
and assemblies and their use on roofing products.
[0002] More particularly the present invention relates to a method
whereby photovoltaic wafers, sails, cells, modules or the like
(generally termed "cells") can be linked or coupled upon
installation and/or during installation so as to enable a useful
electrical output.
BACKGROUND TO THE INVENTION
[0003] There are many systems where a substrated PV unit or an
unsubstrated PV unit requires an electrical connection to a bus,
cable or the like. An instance includes PV electricity generating
systems reliant upon an array of PV units whether as standalone
arrays or when forming part of, for example, the cladding of a
building structure (roof and/or walls).
[0004] In many instances the PV unit in whatsoever form it takes
(whether stand alone or substrated) is subject to weathering at any
electrical connection.
[0005] Furthermore, where a plurality of PV units require
connection on installation, for example when installed as an array
on a roof top, it can be difficult and time consuming to make the
numerous wired or otherwise contacting electrical connections
required in order to derive a useful output. It is crucial to the
functioning of the units that these connections are made properly
at the outset (i.e. before they are subject to weathering and
environmental degradation), however it is easy to overlook the
quality of each individual connection when a large number of them
need to be made in a short space of time to complete the
installation.
[0006] The present invention has as its object, or in at least some
embodiments, advantageously provides: [0007] (a) A PV system, and
PV units and/or related procedures, methods, subassemblies and the
like which will at least avoid the challenge of such weathering or
other environmental degradation, [0008] (b) the connection of PV
units into an electricity reticulation system, [0009] (c) the
provision of a PV system, and PV units and/or related procedures,
methods, subassemblies and the like which have an improved means of
electrical connection on installation
[0010] It is therefore a further or alternative object or advantage
of the present invention to at least provide the public with a
useful choice.
[0011] In this specification where reference has been made to
patent specifications, other external documents, or other sources
of information, this is generally for the purpose of providing a
context for discussing the features of the invention. Unless
specifically stated otherwise, reference to such external documents
is not to be construed as an admission that such documents, or such
sources of information, in any jurisdiction, are prior art, or form
part of the common general knowledge in the art.
[0012] Further aspects and advantages of the present invention will
become apparent from the ensuing description which is given by way
of example only.
SUMMARY OF THE INVENTION
[0013] In an aspect the invention relates to a photovoltaic unit
adapted to provide wireless power transfer output comprising: one
or more photovoltaic cells that generate electrical output, at
least one wireless power transfer transmitter coupled to transfer
the electrical output via wireless power transfer.
[0014] Preferably the photovoltaic unit is for installation on a
roof or a substrate panel to serve as a roofing product.
[0015] Preferably the electrical output is transferred via wireless
power transfer to a load and/or output conductor.
[0016] Preferably the wireless power transfer is via capacitive
coupling whereby the wireless power transfer transmitter forms a
capacitor with a wireless power transfer receiver coupled to (or
for coupling to) the load and/or output conductor.
[0017] Preferably the wireless power transfer transmitter comprises
a capacitor plate.
[0018] Preferably the capacitor plate has surface texturing.
[0019] Preferably the surface texturing is nanoscopic and/or
microscopic surface texturing.
[0020] Preferably two or more photovoltaic cells coupled together
to generate the electrical output, wherein the photovoltaic cells
are coupled together using wireless power transfer.
[0021] In an aspect the present invention relates to two or more
photovoltaic units coupled together to generate electrical output,
each according to the photovoltaic units defined herein, wherein
the photovoltaic cells are coupled together using wireless power
transfer.
[0022] In an aspect the invention relates to a roof or roofing
component comprising a photovoltaic unit according to photovoltaic
units defined herein.
[0023] Preferably roof or roofing component further comprising at
least one wireless power transfer receiver coupled to (or for
coupling to) a load or output conductor for receiving electrical
output from the wireless power transfer transmitter.
[0024] Preferably the wireless power transfer is via capacitive
coupling whereby the wireless power transfer transmitter forms a
capacitor with the wireless power transfer receiver coupled to (or
for coupling to) the load and/or output conductor.
[0025] Preferably the wireless power transfer transmitter comprises
a capacitor plate.
[0026] Preferably the capacitor plate has surface texturing.
[0027] Preferably the surface texturing is nanoscopic and/or
microscopic surface texturing.
[0028] In an aspect the invention relates to a PV unit of any
appropriate form (substrated or not) able to be mounted or adapted
to be mounted so as to receive solar energy directly or indirectly
and generate an electrical output, the apparatus being
characterised in that it is able to transfer energy output using
wireless power transfer (such as inductive and/or capacitive
coupling), said transfer occurring over an inductive and/or
capacitive transfer region.
[0029] Preferably or optionally the projected area of the transfer
region is less than 50% of the area of the solar receiving area of
the PV unit.
[0030] Preferably or optionally the surface area of the transfer
region is from 5% to 1000%, or from 100% to 800%, or from 200% to
600% of the area of the solar receiving area of the PV unit.
[0031] Preferably or optionally the surface area of the transfer
region is from 5% to 1000%, or from 100% to 800%, or from 200% to
600% of the projected area of the transfer region.
[0032] Preferably or optionally the inductive region is greater
than or equal to 0.5% of the area of the solar receiving area of
the unit.
[0033] Most preferably or optionally an optimum area is provided
whereby transfer losses (such as inductive and/or capacitive
transfer losses) are rendered substantially insignificant with
respect to the certainty of the output transfer and the output of
the PV unit.
[0034] Preferably or optionally the transfer of energy output is
achieved by inductive coupling.
[0035] Preferably or optionally the transfer of energy output is
achieved by capacitive coupling.
[0036] Preferably or optionally inductive and/or capacitive
coupling is achieved by the interaction of a transmitter able to
transmit energy/power generated by the PV unit and a receiver able
to receive the transmitted energy.
[0037] Preferably or optionally the transmitter is an induction
coil or pad.
[0038] Preferably or optionally the transmitter is a capacitor
plate.
[0039] Preferably or optionally the transmitter is mounted on or
associated with the PV unit.
[0040] Preferably or optionally the transmitter is housed in a
recess on the PV unit.
[0041] Preferably or optionally the transmitter is housed in a
sealed containment on the PV unit.
[0042] Preferably or optionally the receiver is connected to a
reticulation bus, cable or the like for distributing the electrical
output.
[0043] Preferably or optionally the PV unit is substrated.
[0044] Preferably or optionally the transmitter is mounted on or
associated with the substrate.
[0045] Preferably or optionally the transmitter is housed in a
recess on the substrate.
[0046] Preferably or optionally the transmitter is housed in a
sealed containment within the substrate.
[0047] Preferably or optionally the transmitter is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0048] Preferably or optionally the receiver is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0049] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with a single transfer region.
[0050] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with two transfer regions.
[0051] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with more than two transfer regions.
[0052] In a further aspect the invention consists in PV units
linked (for example neurally) by wireless power transfer (such as
inductive and/or capacitive coupling).
[0053] Preferably or optionally the said PV units are photovoltaic
cells linked neurally and mounted upon a substrate panel to serve
as a roofing product.
[0054] In a further aspect of the invention consists in PV units
linked (for example neurally) by wireless energy transfer (such as
inductive and/or capacitive coupling).
[0055] Preferably or optionally the said PV units are photovoltaic
cells linked neurally and mounted upon a substrate panel to serve
as a roofing product.
[0056] In another aspect the present invention relates to PV units
coupled by wireless power transfer (such as by inductive and/or
capacitive coupling) to a reticulation bus, cable or the like for
distributing the electrical output.
[0057] Preferably or optionally the wireless power transfer
coupling is achieved by energy transfer occurring over a (e.g.
inductive and/or capacitive) transfer region.
[0058] Preferably or optionally the projected area of the transfer
region is less than 50% of the area of the solar receiving area of
the PV unit.
[0059] Preferably or optionally the surface area of the transfer
region is from 5% to 1000%, or from 100% to 800%, or from 200% to
600% of the area of the solar receiving area of the PV unit.
[0060] Preferably or optionally the surface area of the transfer
region is from 5% to 1000%, or from 100% to 800%, or from 200% to
600% of the projected area of the transfer region.
[0061] Preferably or optionally the transfer region is greater than
or equal to 0.5% of the area of the solar receiving area of the
unit.
[0062] Most preferably or optionally an optimum area of the power
transfer region is provided whereby inductive transfer losses are
rendered substantially insignificant with respect to the certainty
of the output transfer and the output of the PV unit.
[0063] Preferably or optionally the wireless power transfer
coupling is achieved by inductive coupling.
[0064] Preferably or optionally the wireless power transfer
coupling is achieved by capacitive coupling.
[0065] Preferably or optionally wireless power transfer coupling is
achieved by the interaction of a transmitter able to transmit
energy generated by the PV unit and a receiver able to receive the
transmitted energy.
[0066] Preferably or optionally the transmitter is an induction
coil or pad.
[0067] Preferably or optionally the transmitter is a capacitor
plate.
[0068] Preferably or optionally the transmitter is mounted on or
associated with the PV unit.
[0069] Preferably or optionally the transmitter is housed in a
recess on the PV unit.
[0070] Preferably or optionally the transmitter is housed in a
sealed containment on the PV unit.
[0071] Preferably or optionally the receiver is connected to a
reticulation bus, cable or the like for distributing the electrical
output.
[0072] Preferably or optionally the PV unit is substrated.
[0073] Preferably or optionally the transmitter is mounted on or
associated with the substrate.
[0074] Preferably or optionally the transmitter is housed in a
recess on the substrate.
[0075] Preferably or optionally the transmitter is housed in a
sealed containment within the substrate.
[0076] Preferably or optionally the transmitter is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0077] Preferably or optionally the receiver is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0078] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with a single transfer region.
[0079] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with two transfer regions.
[0080] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with more than two transfer regions.
[0081] In another aspect the present invention relates to PV units
connected wirelessly to a reticulation bus, cable or the like for
distributing the electrical output.
[0082] Preferably or optionally the wireless connection is achieved
by energy transfer occurring over a wireless energy transfer
region.
[0083] Preferably or optionally the projected area of the wireless
energy transfer region is less than 50% of the area of the solar
receiving area of the PV unit.
[0084] Preferably or optionally the surface area of the wireless
energy transfer region is from 5% to 1000%, or from 100% to 800%,
or from 200% to 600% of the area of the solar receiving area of the
PV unit.
[0085] Preferably or optionally the surface area of the wireless
energy transfer region from 5% to 1000%, or from 100% to 800%, or
from 200% to 600% of the projected area of the wireless energy
transfer region.
[0086] Preferably or optionally the wireless energy transfer region
is greater than or equal to 0.5% of the area of the solar receiving
area of the unit.
[0087] Most preferably or optionally an optimum area of the power
transfer region is provided whereby wireless energy transfer losses
are rendered substantially insignificant with respect to the
certainty of the output transfer and the output of the PV unit.
[0088] Preferably or optionally the wireless connection is achieved
by inductive coupling.
[0089] Preferably or optionally the wireless connection is achieved
by capacitive coupling.
[0090] Preferably or optionally the wireless connection is achieved
by the interaction of a transmitter able to transmit energy
generated by the PV unit and a receiver able to receive the
transmitted energy.
[0091] Preferably or optionally the transmitter is an induction
coil or pad.
[0092] Preferably or optionally the transmitter is a capacitor
plate.
[0093] Preferably or optionally the transmitter is mounted on or
associated with the PV unit.
[0094] Preferably or optionally the transmitter is housed in a
recess on the PV unit.
[0095] Preferably or optionally the transmitter is housed in a
sealed containment on the PV unit.
[0096] Preferably or optionally the receiver is connected to a
reticulation bus, cable or the like for distributing the electrical
output.
[0097] Preferably or optionally the PV unit is substrated.
[0098] Preferably or optionally the transmitter is mounted on or
associated with the substrate.
[0099] Preferably or optionally the transmitter is housed in a
recess on the substrate.
[0100] Preferably or optionally the transmitter is housed in a
sealed containment within the substrate.
[0101] Preferably or optionally the transmitter is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0102] Preferably or optionally the receiver is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0103] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with a single wireless energy transfer
region.
[0104] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with two wireless energy transfer regions.
[0105] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with more than two wireless energy transfer
regions.
[0106] In a further aspect the invention relates to any assembly
and/or subassembly which inductively and/or capacitively transfers
the output from one or more PV units into a reticulation
device.
[0107] Preferably or optionally the transfer occurs over a transfer
region (e.g. implementing inductive and/or capacitive
coupling).
[0108] Preferably or optionally the projected area of the transfer
region is less than 50% of the area of the solar receiving area of
the PV unit.
[0109] Preferably or optionally the surface area of the transfer
region is from 5% to 1000%, or from 100% to 800%, or from 200% to
600% of the area of the solar receiving area of the PV unit.
[0110] Preferably or optionally the surface area of the transfer
region from 5% to 1000%, or from 100% to 800%, or from 200% to 600%
of the projected area of the transfer region.
[0111] Preferably or optionally the transfer region is greater than
or equal to 0.5% of the area of the solar receiving area of the
unit.
[0112] Most preferably or optionally an optimum area is provided
whereby transfer losses are rendered substantially insignificant
with respect to the certainty of the output transfer and the output
of the PV unit.
[0113] Preferably or optionally the transfer is achieved by
inductive coupling.
[0114] Preferably or optionally the transfer is achieved by
capacitive coupling.
[0115] Preferably or optionally inductive coupling is achieved by
the interaction of a transmitter able to transmit energy generated
by the PV unit and a receiver able to receive the transmitted
energy.
[0116] Preferably or optionally the transmitter is an induction
coil or pad.
[0117] Preferably or optionally the transmitter is a capacitor
plate.
[0118] Preferably or optionally the transmitter is mounted on or
associated with the PV unit.
[0119] Preferably or optionally the transmitter is housed in a
recess on the PV unit.
[0120] Preferably or optionally the transmitter is housed in a
sealed containment on the PV unit.
[0121] Preferably or optionally the receiver is connected to a
reticulation bus, cable or the like for distributing the electrical
output.
[0122] Preferably or optionally the PV unit is substrated.
[0123] Preferably or optionally the transmitter is mounted on or
associated with the substrate.
[0124] Preferably or optionally the transmitter is housed in a
recess on the substrate.
[0125] Preferably or optionally the transmitter is housed in a
sealed containment within the substrate.
[0126] Preferably or optionally the transmitter is a pad (e.g.
implementing inductive and/or capacitive coupling) with nanoscopic
and/or microscopic surface texturing on it.
[0127] Preferably or optionally the receiver is an inductor pad
(e.g. implementing inductive and/or capacitive coupling) with
nanoscopic and/or microscopic surface texturing on it.
[0128] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with a single transfer region.
[0129] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with two transfer regions.
[0130] Preferably or optionally the photovoltaic unit is a
photovoltaic cell with more than two transfer regions.
[0131] In a further aspect the invention is the use of a
photovoltaic device (preferably or optionally on or with cladding
or roofing), characterised in that the photovoltaic device has an
alternating current or transient direct current passing through a
zone in proximity to a bus, said bus being receptive to an wireless
power transfer (e.g. inductive and/or capacitive coupling) from the
photovoltaic device produced current to that zone.
[0132] In various aspects, the present invention relates to a PV
unit utilising wireless power transfer used or installed on a
roofing, cladding or siding product which is light weight, easy to
install, weatherproof, durable, resistant to environmental wear,
and aesthetically pleasing. One embodiment relates to a module that
can be used to form a weatherproof covering over top of a building
surface. Another embodiment is a module which can, in additional to
forming a weatherproof covering, be used as part of a thermal
energy recovery or removal system. Yet another embodiment is a
module which can, in addition to forming a weatherproof covering,
and optionally in addition to being useful as part of a thermal
energy recovery or removal system, bears an array of solar cells to
generate electrical energy.
[0133] In an aspect the present invention relates to a PV unit
utilising wireless power transfer for installation on a roofing,
cladding, or siding module comprising a plurality of formed
surfaces moulded from one or more polymeric materials, wherein each
of the formed surfaces comprise three dimensional surface features,
and wherein the formed surfaces are joined (i.e., integrated
together, juxtaposed, or united) without weld lines or injection
moulding points.
[0134] In one embodiment, each formed surface is a moulded segment
along the length of the module. In one embodiment, the three
dimensional surface features of each of the formed surfaces are the
same or different. In one embodiment, the three dimensional surface
features have the same or variable thickness. In one embodiment,
the module is substantially flat. In one embodiment, each formed
surface comprises an underlapping region and an exposed region,
wherein the underlapping region is adapted to be substantially
covered by the exposed region of an adjacent module when installed
on a building surface.
[0135] In one embodiment, the roofing, cladding, or siding module
comprises a plurality of formed surfaces moulded from one or more
polymeric materials, wherein each of the formed surfaces comprise
three dimensional surface features, and wherein the formed surfaces
are sequentially formed in a continuum. In some embodiments, the
module is formed as it runs through a continuous forming process
(as opposed to a die stamping or injection moulding process). Thus,
the formed surfaces with the three dimensional surface features are
sequentially formed in the continuous forming process.
[0136] In an aspect the present invention relates to a PV unit
utilising wireless power transfer for installation on a roofing,
cladding, or siding module comprising: an underlapping region and
an exposed region, wherein the underlapping region is adapted to be
substantially covered by the exposed region of an adjacent module
when installed on a building surface; and an outer surface and an
under surface, wherein the under surface of the underlapping region
is profiled to define a pathway for air flow between the module and
the building surface.
[0137] In one embodiment, the outer surface of the exposed region
comprises surface ornamentation. In one embodiment, the surface
ornamentation resembles asphalt shingles, slate, wooden shakes,
concrete tiles, or the like.
[0138] In one embodiment, the outer surface of the exposed region
comprises a photovoltaic cell or device. In one embodiment, the
module further comprises a solar radiation transmissible film which
is overlaid upon the photovoltaic cell.
[0139] In one embodiment, the profile of the underside of the
underlapping surface is patterned in a manner to (1) create
turbulence in the airflow, (2) increase the surface area of the
module in contact with the passing airflow compared to a module
lacking such a surface pattern, or both (1) and (2). In one
embodiment, the profile of the underside of the underlapping region
comprises a plurality of projections that create a tortuous pathway
above the actual or notional plane of the building surface. In one
embodiment, the profile of the underside of the underlapping region
comprises corrugated form of alternating parallel grooves and
ridges.
[0140] In one embodiment, the module is moulded from one or more
polymeric materials. In one embodiment, the one or more polymeric
materials are selected from the group consisting of polycarbonate,
foamed polycarbonate, thermoplastic polyurethane (TPU),
thermoplastic olefin (TPO), polyvinyl chloride (PVC),
aquilobutalstyrene (ABS), styrene-acrylonitrile resin (SAN),
thermoplastic rubber, and any other amorphous or crystalline
polymer or combination of polymers. In one embodiment, the one or
more polymeric materials are flame retardant. In one embodiment,
the one or more polymeric materials are weather, hail, ultraviolet,
tear, mold and impact resistant.
[0141] In one embodiment, the module comprises at least two layers
of polymeric material, wherein the layers are of the same or
different polymeric material. In one embodiment, at least one
material has high UV resistance. In one embodiment, at least one
material has high thermal conductivity. In one embodiment, the
module further comprises a reinforcement layer.
[0142] In one embodiment, the module or the polymer layers can be
coloured or comprise a blend of colours. In one embodiment, the
polymer on the outer layer of the module can be manufactured to
mimic traditional roofing products. In one embodiment, the polymer
on the outer layer of the module can be coloured to contrast with
the colour of the PV cell layer to define an aesthetic feature,
e.g. shadows.
[0143] In one embodiment, the module comprises a first and a second
polymeric material. In one embodiment, the first polymeric material
has been foamed. In one embodiment, the first polymeric material is
able to chemically bond with the second polymeric material. In one
embodiment, the first polymeric material, the second polymeric
material, or both further comprise thermally conductive inclusions.
In one embodiment, the thermally conductive inclusions have been
blended and/or bonded to a compatible polymer or ionomer prior to
mixing with the first polymeric material. In one embodiment, the
thermally conductive inclusions are aluminum particles. In one
embodiment, the second polymeric material can self seal to a
penetrative fastener. In one embodiment, the first material is
foamed polycarbonate and the second material is thermoplastic
polyurethane.
[0144] In one embodiment, the top and bottom sides of the
underlapping region contain complementary locating elements. In one
embodiment, the underlapping region is profiled to define one or
more regions for fixing by a penetrative fastener. In one
embodiment, the one or more regions for fixing by a penetrative
fastener are adapted to receive a nail or screw gun head to
accurately locate the fixing.
[0145] In one embodiment, the module has a convex precamber
configured to apply a pre-load pressure to encourage the edges and
bottom surface to contact firmly onto an adjacent underlapping
panel when installed on a building. In one embodiment, the upper
surface of the underlapping region, the lower surface of the
exposed region, or both, comprise a strip of flexible polymeric
material configured to prevent water from penetrating between two
overlapping modules.
[0146] In one embodiment, the module has one or more
concertina-shaped features to accommodate thermal expansion and
contraction between fixing points.
[0147] In one embodiment, the upper surface of the underlapping
region comprises channels configured to receive wires of a
photovoltaic array. In one embodiment, the upper surface of the
underlapping region comprises markings to show the correct position
of wires and junctions for a photovoltaic array. In one embodiment,
the upper surface of the underlapping region comprises pockets or
channels configured to receive printed circuit boards (PCB),
communication devices, junction boxes, wires, buses, components,
cells, and/or diodes of a photovoltaic array.
[0148] In one embodiment, the module is manufactured by a
continuous forming process. In one embodiment, the module is
continuously formed into a horizontal strip capable of extending
substantially across an entire section or width of the building
surface to be covered. In one embodiment, the module is
continuously formed into a vertical strip capable of extending
substantially down an entire section or length of the building
surface to be covered.
[0149] In an aspect the present invention relates to a PV unit
utilising wireless power transfer for installation on a roofing,
cladding, or siding assembly comprising a plurality of
partially-overlapping modules that substantially covers a building
surface, wherein each module comprises an underlapping region and
an exposed region, wherein the underlapping region is adapted to be
substantially covered by the exposed region of an adjacent module
when installed on a building surface and the exposed region is
adapted to be substantially exposed when installed on a building
surface; an outer surface and an under surface, wherein the under
surface of the underlapping region is profiled to define a pathway
for air flow between the module and the building surface.
[0150] In one embodiment, one or more of the modules comprises a
photovoltaic cell or device. In one embodiment, the photovoltaic
cell or devices are electrically connected by continuous bus
strips. In one embodiment, the continuous bus strips only require
one terminating junction point to be connected on installation. In
one embodiment, the air flow between the underlapping region and
the building surface is induced by convection or a fan.
[0151] In one embodiment, the modules overlap down the fall of the
building surface. In one embodiment, the modules overlap across a
building surface. In one embodiment, each module is adapted to be
fixably attached to the building surface by at least one fastening
member or adhesive. In one embodiment, at least one fastening
member is a nail, staple or screw. In one embodiment, the roofing,
cladding, or siding assembly forms a weathertight seal over the
building surface.
[0152] In an aspect the present invention relates to a PV unit
utilising wireless power transfer for installation on a system for
removing or recovering thermal energy from a building surface, the
system comprising a building surface; a roofing, cladding, or
siding assembly comprising a plurality of partially-overlapping
modules that substantially covers the building surface, wherein
each module comprises an underlapping region and an exposed region,
wherein the underlapping region is adapted to be substantially
covered by the exposed region of an adjacent module when installed
on a building surface and the exposed region is adapted to be
substantially exposed when installed on a building surface; an
outer surface and an under surface, wherein the under surface of
the underlapping region is profiled to define a pathway for air
flow between the module and the building surface; and a fan adapted
to induce the air flow.
[0153] In one embodiment, the system further comprises a heat
exchanger. In one embodiment, the heat exchanger is part of an air
conditioning system, water heating system, or air or media (e.g.,
sand, ground glass, or concrete) heating system.
[0154] In an aspect the present invention relates to a PV unit
utilising wireless power transfer for installation on a system for
generating electricity and recovering or removing thermal energy
from a building surface, the system comprising a building surface;
a roofing, cladding, or siding assembly comprising a plurality of
partially-overlapping modules that substantially covers the
building surface, wherein each module comprises an underlapping
region and an exposed region, wherein the underlapping region is
adapted to be substantially covered by the exposed region of an
adjacent module when installed on a building surface; and an outer
surface and an under surface, wherein the under surface of the
underlapping region is profiled to define a pathway for air flow
between the module and the building surface, and wherein the outer
surface of the exposed region comprises one or more photovoltaic
cells.
[0155] In one embodiment, the system further comprises a vent for
exhausting the air flow. In one embodiment, the system further
comprises a heat exchanger adapted to receive the air flow. In one
embodiment, the air flow is induced by a fan. In one embodiment,
the speed of the fan is proportional to the energy created by one
or more PV cells. In one embodiment, the air flow is reversible in
order to heat the roof to remove snow, ice, and/or moisture. In
another embodiment, the air flow is able to move air from a warmer
section of the roof to a cooler section of the roof. In one
embodiment, the system is operable (a) to generate electricity from
the one or more photovoltaic cells and (b) to duct an induced or
uninduced air flow to be heated and outputted to the heat exchanger
during times of solar absorption or heat transmission by the
modules.
[0156] In an aspect the present invention provides a method for
simultaneously generating electricity and recovering thermal energy
from a building surface, the method comprising inducing an airflow
to pass through an air passage between a building surface and an
under surface of a plurality of partially-overlapping modules that
substantially cover the building surface; and collecting electrical
energy from one or more photovoltaic cells present on an exposed
surface of the modules utilizing wireless power transfer; wherein
each module comprises an underlapping region and an exposed region,
wherein the underlapping region is adapted to be substantially
covered by the exposed region of an adjacent module when installed
on a building surface and the exposed region is adapted to be
substantially exposed when installed on a building surface; and an
outer surface and an under surface, wherein the under surface of
the underlapping region is profiled to define a pathway for air
flow between the module and the building surface.
[0157] In an aspect, the present invention provides a method of
manufacture of a roofing, cladding, or siding module on which a PV
unit utilising wireless power transfer can be installed, the method
comprising: providing to a continuous forming machine a feed
material able to assume and retain a form after being moulded
between a first forming surface and a second forming surface;
allowing the formation to take place as such surfaces are advanced
in the same direction; wherein the output is a roofing, cladding,
or siding module comprising: an underlapping region and an exposed
region, wherein the underlapping region is adapted to be
substantially covered by the exposed region of an adjacent module
when installed on a building surface; and an outer surface and an
under surface, wherein the under surface of the underlapping region
is profiled to define a pathway for air flow between the module and
the building surface.
[0158] In one embodiment, the feed material comprises a layer of a
first material beneath a layer of a second material. In one
embodiment, the first material is extruded to a supporting surface
of a continuous forming machine, and the second material is
extruded to the top surface of the feed of first material. In one
embodiment, the exposed region comprises both materials, and the
underlapping region comprises, at least in part, only one of the
materials. In one embodiment, the axis of advancement of the
materials in the continuous forming machine is commensurate with
the longitudinal axis of the module as it lies with the
longitudinal axis across the fall of a roof to be clad thereby.
[0159] In one embodiment the entire roofing, cladding or siding
module is made from a single material.
[0160] In one embodiment the module design features can be achieved
by thermoforming, pressing, or other method of forming, either
continuously or discontinuously wood, metal, concrete, resins,
glass, clay, composites or the like.
[0161] In an aspect, the present invention provides a method of
manufacture of a roofing, cladding or siding on module on which PV
unit utilising wireless power transfer can be installed, the method
comprising: providing a feed material in liquid or viscous form to
a mould in a moulding position; allowing the material to be moulded
as a segment in the moulding position; advancing the moulded
segment to a position subsequent to, yet partially overlapping the
moulding position; providing further material in liquid or viscous
form to the moulding position; allowing the material to be moulded
as a further segment in the moulding position along with, or so as
to adhere to, the overlapping section of the previously moulded
segment; wherein the output is a roofing, cladding, or siding
module comprising: an underlapping region and an exposed region,
wherein the underlapping region is adapted to be substantially
covered by the exposed region of an adjacent module when installed
on a building surface; and an outer surface and an under surface,
wherein the under surface of the underlapping region is profiled to
define a pathway for air flow between the module and the building
surface.
[0162] In an aspect, the invention relates to a PV unit utilising
wireless power transfer for installation a roofing, cladding, or
siding module having (i) a region to underlap a like or other
module and (ii) a region to overlap a like or other module; wherein
the overlap region has on, or at least towards, its upper surface
serially formed zones of three dimensional features, such zones
being of polymeric material(s) provided as a continuum for that
module's zones.
[0163] In some embodiments, the polymeric material is a layer over
at least one underlying layer of polymeric material(s). One or
other of the polymeric materials may include a thermally conductive
inclusion. In one embodiment, each such zone of three dimensional
features of an overlap region and a corresponding part of an
underlap region is formed simultaneously. In one embodiment, the
same polymeric material(s) provides each said zone and at least
part of the underlap region.
[0164] In one embodiment, each region to underlap and each region
to overlap are three dimensionally contoured. Such contouring can
be through to the under surface to provide for compatibility in
overlap indexing. In one embodiment, the overlap region on its
upper surface is both dimensionally contoured for aesthetic
purposes and provided with zones of features for solar related
functionality purposes, e.g. features for association with
photovoltaics. In one embodiment, such zones of three dimensional
features are mutually juxtaposed or at least mutually close.
[0165] In an aspect, the invention relates to a PV unit utilising
wireless power transfer for installation on a building integrated
solar energy recovery system, the system comprising, including or
using a roofing, cladding or siding of modules or the equivalent
("modules") partially overlapping their adjacent modules down
and/or across a building surface yet to collect in sunlight either,
or both, (a) heat solar energy as heat at least in part to pass to
an underlying air flow, and/or (b) to generate electricity
photovoltaically for outputting and consequential heat at least in
part to pass to said underlying air flow. In one embodiment, the
modules, as installed on the building surface, with profile
features of each module, provide an underlying pathway for an
airflow to be heated by solar energy absorption and/or transmission
through said modules. In one embodiment, as part of the cladding
array, photovoltaic devices or functionality included and/or
carried by a region or regions of any one or more module are not
overlapped by an adjacent module.
[0166] In an aspect, the invention relates to a PV unit utilising
wireless power transfer for installation on a building integrated
solar energy recovery system to either or simultaneously: (a)
generate electricity from the photovoltaic array of shingles with a
photovoltaic functionality; and/or (b) duct heated air (e.g. for
heat transfer purposes) from an induced or uninduced air flow under
one or more roofing, cladding or siding modules during times of
solar absorption and/or heat transmission by the modules.
[0167] In an aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding component suitable or installed to pass solar
energy received by at least some of its regions into an underlying
airstream, and with a photovoltaic regional functionality with a
photovoltaic receiving region to convert received solar energy into
an electrical output. In one embodiment, when as part or as part of
a series down or across an underlying building surface, is useable
whereby each photovoltaic receiving region is fully exposed despite
partial overlapping of one component to another to better shed
water; and is useable whereby, despite attachment to the underlying
building surface, there is a set out from the underlying building
surface sufficient to allow a passage of an underlying
airstream.
[0168] In some embodiments, at least part of the profile of each
roofing component has been moulded (i) by a CFT (as herein
defined); and/or (ii) to accommodate a photovoltaic functionality;
and/or (iii) to accommodate interconnection functionalities of
photovoltaic areas; and/or to define at least in part said
configuration; and/or (iv) to be very much greater in dimension
across the building surface to be covered than the dimension it
will cover down said building surface; or (v) to be very much
greater in dimension down the building surface to be covered than
the dimension it will cover across said building surface.
[0169] In some embodiments, the dimension of the module in the
direction that extends across the building surface is at least 3
times, or at least 4 times, or at least 5 times, or at least 10
times, or at least 15 times, or at least 20 times that of the
dimension of the module that extends down the building surface. In
some embodiments, the dimension of the module in the direction that
extends down the building surface is at least 3 times, or at least
4 times, or at least 5 times, or at least 10 times, or at least 15
times, or at least 20 times that of the dimension of the module
that extends across the building surface.
[0170] In a further aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding module or equivalent ("module") comprising or
including a moulding of a first material and a second material;
wherein the first material defines a first region or first regions
("first region(s)") and a second or second regions ("second
region(s)"), whether profiled or not; and wherein the second
material defines an overlay or underlay of at least part of one of
said first and second regions; and wherein a plurality of said
modules lapping their neighbour down or across a building surface
with a notional or actual planar surface to be overclad by such a
series of modules to form a weathertight seal over said building
surface.
[0171] In a further aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding assembly comprising or including a structure to
provide a support surface, and a plurality of modules to cover the
underlying support surface, the modules relating to any
neighbour(s) in an overlapping arrangement down the fall or pitch
of the underlying surface, thereby to define the exterior fall or
pitch of the roofing, cladding or siding assembly; wherein at least
some of the modules include photovoltaic ("PV") devices exposed to
sunlight able to generate an electrical output; and wherein the
plurality of modules define a pathway above the support surface for
an air flow, induced or otherwise, to be heated by heat exchange
from at least some of the modules as a consequence of heating of
the modules by received sunlight or heating of the modules as a
consequence of the effect of received sunlight on the PV devices,
or both.
[0172] In a further aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding assembly as herein described to either or
simultaneously: (a) to generate electrical output from said PV
devices; and/or (b) heat an induced or other air flow by heat
exchange from at least some of the modules as a consequence of
heating of the modules by received sunlight or heating of the
modules as a consequence of the effect of received sunlight on the
PV devices, or both.
[0173] In a further aspect the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding component, or substrate therefor, which
comprises or includes the steps of: providing to at least one of
the forming surfaces of a continuous or discontinuous forming
machine a feed of material able to assume and retain a form after
being moulded between that first mentioned forming surface and a
second forming surface, and allowing that formation to take place
as such surfaces are advanced in the same direction; wherein the
output is of a form having a profiled region to step out part of
that region from an underlying actual or notional planar surface,
yet providing another region to, at least in part, overlap said
profiled region of a like form.
[0174] In a further aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding component, or substrate therefor, which
comprises or includes the steps of: providing material in liquid or
viscous form to mould in a moulding position; allowing said
material to be moulded as a segment in said moulding position;
advancing said moulded segment to a position subsequent to, yet
partially overlapping said moulding position; providing further
material in liquid or viscous form to the moulding position;
allowing said material to be moulded as a further segment in the
moulding position along with, or so as to adhere to, the
overlapping section of the previously moulded segment; wherein the
output is of a form having a profiled region to step out part of
that region from an underlying actual or notional planar surface,
yet providing another region to, at least in part, overlap said
profiled region of a like form.
[0175] In a further aspect, the invention provides a method of
manufacture of a roofing, cladding or siding component, or
substrate therefor on which PV unit utilising wireless power
transfer can be installed, which comprises or includes the steps
of: (1) extruding or otherwise providing a feed of a first material
to a supporting surface of a continuous forming machine, the feed
having a width WI and thickness TI; (2) extruding or otherwise
providing a feed of a second material to the top surface of the
feed of first material, the feed having a width WII and thickness
TII; (3) allowing the two materials to be formed; and wherein the
output is of a form having a first profiled region to step out part
of that region from an underlying actual or notional planar
surface, yet providing a second region to, at least in part,
overlap said profiled region of a like form; and wherein said
second region is covered by both materials, and said profiled
region is covered, at least in part, by only one of the materials.
In one embodiment, the axis of advancement of the materials in the
continuous forming machine is commensurate with the longitudinal
axis of a roofing shingle that is to lie with said longitudinal
axis across the fall of a roof to be clad thereby.
[0176] In a further aspect, the invention relates to a on PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding component, or substrate of a roofing, cladding
or siding component including product having a first region and a
second region, the component to be used as a covering across the
fall of a building structure and to overlap at least in part with
its first region, and to underlap at least in part with its second
region, the first and second regions of a like component or
substrate; wherein the component has been formed by a feed of
materials into a continuous forming machine to profile at least one
or either, or both, of the first and second regions or at least
parts thereof; and wherein the advance direction of the continuous
forming machine defines the elongate axis of the component that is
to lie across the fall of the building surface.
[0177] In another aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a roofing,
cladding or siding module adapted to be fixed with its elongate
axis across the fall of the building surface to be clad; the module
having a first longitudinal region to underlie, in use, a like
module or flashing, and a second longitudinal region, in use, to
overlie a like module or to simply be exposed; wherein the first
and second regions share in common a first material; and wherein
the first and second regions share in common a second material, yet
the second region has its upper surface defined by a second
material while only part of the first region (i.e. that part of the
first region proximate to the second region) has its upper surface
defined by said second material; and wherein there has been such
sharing of the first and second materials since a continuous
forming process; and wherein one, some or all of the following
apply: (i) at least the underside of the first region defines a
profile of projections (e.g. mesa-like or otherwise) to stand the
remainder of the first region off from an actual support or
notional support plane; (ii) such projections define a tortuous
pathway above the actual or notional plane; (iii) the topside of
the first region, with depressions, provide a female version of the
male underside; (iv) the second material is weather resistant; (v)
the first material has been foamed; (vi) the first material
includes particulate thermally conductive inclusion; (vii) the
second material can self seal to a penetrative fastener; (viii) the
first material is a polymeric material, the second material is a
polymeric material, at least the upper surface of the second region
has been profiled; (ix) the upper surface of the second region has
been profiled to simulate conventional roofing products (e.g.
tiles, slate, shingles shakes or the like); (x) the upper surface
of the second region channels, pockets or the like to accommodate
or accommodating the buses and/or cells of a photovoltaic array;
(xi) the first and second materials have been coextruded or
serially extruded into a continuous forming machine; and (xii) the
extrusion has been into an advancing continuous forming machine
where the elongate axis is aligned to the advancement.
[0178] In a further aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a roofing
shingle, tile or equivalent module ("shingle") substantially as
herein described, with or without reference to the accompanying
drawings.
[0179] In a further aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a roof
assembly substantially as herein described, with or without
reference to the accompanying drawings.
[0180] In a further aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a building
integrated solar energy recovery system substantially as herein
described, with or without reference to the accompanying
drawings.
[0181] In a further aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a roof clad
by roofing components of any aspect of the present invention.
[0182] In a further aspect, the invention relates to a PV unit
utilising wireless power transfer for installation on a building
surface clad by cladding or siding components of any aspect of the
present invention.
[0183] As used herein the term "and/or" means "and" or "or", or
both.
[0184] As used herein "(s)" following a noun means the plural
and/or singular forms of the noun.
[0185] The term "comprising" as used in this specification means
"consisting at least in part of". When interpreting statements in
this specification which include that term, the features, prefaced
by that term in each statement, all need to be present but other
features can also be present. Related terms such as "comprise" and
"comprised" are to be interpreted in the same manner.
[0186] As used herein the term "object" denotes a possible purpose
or utility for the invention described but such a purpose or
utility need not be construed as a mandatory feature of the
invention.
[0187] The term "PV unit" includes photovoltaic or photoelectric
wafers, sails, cells, arrays and modules (themselves generally
termed "cells"), as single items and/or multiple groupings of such
items, and assemblies and/or subassemblies comprising any or all of
these items or groupings of items.
[0188] The term "wireless power transfer" (also termed "AC
coupling") includes power transfer by inductive coupling, resonant
inductive coupling, capacitive coupling and all other methods of
wireless energy/power transfer.
[0189] The term "wireless power transfer" and "wireless energy
transfer" can be used interchangeably in a general sense to denote
transfer via some type of AC or other wireless coupling (such as
inductive and/or capacitive coupling).
[0190] Relative terms, such as "lower" or "bottom", "upper" or
"top," and "front" or "back" may be used herein to describe one
element's relationship to another element as illustrated in the
Figures. It will be understood that relative terms are intended to
encompass different orientations of the device in addition to the
orientation depicted in the Figures. For example, if the device in
one of the figures is turned over, elements described as being on
the "lower" side of other elements would then be oriented on
"upper" sides of the other elements. The exemplary term "lower",
therefore, encompasses both an orientation of "lower" and "upper,"
depending of the particular orientation of the figure. Similarly,
if the device in one of the figures is turned over, elements
described as "below" or "beneath" other elements would then be
oriented "above" the other elements. The exemplary terms "below" or
"beneath" can, therefore, encompass both an orientation of above
and below.
[0191] As used herein, the term "formed surface" refers to a
moulded segment of a polymeric material corresponding to an
individual dye or mold of a continuous forming machine.
[0192] As used herein, the term "building surface" refers to a wall
surface or a top surface, etc. of a building, e.g. an exterior
wall, a roof, a ceiling, etc., unless otherwise specified. In the
context of a roof, the building surface typically comprises a
waterproof roofing membrane attached to the roof deck adjacent an
eave of the roof for preventing water damage to the roof deck and
an interior of a building from wind-blown rain or water buildup on
the roof. The roof deck is typically made of an underlying
material, such as plywood. The waterproof membrane may be any of a
number of waterproof roofing membranes known in the art such as but
not limited to bituminous waterproof membranes, modified bituminous
roofing membranes, self-adhering roofing membranes, or single ply
waterproofing roofing membranes (e.g. EPDM waterproof roofing
membranes, PVC waterproof roofing membranes, TPO waterproof roofing
membranes). One exemplary membrane sheet is Deck-Armor.TM. Roof
Protection, manufactured by GAF Corp., Wayne, N.J.
[0193] As used herein, the term "roofing" means the provision of a
protective covering on the roof surface of a building. Without
limitation, such a protective covering might take the form of
shingles, tiles, panels, shakes, planks, boards, modules, mouldings
or sheets.
[0194] As used herein, the terms "cladding" and/or "siding" mean
the provision of a protective covering on a side or other surface
of a building. Without limitation, such a protective covering might
take the form of shingles, tiles, panels, shakes, planks, boards,
modules, mouldings or sheets.
[0195] As used herein, the terms "profiled" and/or "contoured" mean
having a region, or regions which extend above or below a notional
planar surface lying along the longitudinal axis of the product.
This includes profiling or contouring of only one upper or lower
surface, and/or profiling or contouring of an entire thickness of
material such that the upper and lower surfaces have the same
relative degree of extension above or below the notional planar
surface.
[0196] As used herein, the term "thermally conductive particles" or
"thermally conductive inclusions" refers to particles or inclusions
of any conductive material. These include, but are not limited to,
particles of the following materials: metals, metal hybrids,
carbon, silica, glass, conductive polymers, salts, carbon nanotubes
and compounds of these substances. In addition to assisting in heat
transfer, the thermally conductive particles or inclusions may also
act as a reinforcing material.
[0197] As used herein, the term "polymer" (and associated terms
such as "polymeric") includes polymers, polymer blends, and
polymers with or without additive inclusions.
[0198] This invention may also be said broadly to consist in the
parts, elements and features referred to or indicated in the
specification of the application, individually or collectively, and
any or all combinations of any two or more said parts, elements or
features, and where specific integers are mentioned herein which
have known equivalents in the art to which this invention relates,
such known equivalents are deemed to be incorporated herein as if
individually set forth.
[0199] The invention consists in the foregoing and also envisages
constructions of which the following gives examples only.
[0200] The entire disclosures of all applications, patents and
publications, cited above and below, if any, are hereby
incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0201] Preferred embodiments of the invention will be described by
way of example only and with reference to the drawings, in
which:
[0202] FIG. 1 shows a typical glass solar panel carrying
photovoltaic cells and having a series of inductive power transfer
zones down one side of the panel.
[0203] FIG. 2 is a close up view of the cells shown in FIG. 1.
[0204] FIG. 3 is a view of the solar panel of FIGS. 1 and 2 showing
the main power take off cable running down the underside of the
panel.
[0205] FIG. 4 shows a sectional view of some preferred components
as arranged to achieve inductive power transfer of the energy
produced by a PV cell.
[0206] FIG. 5A shows a glass solar panel carrying photovoltaic
cells, each of which is connected to a power generation and output
system by two inductive power transfer zones.
[0207] FIG. 5B shows the reverse side of the panel shown in FIG.
5A.
[0208] FIG. 6 shows a formed substrate carrying an array of PV
cells, and having at one end a device for the inductive transfer of
energy from the PV cells to a receiver able to receive the
transmitted energy.
[0209] FIG. 7 shows a series of formed substrate panels, each
carrying an array of PV cells and each having at one end a device
for inductive power transfer, as assembled on a roof top, each
inductively connected to a main reticulation bus running down the
edge of the roof.
[0210] FIG. 8 is an exploded view of FIG. 7.
[0211] FIG. 9 shows one embodiment whereby two PV modules are
electrically connected with an inductive connection.
[0212] FIG. 10 shows in schematic form the electrical arrangement
of a PV unit with wireless power transfer.
[0213] FIG. 11 shows an illustrative embodiment of a continuously
formed roofing, cladding or siding module in its basic form.
[0214] FIG. 12 shows an illustrative embodiment of a continuously
formed roofing, cladding or siding module fixed in an overlapping
arrangement upon a building surface.
[0215] FIG. 13 shows the underlapping, exposed and fixing regions
of an illustrative embodiment of the roofing module.
[0216] FIG. 14 shows an embodiment of the module having been formed
to have a sinusoidal profile to simulate concrete tiling.
[0217] FIG. 15 shows an embodiment of the module having been formed
to have a jagged profile to simulate weatherboarding.
[0218] FIG. 16 shows an embodiment of the module having been formed
to have relief contours on its upper surface to simulate asphalt
shingle.
[0219] FIG. 17 shows a series of modules fixed in a lapping
arrangement with offset vertical alignment for added visual
appeal.
[0220] FIGS. 18A-18C show the detail of the fixing region of one
embodiment of the module and the locators through which fasteners
can be driven to secure the module to the building surface.
[0221] FIG. 19 shows a nail type fastener sitting within a locator
recess sealed off by an overlapping module.
[0222] FIG. 20 shows an illustrative embodiment of the roofing
module which has been moulded to have a precamber.
[0223] FIG. 21A shows an embodiment of the module which includes
adhesive strips for securing the modules to create a weathertight
seal.
[0224] FIG. 21B shows an exploded view of the module of FIG.
21A.
[0225] FIG. 22 shows an embodiment of the module where a first
adhesive strip is affixed along the lower edge of the module on the
back side of the moulded material layer, while a second is affixed
to the top side just below the line of the fixing region.
[0226] FIG. 23A shows an alternative embodiment wherein the
adhesive strips are positioned so that both strips are on the front
of the module; one at the rear edge and one just below the line of
the fixing region. FIG. 13B shows an embodiment where a strip of
material on the upper surface of the underlapping region serves as
a weather-tight barrier.
[0227] FIG. 24 shows diagrammatically a continuous forming
apparatus contemplated as providing for the continuous forming of
various modules described herein.
[0228] FIG. 25 shows a module wherein a second layer of material
has been formed overtop of, but not entirely covering, a first
layer of material.
[0229] FIG. 26 shows an illustrative embodiment of a module wherein
a thermoplastic polyurethane layer has been formed along with, and
on top of, a foamed polycarbonate layer, to give product
characteristics desirable for a roofing shingle.
[0230] FIG. 27 is an exploded view of a roofing assembly to be used
in the collection of thermal and/or solar energy.
[0231] FIG. 28A is a side on view of the module assembly of FIG.
27.
[0232] FIGS. 28B-28C shows a cross-section of the module and air
filter at the edge of a building surface.
[0233] FIG. 29 is a diagram showing how heat recovered from the
roofing system can be collected and used.
[0234] FIG. 30 shows a cross section of a profiled feature moulded
as part of the underlapping region of a module.
[0235] FIG. 31A shows the underside of a module with projection
features included to encourage turbulent flow of the underpassing
air stream.
[0236] FIG. 31B shows a module surface (as seen in FIG. 31A) with a
series of fine ribs integral to the moulding so as to increase the
module's contact surface with the air stream and assist heat
transfer.
[0237] FIG. 31C is a close up view showing the profile of the ribs
of FIG. 21B.
[0238] FIG. 32 shows two modules positioned in a lapping
arrangement and having complementary surface textures on their
respective contact surfaces.
[0239] FIG. 33 shows an overlapping series of one embodiment of the
module designed to carry a solar array for photovoltaic power
generation.
[0240] FIG. 34 is a detailed view of the module of FIG. 33.
[0241] FIG. 35 shows a method of endwise joining two modules with
an overlaid solar panel secured across the joining region.
[0242] FIG. 36A shows the detail of the relief features on the
surface of the building integrated photovoltaic embodiment of the
module which are designed to locate a series of electrically
connected photovoltaic cells.
[0243] FIG. 36B shows the detail of the channels configured to
receive cables or wires of the photovoltaic array cavities
configured to receive junction boxes. This figure also shows
surface marking to indicate the location position of the underlying
electrical fittings and connections.
[0244] FIG. 37 shows diagrammatically a continuous forming
apparatus contemplated as providing for the continuous forming of
modules and lending itself to the online introduction downstream of
a photovoltaic functionality system.
[0245] FIG. 38 shows a building on which various embodiments of the
current invention have been installed.
[0246] FIG. 39A shows the detail of a concertina feature designed
to accommodate thermal expansion and contraction of the module.
[0247] FIG. 39B shows the detail of the concertina feature placed
between two fixing points.
[0248] FIG. 40 shows a "dummy" module positioned in a lapping
arrangement with a cutout for a pipe emerging from the building
surface. BIPV modules are shown on either side of the "dummy
module".
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0249] A first embodiment of the invention is shown in FIG. 1
wherein an array of solar (PV) cells 001 are mounted on a typical
glass solar panel 002 and wired in parallel to pairs of positive
201 and negative 202 cables running across the width of the panel
(as can been seen more clearly in FIG. 2). Together they form a PV
unit and generate electrical/power output (such as output voltage
and/or current) at e.g. the right hand end of each cable there is a
wireless power transfer (e.g. inductive and/or capacitive)
transmission device (transmitter) 203 which may or may not be
recessed or encapsulated into the glass. There may be a separate
transmission device for each cable, or they may be shared as shown
in FIG. 2. The transmitter can transmit power to a reciprocal
receiver on a load and/or output conductor.
[0250] For example, a main power take off cable/conductor (which
can connect to a load) 301 runs on the underside of the panel in
the vertical direction, and there are respective/reciprocal
wireless power transfer (e.g. inductive and/or capacitive)
receiving devices or means (receiver) 302 spaced at intervals along
this cable. This can be seen in FIG. 3. The transmitter 203 and
receiver 302 work co-operatively to provide wireless power
transfer. The takeoff cable can be installed prior to the solar
panel and connected as required to other devices which will
eventually draw power from the solar module/panel.
[0251] When the solar panel is installed (for example on a roof or
other exterior building surface) all that is required is to align
the transmission device(s) 401 with the receiving device(s) 402.
Because there does not need to be direct physical contact between
the transmission device and the receiving device, the transmission
device 401 can be housed within a recess 403 integral to the form
of the glass panel as shown in FIG. 5. Similarly there may be
features or markers in the underside of the panel 404 to house the
receivers on installation and to assist in locating them
correctly.
[0252] Housing the transmitting and receiving components in
recesses also protects them from weathering, abrasion and impact,
and will help to reduce the instance of failure of the power
generation system at the electrical connection points. It may be
that the transmission device and associated components are
completely concealed within the substrate for this purpose.
[0253] The surfaces of the transmission device 405 and the
receiving device 406 should be positioned in close proximity to one
another, for example, as shown in FIG. 4. This means that no
electrical connections need be made once the system components are
in position, and also that a small degree of misalignment and/or
non-contact at the electrical connection points can be
tolerated.
[0254] The components of the transmission device itself may take a
number of forms depending on the wireless power transfer method
employed, as will the form of the receiving device; however in one
embodiment both the transmitter and receiver are coils or pads
which together form an inductive or capacitive coupling. In
capacitive coupling, the transmitter and receiver together form a
capacitor. Each, for example, may take the form of a respective
capacitor plate.
[0255] Where the transmitter and receiver are pads or plates,
microscopic and/or nanoscopic or other surface texturing can be
applied to the pad surfaces (for example surfaces 405 and 406) to
increase the surface area of the pad or plate, and therefore aid in
the efficiency and/or rate of wireless power transfer. In one
embodiment the surfaces may be patterned or profiled with a high
ratio aspect pattern (for example, by a series of finely pointed
peaks).
[0256] A device, possibly an intermittent switching device, may be
required to convert the direct current output from the solar cells
to alternating current prior to transmission through the
coupling.
[0257] A second arrangement is as shown in FIGS. 5A and 5B, wherein
there is an array of solar (PV) cells 501, each having its own
wireless power transfer means. In this arrangement there are a
networked series of power-takeoff cables 502 running across the
solar array. There may be one or more wireless power transfer zones
(e.g. inductive and/or capacitive) 503 on each cell depending on
the wiring configuration. The connection density should be selected
according to the useful power output requirements of the
system.
[0258] A further and preferred embodiment of a unit having a region
able to be capacitively or inductively used to transfer output
power from a PV device is as shown in FIG. 6. A formed substrate
panel 601, of the sort which can be mounted on the roof top of a
building, bears a plurality of photovoltaic cells 602 which are
electrically connected to a single output terminal at one side of
the panel. At the output terminal there is a device for inductive
or capacitive power transfer 603 to a receiving conductor.
[0259] The substrate panel, or a series of such panels, can then be
installed upon a roof or other surface exposed to solar energy,
along with one or more wireless transfer power receiver(s) . The
receiver(s) are in turn connected to a power distribution network
so that the electrical energy can be directed as required.
[0260] The preferred method of assembly for a power generation
system incorporating the photovoltaic unit described is shown in
FIG. 7, wherein a number of substrate panels 701 are fixed down the
fall of a roof. Each panel has, at e.g. its right hand end, a
device 702 for wireless power transfer of the energy collected by
the solar cells mounted upon it to a single output 703.
[0261] FIG. 8 is an exploded view of the assembly of FIG. 7, which
shows that running down the e.g. right hand side of the fall of the
roof, but underlying the panels, is a main electrical bus strip
801. The bus strip (by itself or by way of connected receiver
devices) is able to receive the energy transmitted by the wireless
power transfer devices on each of the substrate panels. The energy
is then distributed, via the bus strip, as useful electrical
output.
[0262] The positioning of the receivers (if any) along the bus
strip can be calculated before the bus strip is installed on the
roof. Subsequently the panels can be affixed onto the roof so that
the corresponding transmission zones and receiving zones are
aligned. The substrate panel moulding may also have features 802 to
aid in the location of the transmitter respective to the
receiver.
[0263] As discussed, it is also particularly advantageous to be
able to wirelessly (e.g. inductively and/or capacitively) make
connections between adjacent PV units as they are installed on a
roof or building surface. It is possible to do this by providing
corresponding transmitting and receiving regions on each adjacent
module and then installing the modules so that the transmitter and
receiver regions are overlaid. The embodiment shown in FIG. 9 gives
an example of how wireless joining of adjacent modules can be
achieved by laying a connector cell 901 over top of the join
between the modules that two or more power transfer regions 902 of
the connector cell are in close proximity to one or more power
transfer regions of the each of the modules. The connector cell may
be a functional solar cell, or may just be a cell without PV
functionality which merely serves as a conductor. Concealing the
joint between the modules with the connector cell can be an
aesthetic improvement compared to installing a series or array of
modules with visible join lines between them. Individual PV cells
of a PV unit can also be coupled by wireless power transfer to
produce output.
[0264] FIG. 10 shows in schematic form the invention. A PV unit is
coupled to a wireless power transfer transmitter (e.g. inductor
coil or capacitor plate) which is inductive and/or capacitively
coupled to a reciprocal wireless power transfer receiver (e.g.
conductor coil or capacitor plate) which itself is coupled to a
load directly or via an output conductor.
[0265] In one embodiment, the PV system/unit described can be
installed on a BIPV roofing system/product as described below.
[0266] In some embodiments, the roofing product comprises modules
having g a plurality of formed surfaces moulded from one or more
polymeric materials (which may be in layers), wherein each of the
formed surfaces comprises three dimensional surface features. The
present technology also relates to a product having good thermal
conductivity and a capacity for photovoltaic ("PV") and/or solar
thermal energy generation, and related subassemblies, assemblies,
uses and methods. The present technology has several advantages.
For example, the roofing, cladding or siding product may reduce the
amount of heat energy transferred to the interior of the building
upon which it is mounted; and/or to provide a system which
incorporates a roofing, cladding or siding product to that effect;
and/or to provide a method by which mass production of such a
product could be achieved; or at least provides the public with a
useful choice.
[0267] In embodiments a Building Integrated Photovoltaic ("BIPV")
and/or solar thermal roofing, cladding or siding product is
provided which is reasonably light weight, easy to install, durable
and resistant to environmental wear; or at least provides the
public with a useful choice.
[0268] In other embodiments, a BIPV and/or solar thermal roofing,
cladding or siding product is provided that does not require a
fastener (nail, screw, bolt, etc.) to penetrate the exposed
surfaces of the roof, thereby making the product less likely to
leak compared to convention BIPV products; or at least provides the
public with a useful choice.
[0269] In other embodiments, a BIPV and/or solar thermal roofing,
cladding or siding product is provided capable of large surface
area coverage, that can be mass produced in high volumes and with
reasonable speed of production; and/or to provide a method by which
such mass production of such a product could be achieved; or at
least provides the public with a useful choice.
[0270] In other embodiments, a BIPV and/or solar thermal roofing,
cladding or siding product is provided which will allow heat energy
to be transferred away from the photovoltaic cell to maximise its
operational efficiency; and/or to provide a system which
incorporates a BIPV roofing, cladding or siding product to that
effect; and/or to provide a method by which mass production of such
a product could be achieved; or at least provides the public with a
useful choice.
[0271] In other embodiments, an airway path is provided to allow
space for wires and other electrical components to run between the
roof and the building structure with such wires and electrical
components located above a waterproof membrane on the building
substrate surface therefore ensuring that the waterproof membrane
is not penetrated.
[0272] In yet other embodiments, a building integrated system is
provided which allows solar, ambient and photovoltaically generated
heat to be transferred away from a building surface and used
elsewhere; and/or the components of such a system; and/or a method
of manufacturing such components; or at least provides the public
with a useful choice.
[0273] Various embodiments relate to a roofing, cladding or siding
product to be secured to a building in a lapping arrangement. In
one embodiment the product is formed as a module to be laid
horizontally across a surface and lapped vertically down that
surface, however, it is also possible to manufacture the product so
as to allow it to be laid in vertical columns which would then lap
across the surface. In particular, three illustrative embodiments
of the product are described below. The first is a module which can
be used to form a weatherproof covering over top of a building
surface; the second is a module which can, in additional to forming
a weatherproof covering, be used as part of a thermal energy
recovery system; and the third is a module which can, in addition
to forming a weatherproof covering, and optionally in addition to
being useful as part of a thermal energy recovery system, bears an
array of solar cells to generate electrical energy.
[0274] In one aspect, a roofing, cladding or siding product is
provided which is reasonably light weight, easy to install, durable
and resistant to environmental wear. In some embodiments, the
roofing, cladding or siding product is capable of large surface
area coverage, can be mass produced in high volumes and with
reasonable speed of production; and/or provides a method by which
such mass production of such a product can be achieved.
[0275] In one embodiment, the roofing, cladding or siding product
is a module comprising a plurality of formed surfaces moulded from
one or more polymeric materials (which may be in layers), wherein
each of the formed surfaces comprises three dimensional surface
features, and wherein the formed surfaces are joined without weld
lines or injection moulding points. Each formed surface refers to a
moulded segment along the length of the module that corresponds to
an individual dye or mold of a continuous forming machine. See
PCT/NZ2006/000300 (published as WO2007/058548). Use of the term
"joined" in this context is not intended to require that each of
the formed surfaces were ever separated, i.e., the formed surfaces
may be integrally formed together in situ during the manufacturing
process. In another embodiment, the module design features can be
achieved by thermoforming, pressing, or other method of forming,
either continuously or discontinuously wood, metal, concrete,
resins, glass, clay, composites or the like.
[0276] In particular, the product can be manufactured in long
strips (as seen in FIG. 11) by a continuous process which
incorporates a continuous forming step, and therefore can be made
in varying lengths as required depending on the required coverage
area. Production is such that a single moulded module, capable of
extending across the entire width or section of the roof or
building to be protected, can be manufactured. For example, the
modules may be very much greater in dimension across the building
surface to be covered than the dimension it will cover down the
building surface. In one embodiment, the dimension of the module in
the direction that extends across the building surface is at least
3 times, or at least 4 times, or at least 5 times, or at least 10
times, or at least 15 times, or at least 20 times that of the
dimension of the module that extends down the building surface.
Alternatively, the modules may be very much greater in dimension
down the building surface to be covered than the dimension it will
cover across the building surface. In one embodiment, the dimension
of the module in the direction that extends down the building
surface is at least 3 times, or at least 4 times, or at least 5
times, or at least 10 times, or at least 15 times, or at least 20
times that of the dimension of the module that extends across the
building surface.
[0277] In some embodiments, the modules are about 0.2-1 in length,
1-20 metres in length, about 3-10 metres in length, or about 4-8
metres in length, or 2-4 metres in length. Modules of 4-5 metres in
length, and modules of 8 metres in length are suitable
manufacturing sizes, but the manufacturing process allows custom
lengths to be accommodated just as easily. A plurality of such
modules can then be arranged in lapping rows down the surface of
the structure, for example, as shown by the lapping roof shingles
seen in FIG. 12.
[0278] The features of an illustrative embodiment of the basic
roofing product are as shown in FIG. 13. There is an underlapping
region 1301, and an exposed region 1302 (i.e. to be exposed when a
series of modules are positioned in a lapping arrangement). There
may also be a fixing region 1303 where the module 1300 is to be
attached to the building surface, and this may or may not be within
the underlapping region 1301, but is suitably or optionally within
the underlapping region 1301. The regions may exist in various
proportions comparative to each other, and there may be profiling
or contouring 1304 of any or all regions in a continuous or
discontinuous pattern along the length of the module 1300. In one
embodiment, the width of the underlapping region 1301 approximately
equals the width of the overlapping region 1302. In other
embodiments, the width of the underlapping region 1301 is about
95%, about 90%, about 80%, about 75%, about 60%, about 50%, about
40%, about 30%, about 25%, about 15%, or about 10% of the width of
the overlapping region 1302. In some embodiments, the overlapping
region 1302 is from about 5 cm to about 60 cm wide and the
underlapping region 1301 is from about 5 cm to about 60 cm
wide.
[0279] Variations in the profiling or contouring can be used to
create different stylistic or ornamental effects. For example, the
module may be moulded with a sinusoidal profile, as shown in FIG.
14, to simulate concrete tiling; an angular profile, as shown in
FIG. 15, to simulate weatherboarding; with relief features on its
upper surface, as shown in FIG. 16, to simulate asphalt shingles;
or with a variable upper surface contour to simulate slate tiling
or wooden shakes. The continuous forming process allows a variety
of different 3D surfaces to be produced with the same equipment
simply by swapping out the die faces on the forming machine as
required.
[0280] The colour and visual properties of material feeds can be
changed fairly easily also just by inputting different materials
and additives (particularly colouring additives) at the feeding
stage. This means that it is possible to mass manufacture
consecutive runs of different types of product (e.g. a product
simulating concrete tiles, a product simulating slate tiles and a
product simulating asphalt shingles) without significantly altering
the equipment on the manufacturing line.
[0281] The modules may be installed in various vertical alignments
as desired and/or as permitted by the surface contouring. The
offset vertical alignment shown in FIG. 17 gives the effect of
traditional "tiled" roofing, while other alignments will also
produce interesting visual and/or stylistic effects.
[0282] FIG. 18A shows a series of locator recesses 1801 within the
fixing region 1802 of a moulded module 1800 for locating nail or
screw type fasteners. There are bosses 1803 (i.e. thickened
sections of material) at the bottom of each recess to provide a
strong area for the fastener shank to pass through, and these also
create a flat surface 1804 to butt with the building surface
underneath the module. The sides of the recess 1805 slope outward
so that a hammer or pneumatic nail or staple gun can be used to
drive the fastener home without damaging the surrounding module
material.
[0283] FIG. 18B shows there may be "starter" holes or locators 1801
within the fixing region 1802 for locating the fasteners 1806
(e.g., nails, staples, or screws) which attach the module to the
building surface. These locators 1801 can be moulded features or
extra surface markings. The purpose of such locators 1801 is to
simplify installation by showing how many fasteners 1806 are
required and how far apart they ought be spaced. Furthermore, as
shown in FIG. 18C, the locators 1801 may include recesses that are
adapted to fit conventional nail or screw gun heads 1807. This
provides easy alignment and accurate location of the fastener for
the installer. There may be a layer of reinforcement material
covering the fixing region of the module to prevent the module
material from tearing where it is penetrated by the fasteners, in
which case the locators can serve to ensure that the fasteners are
positioned within the reinforced zone.
[0284] Once the module is fixed to the roof the head of the
fastener should be flush with or sit below the top of the locator
opening. As shown in FIG. 19, this allows the overlapping region of
a subsequently affixed module to sit flat over top of the first
module.
[0285] The module may be formed with a convex precamber (as shown
in FIG. 20) to apply a pre-load pressure to encourage the edges and
bottom surface of the overlapping panel to contact firmly onto the
underlapping panel when installed on a building. This also provides
high thermal conductivity between the underlapping panel and the
overlapping panel. Additionally, adhesive strips 111 (shown in FIG.
21A) running along the length of each module can be used to connect
one module to the surface of the next, creating a waterproof seal
and stopping grit and particulates from working their way under the
roofing or cladding layer. There is also an advantage to securing
those regions of the module which are farthest from the fixing
region so that the exposed portions of the module cannot flap up in
the wind and cause damage through fracture or bending stresses.
This may be done with adhesive strips or by other means. If
adhesive strips are used, it may be beneficial to have them covered
by release strips 113 for transport and storage (as showing in FIG.
21B). The release strips would be removed during installation.
[0286] The placement of the adhesive strip(s) on the module can
vary. As shown in FIG. 22, in one embodiment, a first adhesive
strip 121 is affixed along the lower edge of the module on the back
side of the moulded material layer, while a second 122 is affixed
to the top side just below the line of the fixing region. Thus a
series of modules can be arranged as shown in FIG. 22, where the
strip on the back side adheres to the strip on the front side.
[0287] Alternatively, as shown in FIG. 23A, the adhesive strips can
be positioned so that both strips are on the front of the module;
one at the rear edge 131 and one just below the line of the fixing
region 132. In this case the adhesive will secure two points of the
module and will adhere directly to the substrate layer of the
overlapping module. A further alternative or addition is to apply
an adhesive paste to the region 112 during installation.
[0288] As shown in FIG. 23B, the module may be pre-formed with a
strip of material 133 on the upper surface of the underlapping
region that serves as a weather-tight barrier when placed into
contact with an adjacent module. This flexible strip of material
133 prevents the backflow of water or air in between the
overlapping modules. A further alternative or addition is to place
a similar strip of polymeric material on the lower surface of the
exposed region, to prevent water from penetrating between the two
overlapping modules.
[0289] In one embodiment, a sequence of steps in the manufacture of
the roofing and/or cladding product is to firstly prepare the
module material for forming (which may involve bringing the
material to a molten, semi-molten or pliable state), secondly,
feeding the material to a pressure forming zone, and thirdly,
forming and setting the material as it advances through the
pressure forming zone. While there are various methods of mixing
and presenting the materials prior to forming, a suitable method is
to deposit an extruded feed layer of a first material 141 onto an
advancing support surface of a continuous forming machine, and to
subsequently introduce a further extruded feed layer of another
material 142 overtop of this, as shown in FIG. 24. The first
material and the second material or additional may be the same or
different, and may be of the same or different form. Both materials
then proceed as a layered feed 143 to the pressure forming zone
144, and are moulded into a single module panel 145. The product
can be manufactured so that there are different features on the top
of the moulded panel to those on the bottom by using different dies
in the upper and lower rotating tracks 146 of the CFT machine. The
modules can also be manufactured using a single material only.
[0290] Upon arrival at the pressure forming zone it may be that the
second material feed entirely covers the first, however the feeds
may be arranged so that only a portion of the first feed 151 is
covered by the second 152 (as in FIG. 25). There may only be a thin
strip of the second material or additional material on top of the
first or second feed, and the positioning of the strip across the
width of the first feed can vary. These variations can be achieved
during manufacture by changing the positioning of the various
extruders relative to each other and by altering the width of the
feeds.
[0291] In some embodiments, the first material layer has a width WI
and a thickness TI and the second material layer has a width W2 and
a thickness T2. In one embodiment, WI is wider than WII. In one
embodiment, WI and WII are of equal widths. In one embodiment, WII
is wider than WI. In one embodiment, TI is thicker than TII. In one
embodiment, TI and TII are of equal thickness. In one embodiment,
TII is thicker than TI. In one embodiment, WI and WII are within
the range of 5 centimetres to 3 metres. In one embodiment, TI and
TII are within the range of 0.1 to 100 millimetres.
[0292] Additional material layers (whether extruded, roll fed, or
otherwise presented) can also be added prior to or after the
forming process. This allows for the continuous forming of a
multi-layered product, each material layer having a particular set
of properties which are advantageous to the product. In particular,
it may be desirable to add one or more reinforcing layers to the
product. Such layers may comprise a metal, cloth or fibreglass
mesh, jute or other fabric, glass fibre, carbon fibre, aluminium
sheet or a reinforcing polymer. These can be laid beneath, on top
of, or in between the other material layers prior to the forming
step, and may or may not undergo deformation during the forming
step. The thickness of the module panel 153 produced will be
determined in part by the materials selected and the number of
layers fed in. In one embodiment the thickness of the panels may be
within the range of about 0.5-55 mm.
[0293] The various layers of material may chemically bond together
prior to or during the forming step, however their ability to do so
will depend entirely on the materials selected. Where the materials
selected are not prone to chemical bonding, it may be necessary to
assist adhesion with a plasma or adhesive layer; or to feed in a
supplementary material with a chemical affinity for both of the
material layers. This can be applied in-line as an interposing
layer or deposit atop the first substrate material feed prior to
the introduction of the second. The various layers of material may
also mechanically bond together due to the surface finishes or
features between the layers.
[0294] A similar product can be achieved by the segmental injection
moulding of the roofing and/or cladding modules, however such a
process has a much slower output capacity. Large areas of product
need to be produced for building applications and it is desirable
to be able to produce these large surface area products in high
production volumes to make the process economical. Moreover, such a
process would result in a product containing weld lines and
injection moulding points. Weld lines are formed when two or more
molten polymer flows meet during the injection molding process.
This can occur when a polymer flow splits to go around an
interruption (e.g., a post that forms a hole) and then rejoins, or
when polymer melt fronts meet, from multiple injection points. This
can also occur when molten polymer meets a non molten polymer.
Consequently, a visible weld line is observed and the adhesion/bond
in this weld line at the interface is weaker than the balance of
the polymer within the product. Injection moulding points are the
area of a product where the heated material was fed into the mold
cavity. It is also difficult to make a product comprising more than
one layer of material using injection moulding, and injection
moulding can produce colour differences or variations that affect
the aesthetics of the final product. On the other hand, the
continuous forming machine can produce approximately 5-60 m of
product per minute, which makes it a preferable to use this
production method over other processes which could be used to
manufacture a 3D polymer product. The continuous forming machine
also produces a product that lacks weld lines or injection moulding
points, and optionally contains multiple layers of material.
[0295] A number of materials are suitable for use in the production
of a roofing and/or cladding product by a continuous forming
process; however it is most cost effective to produce the moulded
panel from a foamed material (e.g. foamed polycarbonate). Not only
does this reduce the amount of raw material required for
production, but also results in a lightweight product. This can be
advantageous in the retrofitting of roofing or cladding to an
existing building. For example, where there is a building with an
existing but degraded roof, re-roofing can occur by placing the new
lightweight shingle directly over top of the existing shingle
(usually asphalt shingle).
[0296] The foamed polycarbonate (or alternative substrate material)
may be accompanied by one or more additional materials to enhance
the properties of the product. A suitable material is Thermoplastic
Polyurethane (TPU), which can be fed into the moulding process
along with the polycarbonate as shown in FIG. 24. Foamed
polycarbonate and similar materials are favoured in roofing
products because they have fire retardant properties, but the
addition of a TPU layer improves the performance of the product
because the TPU has better durability, physical properties and
resistance to environmental wear. In particular, TPU is puncture
resistant, tear resistant, and UV resistant, and will retain the
aesthetic appeal of the product for a longer period of time
compared to polycarbonate alone.
[0297] The panel at its point of exit from the forming step is
shown in FIG. 26. The TPU layer (or a layer of alternative
material) 161 is moulded on top of the polycarbonate (or other
foamed material) layer 162 to form the body of the shingle module.
While it is desirable to use as much foamed material as possible to
reduce materials, in some embodiments, the TPU layer may cover the
region 163 which extends from the lower edge of the shingle up to a
line above the fastener fixing region. This is so that the areas of
the shingle exposed to the elements will have good durability, and
all of the areas of the shingle penetrated by fasteners will have
good tear resistance. An advantage to using TPU in this instance is
that the TPU, once punctured, will tend to contract around the
shank of the fastener to make a watertight seal.
[0298] Other materials which may be used include (but are not
limited to) polycarbonate (PC), general purpose polystyrene (GPPS),
polymethyl methacrylate (PMMA), polyethylene terephthalate (PET),
polyester methacrylate (PEM), polypropylene (PP), high impact
polystyrene (HIPS), acrylonitrile butadiene styrene (ABS),
polyester (PES), polyamides (PA), polyvinyl chloride (PVC),
polyurethanes (PU), polyvinylidene chloride (PVDC), polyethylene
(PE), polytetrafiuoroethylene (PTFE), polyetheretherketone (PEEK)
(polyetherketone), polyetherimide (PEI), Polyimide (PI), polylactic
acid (PLA), high impact polystyrene, acrylonitrile butadiene
styrene (ABS), acrylics, amorphous polymers, high density
polyethylene (HDPE), polyethylene terephthalate (PET), low density
polyethylene (LDPE), linear low density polyethylene (LLDPE),
medium density polyethylene (MDPE), cross linked polyethylene
(PEX), Ethylene vinyl acetate (EVA), Ethylene vinyl alcohol (EVOH),
thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO),
thermoplastic rubber (TPR), polypropylene (PP), Fluorinated
ethylene propylene (FEP), Polybutylene terephthalate (PBT),
Polyoxymethylene (POM), Polyphenylene oxide (PPO), Polypropylene
homopolymer (PP-H) Polypropylene copolymer (PP-C), silicon
polymers, styrene-acrylonitrile resin (SAN) and thermoplastic
rubber. The materials may be a blend of any or all of these. The
materials may also comprise additives to enhance properties such as
resistance to fracture, impact, ultraviolet light, and thermal or
tensile stresses. Materials which could also be considered in
manufacture are various polystyrenes, nylons, acrylics,
polyethylene, thermoplastic ethylene, polypropylene and phenolic,
and combinations of or containing these. No matter which materials
are chosen, the materials must be compatible so that they do not
delaminate. If the materials are not compatible, they may still be
used; however, a tie or bond layer must be introduced between them.
Examples of tie or bond layers include, but are not limited to,
ethylene vinyl acetate (EVA), thermoplastic polyolefin (TPO),
thermoplastic elastomer (TPE), silicon adhesives, epoxy adhesives,
and acrylic adhesives. One of skill in the art is capable of
choosing materials in the appropriate combinations to suit the
purposes described herein.
[0299] In various embodiments, the roofing module is flame
resistant, resistant to tearing (especially at puncture and
attachment points), able to be easily and cleanly cut with everyday
tools to aid installation, able to endure environmental and UV
exposure for over 20 years, able to endure cyclic freezing and
thawing without failure, resistant to delamination at temperatures
of between -40 and 100 degrees Celsius, impact resistant to a
reasonable extent, impenetrable by water even at fixing points, low
density, resistant to penetration and abrasion, colourfast,
resistant to microbial attack, compatible with adhesives and made
of materials which are stable in high humidity and wet conditions
and which retain their pliability at high and low temperatures and
which do not delaminate. All of these factors come into play when
choosing appropriate materials or material combinations for the
manufacture of the product. It is also desirable that the
material(s) used are non-toxic, or that at least the upper layers
of the product are (if a layered product is produced). This avoids
the prospect of toxic contamination in the event that water is to
be collected from one or more building surfaces for subsequent
use.
[0300] In some embodiments, the product may be produced from a
recyclable material or several different recyclable materials. The
combination of materials chosen in the manufacture of the product
is suitably one that can be recycled without first having to
dismantle the product into its constituent materials.
[0301] It is also important to choose a material with a low
co-efficient of thermal expansion to avoid warping along the length
of the product. If the material undergoes too much movement once
attached to the building surface it may fail at or between the
attachment points. Failure can also be a problem if a layered
product is produced with two or more materials having vastly
different thermal expansion co-efficients. In one embodiment, as
shown in FIGS. 39A-39B, thermal expansion and contraction can be
accommodated by moulding each module to have one or more
concertina-shaped features 291 that will expand or contract between
two fixing points 292.
[0302] In various embodiments, the roofing or cladding module may
incorporate additional properties or functionalities, including but
not limited to: a photovoltaic functionality; and/or (iii)
interconnection functionalities of photovoltaic areas, as described
in further detail below.
[0303] An alternative embodiment of the roofing and/or cladding
product is one that has all of the previously described features,
along with several additional features that make the product
suitable for use as part of a thermal energy recovery system. The
thermal energy can be obtained from a building surface that has
been exposed to sunlight for a period of time, although there are
other less significant sources that may contribute. The thermal
energy can then be exhausted or transferred to a passing fluid flow
(air being the most practical option) between the product and the
building surface, and subsequently used elsewhere in the
system.
[0304] A notable feature of this embodiment is that the building
underlay forms one boundary of the airway path. This embodiment is
different from box, round or other geometric closed cross section
shapes e.g. Corflute.RTM. roof or similar products, which are
segmented into confined zones for airflow that can become blocked.
The overall cost of materials is also reduced compared to box,
round or other geometric closed cross section shaped roofing
materials, which contain a backing material to define a
self-contained pathway for airflow. By contrast, this embodiment
regards the whole roof as one large surface of airflow, with the
cavity for airflow bounded on one side by the modules and the
roofing underlay on the other side.
[0305] As an example of such a system, FIG. 17 shows a roof
assembly involving a series of overlapping shingle modules. FIG.
18A shows an illustrative embodiment of two modules from side on.
The roofing underlay, such as a plywood surface and/or a
weatherproofing, insulating or highly reflective membrane 171, and
the layer of roofing shingle will be slightly set off from the
membrane so that there is a gap 181 to allow the passage of an air
stream between the two layers. The gap can be maintained by
features of shape integral to the shingle module moulding 182 or by
additional spacer/standoff components. Thus, the roof assembly
forms a single layer on top of the building underlay but the formed
features 182 (i.e., the profiled "feet" on the underside of the
underlapping region) make the stand-off for the air to pass
through. FIGS. 28B and 28C illustrates a tile at the edge of the
building surface and shows that a filter 184 can be placed between
the tile and the building underlay to allow for the passage of air
from the outside into the set off. It is most efficient to force
the air in the direction which it would naturally travel as it gets
hotter, i.e. from the bottom of the building surface to the top;
however alternative embodiments where the air is drawn across the
surface may also be conceived. The warm air can then be drawn
through inlet spigots 172 near the upper edge of the surface into a
central manifold duct 173. The warm air can be exhausted directly
to the atmosphere or used elsewhere in the building.
[0306] FIG. 29 shows how the energy from the warmed air can be used
elsewhere in the building. A fan 191 can be used to create airflow
to pull the air into the manifold duct. The warmed air can then be
expelled from the fan and used as the working fluid of a heat
exchanger 192 which can be employed as required, for example in
water heating 193 or air conditioning 194. Alternatively the hot
air can be directly used for heating applications. A flap valve
(not shown) may be installed to release hot air from the manifold
duct in the event that the fan fails. In some embodiments, the
airflow is reversible, such that warm air can be directed from the
heat exchanger to the roof in order to, for example, melt snow or
ice on the roof, purge residual moisture, or clear dust, dirt, or
debris from the system. Different manifolds may also be included to
direct warm air from one part of the roof to another depending on
the energy need. For example, air may be directed from a
sun-exposed portion of the roof to a shaded, snow-covered portion
in order to melt snow from that portion. Other variations would be
readily apparent to one of skill in the art.
[0307] In some embodiments, the speed of the fan is proportional to
the thermal energy received in a particular area of the roof. The
fan speed can be controlled in a variety of ways, including
temperature sensors or timers. In one embodiment, the fan speed is
controlled by driving the electric motor using one or more
dedicated PV cells on the surface of the roof. Thus, the fan
control will be directly related to how hot and/or intense the sun
is on certain parts of the roof at different times of the day. For
example, a building surface may be divided into sections in which
separate fans control airflow in each section, e.g. a standard
house might have four sections and each would have its own fan
which would increase in speed as the intensity of the sun increases
on that side of the roof and decrease in intensity as the sunlight
intensity decreases. As such, the fans in the different sections
will be increasing and decreasing in speed depending on whether the
particular section is in full sun or is partially shaded.
[0308] In one embodiment, a thermal embodiment of the module can be
moulded or profiled with a raised patterning 211 in the
underlapping region to define a tortuous pathway above the actual
or notional plane. This causes turbulence in the flow of the forced
fluid and therefore increases the convective heat transfer from the
module to the flowing fluid. As described in detail in the next
section, when PV functionalities are included on the module, the
feet also provide a passageway for the wiring for electrical
connection, e.g. to the PV cells, and allow for the incorporation
of electronics into the shingle. The feet may be designed to also
provide strength so that if a person walks on the shingle it will
not crush or fold under. The feet may also be designed to provide
an even airflow across the entire airway space. The feet may also
be designed to provide a minimal pressure drop between the air
intake and the air outlet. The feet may also be designed to provide
for the location and securing of cables and Tee fittings. The feet
may also be designed to provide a pathway for the cables and Tee
fittings that has minimal obstruction. The pathway for the cables
may be vertical, horizontal or diagonal.
[0309] There are many different patterns which will achieve this,
including the alternating pattern of mesa-like projections shown in
FIG. 31. Again the proportion of the shingle which is patterned may
vary in comparison to the size of the underlapping region. The
projections on the underside of the module need not be the same
across the entire width. In one embodiment, the projections
decrease in height as one moves across the width of the tile such
that there is a taper between the building surface and the
underlapping region of the module. Therefore, when an overlapping
module is placed on top, it is kept parallel to the building
surface. For example, the projections may reduce in size from about
21 mm to about 16 mm as one moves towards the back of the tile to
make it easier to fit the overlapping tile and keep the overlapping
tile parallel to the building surface. The shape and layout of the
projections may also vary.
[0310] In another embodiment, the patterning is in the form of a
corrugation between the module and the building surface. For
example, the module can be moulded into alternating parallel
grooves and ridges.
[0311] FIG. 30 shows how the profiles may have chamfered sides 201
or other features of shape to prevent water from gravity pooling in
the depressions when the underlying surface on which the product is
installed is an angled surface (for example a roof). A series of
fine ribs 212 moulded on the underside of the module, or roughened
surface texture, could alternatively or additionally be used to
create turbulence in the air flow. This will also create more
surface area for conductive heat transfer from the module. In some
embodiments, the geometry of the ribs or texturing can be chosen to
assist in heat transfer. For example, if the texture is, in
profile, a series of triangular peaks 213, this will allow more
efficient heat transfer to the passing air flow than if the texture
is, in profile, a series of square toothed projections.
[0312] As a further option, the surfaces which come into contact
when lapping could have complementary texturing on them to assist
their interengagement; for example, as shown in FIG. 32. A
thermally conductive paste or adhesive may additionally or
alternatively be applied between the contact surfaces to enhance
this, or the adhesive strip feature may be thermally conductive or
have a thermally conductive component. In one embodiment, the upper
and lower surfaces of the under and overlapping modules
respectively have a serrated profile 221 capable of interlocking
when the modules are in position. The serrations can be shaped so
that they "wedge" into each other and exert some degree of
compressive force against one another. The surface textures might
otherwise be splines, knurls, teeth or undulations of another type.
The texturing brings the surfaces into better contact so that there
is more surface area to facilitate heat transfer between the
lapping modules, and could also be used to aid in locating the
modules when they are installed on a building surface.
[0313] Although foamed materials reduce the cost and weight of the
product, the air inside the foam acts as a heat insulator. This can
be advantageous if you want to stop heat from the sun being
transferred into the ceiling cavity of the building, but it is not
ideal for heat transfer in an energy recovery system. Therefore the
thermal embodiment of the roofing and/or cladding product may be
adapted to increase its heat transfer capacity. In order to achieve
a foamed material with high heat conductivity, thermally conductive
particles (e.g. aluminium flakes) can be introduced into a polymer
prior to the forming process.
[0314] The particles help to create a heat pathway through the
material and increase the overall thermal conductivity
significantly. The particles may also provide structural
reinforcement to the material. For example, where a module moulded
from polycarbonate may have a thermal conductivity of 21 W/mK, the
same module moulded from a loaded polycarbonate blend having 30%
aluminium will have a thermal conductivity of 25 W/mK. A module
moulded from 3% foamed polycarbonate may have an even lower thermal
conductivity of 18 W/mK, but this can be improved to 24 W/mK with
the addition of 30% aluminium. The module material can be loaded
with the thermally conductive substance prior to the manufacture of
the module.
[0315] In order to prevent the final product from being too
brittle, a compatiblising polymer, such as an ionomer, can be
blended with the metal particles changing them from a reactive
contaminant to a reinforcement agent with elevated levels of
thermal conductivity. It is desirable to have some degree of
elasticity to the formed material for use in building product
applications.
[0316] Another embodiment of the roofing and/or cladding product of
the current invention is that which is adapted for use in a system
to generate electrical energy from solar power. Such products are
generally referred to as building integrated photovoltaic
products
[0317] ("BIPV"). As shown in FIG. 33, a series or array of
photovoltaic cells may be carried on the exposed region of the
module so that they capture photons when installed on a building
surface.
[0318] FIG. 34 shows a more detailed view of an energy generating
module, which may comprise one or more moulded material layers 241,
a solar array layer of connected photovoltaic cells 242, and an
optional transparent surface laminate layer 243. The energy
generating module may also comprise bonding/encapsulation/tie
layers to the front and/or back of the PV layer and may also
contain layers to stop the corrosion of the PV layer e.g.
polyethylene, EFTE, etc. On the solar array layer, typically or
optionally each of the photovoltaic cells in the row are connected
via two bus strips which extend the entire length of the module;
one running across the upper edges of the cells 244 and one running
across the lower edges 245. The advantage of this is that the bus
strips contact all of the cells so that only a single electrical
junction for each module need be connected to a main power take-off
on installation. A further option is to have the bus strip material
integrally moulded into the substrate panel during the forming
process.
[0319] FIG. 21B shows an exploded view of all of the layers of an
illustrative BIPV product. The transparent laminate 243 is over a
solar array layer of connected photovoltaic cells 242, which is
over a moulded material layer 241. The release sheet 113 of an
adhesive strip 121 are also shown. Optional adhesive, tie, or
bonding layers (not shown) may be added to the surface of any of
the layers.
[0320] Where it is necessary to join two modules across the width
of a surface (i.e. the electrical join is not at the main power
take-off junction, but between two modules), the method shown in
FIG. 35 can be used. The modules may be positioned end on end and
then an extra cell 251 can be placed over the discontinuity to
create an electrical connection between the modules while also
visually concealing the physical join line for improved
aesthetics.
[0321] The BIPV system may incorporate one or more "dummy" cells at
various locations across the surface of the roof. In a suitable
embodiment, the dummy cells will look identical to the rest of the
PV cells but will have no functionality. Because the dummy cell is
not active, it can be cut to fit the shape/space required and can
be penetrated safely if necessary. As shown in FIG. 40, two "dummy"
modules 301 are positioned in a lapping arrangement with a cutout
for a pipe 302 emerging from the building surface. BIPV modules 283
are shown on either side of the "dummy module. In addition, dummy
cells may be positioned at the ends of the building surface or may
be positioned at predetermined locations to provide for the
installation of various building features (satellite receivers,
antennas, pipes, etc.). One advantage of the dummy cells is that
they age identically to the rest of the PV cells and therefore the
entire roof surface maintains consistent aesthetic features over
time. In some embodiments, the dummy cells may be scribed with
markings that indicate that these cells can be safely penetrated,
e.g., for the installation of hardware or for fire safety.
[0322] The modules may be suitably joined by an overlapping module
(for weatherproofing) or an adhesive pad which extends across the
join and contacts the underside surfaces of both modules. It may
also be necessary to add a similar adhesive pad to the top side
surfaces, or to smear the reverse side of the joining cell with an
adhesive paste to secure the join.
[0323] While the PV cells could simply be placed on any top surface
of a module, in some embodiments the module is formed with a number
of relief features on its upper surface to locate and register the
PV cells. These can be more clearly seen in FIG. 36A. There are
recessed panels or pockets 261 in the cell bearing portion of the
shingle modules which locate each individual cell, and these are
separated by raised or recessed channels 262. The channels create
the impression of "tiled" roofing, and generally add to the
aesthetics of the product. Regions at the top and bottom of the
channels 263 provide space for the bus strips to pass through
between each pocket. It may be desirable that these regions are
less raised or lowered than the other parts of the channel so that
the bus strip does not have to be bent excessively when it is
adhered to the contours of the module substrate.
[0324] The exposed portion of the solar cell carrying module may be
profiled with two (or more) rows of pocketing so as to accommodate
two (or more) rows of solar cells upon a single module. In such a
case there will provision to locate a set of bus strips for each
row, or the profiling may provide for the location of a shared bus
strip(s) to be positioned between the rows.
[0325] The modules may be molded to accommodate various components
of the photovoltaic system. For example, as shown in FIG. 36B, the
upper surface of the underlapping region may include channels 264
configured to receive cables or wires of the photovoltaic array.
Moreover, the upper surface of the underlapping region may also
include formed cavities 265 configured to receive junction boxes
266, printed circuit boards (PCB), communication devices, cables,
wires, buses, components, cells, or diodes, and the like of the
photovoltaic array. Thus, the modules may contain all of the
hardware and software required to connect and regulate the PV
cells. Because there are no penetrations between the two
overlapping modules, the assembly can be completely waterproofed.
Furthermore, the upper surface of the exposed region may contain
scribings or markings, such as an impression or line corresponding
to the molded cavities, thus informing an installer or repair
person that various components are located in the space below. The
upper surface of the underlapping region may also include formed
markings 267 to indicate the correct location of wires and Tee
connections for wires, that are located in the pathway for airflow
181 underneath the underside of the underlapping region.
[0326] With the modules installed as shown in FIG. 33 most of cell
bearing portion of the module is exposed while the rest of the
module, including the fixing region and fastening means is
completely covered by neighbouring modules. This enables maximum
power generation but still provides some degree of protection for
the fastenings to reduce their rate of degradation and corrosion.
The upper electrical bus strip is also protected by the front edge
of the overlapping panel for both weather and aesthetic reasons.
Furthermore, because there are no penetrations that traverse the
entire thickness of the roofing material, this product overcomes
the limitations of existing solar products, which penetrate the
roof membrane with bolts, screws, or nails that must be caulked and
can leak. Wires 231 can also run between the bottom of the module
and the weatherproof underlay without penetrating the underlay (as
shown in FIG. 33).
[0327] The process by which the solar version of the roofing
product can be continuously manufactured is shown in FIG. 37. The
first, second and third steps of preparing, presenting and forming
the module are the same as those described previously, however the
fourth step 271 is the application of the solar array and the
optional fifth step 272 is the application of a laminate layer over
the solar cells which may have bonding between layers or adhesive
layers between them.
[0328] Once the module has been formed the PV cells can be
deposited on top in such a way as to be located by the relief
features on the upper surface. FIG. 37 shows the PV cells being fed
onto the substrate from a continuous roll feed. In this case the
upper and lower bus bars would need to be associated with the cells
in a prior step to form the roll.
[0329] Another option is to deposit the cells individually into the
pocketed relief features of the substrate and to subsequently apply
the bus bars (possibly separated by a spacing web) from a separate
roll feed. Yet another option is to feed the bus bars onto the
substrate and then overlay the solar cells.
[0330] An optional step is to apply a transparent laminate 273 to
protect the cells. It is convenient to pre-form (also by continuous
moulding 274) and apply the laminate in-line, as shown in FIG. 36,
so that the addition of this layer can occur without any increase
in the overall production cycle time. This can be laminated with
some degree of electrostatic or adhesive binding to increase
adhesion. While a variety of materials may be suitable as the
laminate, a suitable material is fluoropolymer. Ethylene
tetrafluoroethylene (ETFE) is an example of an appropriate
fluoropolymer, but other polymers able to remain optically
transparent may also be used. The fluoropolymer creates an
essentially "self cleaning" top surface so that performance of the
PV cells is not inhibited by deposits of dirt and debris.
Fluoropolymer is also very stable in ultraviolet light and usually
retains its light transmitting capacity for longer than glass,
which is another commonly used material in PV applications. It is
preferable to choose a material which would be able to maintain
light transmission during long periods (approximately 10 -25 years)
of environmental exposure. The laminate is applied also over region
117 to cover parts of the panel which are not directly exposed to
light but which will receive reflected light. This laminate also
gives superior durability to the exposed outer area of the panel
and may be used even without PV cells to provide greater long term
durability.
[0331] In another aspect, the present invention provides a building
integrated photovoltaic system which allows combined solar, ambient
and solar-generated heat to be collected and directed away from a
building surface and optionally used elsewhere. For instance, the
photovoltaic cells of the energy generating module could heat up
during operation. As well as potentially causing the interior of
the building to heat up as a result, the cells will also perform
less efficiently as they grow hotter. A further issue is that the
material around the cells will tend to expand due to the heat and
this can generate stresses and/or movement that may eventually lead
to product failure. Therefore, there is an added advantage in
combining the features of the BIPV product with those of the
thermal product, and using the hybrid module as part of a system
which generates electrical energy while also allowing heat energy
to be transferred away from the solar cells, recovered, and put to
use as desired. FIG. 38 shows a building on which the non energy
harvesting product 281, the thermal product 282 and the BIPV
product 283 have all been installed at different regions of the
same building according to energy and cooling requirements.
[0332] The foregoing description of the invention includes
preferred forms thereof. Modifications may be made thereto without
departing from the scope of the invention.
* * * * *