Thermally regulated photovoltaic roofing assembly

• US 5,505,788 A
• Filed: 06/29/1994
• Issued: 04/09/1996
• Est. Priority Date: 06/29/1994
• Status: Expired due to Term

• Current Assignee: Sunpower Corporation (Totalenergies Se)
• Original Assignee: Thomas L. Dinwoodie
• Inventors: Dinwoodie, Thomas L.
• Primary Examiner(s): Weisstuch, Aaron
• Application Number:
  US08/267,499
• Time in Patent Office: 650 Days
• Field of Search: 136/244, 136/246, 136/251, 136/291, 52/173.3
• US Class Current: 136/246
• CPC Class Codes: E04D 13/1693 the upper surface of the insulating material forming an inclined surface
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 2025/601 by bonding, e.g. by using adhesives
• CPC Class Codes: F24S 25/11 using shaped bodies, e.g. concrete elements, foamed elements or moulded box-like elements
• CPC Class Codes: F24S 25/15 using bent plates; using assemblies of plates
• CPC Class Codes: F24S 25/16 Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/33 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
• CPC Class Codes: F24S 25/40 using plate-like mounting elements, e.g. profiled or corrugated plates; Plate-like module frames extending in directions away from a supporting surface F24S25/10
• CPC Class Codes: F24S 40/85 Arrangements for protecting solar collectors against adverse weather conditions F24S40/10 takes precedence
• CPC Class Codes: F24S 60/10 using latent heat
• CPC Class Codes: H01L 31/0521 using a gaseous or a liquid coolant, e.g. air flow ventilation, water circulation
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10S 136/291 Applications

Abstract

A photovoltaic roofing assembly comprises a roofing membrane (102), a plurality of photovoltaic modules (104, 106, 108, 110) disposed as a layer on top of the roofing membrane (102), and a plurality of pre-formed spacers, pedestals or supports (112, 114, 116, 118, 120, 122) which are respectively disposed below the plurality of photovoltaic modules (104, 106, 108, 110) and integral therewith, or fixed thereto. Spacers (112, 114, 116, 118, 120, 122) are disposed on top of roofing membrane (102). Membrane (102) is supported on conventional roof framing, and attached thereto by conventional methods. In an alternative embodiment, the roofing assembly may have a tapered profile for orienting modules (204, 206, 208, 210) in a direction of increased sun exposure. Other embodiments include the use of phase change material for temperature regulation, and incorporating an insulation block into the assembly as a means of spacing and of building thermal control. Such construction results in a simple, readily assembled roofing assembly which regulates the temperature of the photovoltaic module and roofing membrane and avoids the need for rooting penetrations for hold-down to the building rooftop. Photovoltaic modules (104, 106, 108, 110) serve the purpose of electric generator, and in addition, the multiple purposes of ballast, UV block, and weather protector for the insulation block and roofing membrane below. A fluid convects within the passageways created by the spacers, transferring heat from the backside of the photovoltaic modules. Rainwater drains through the joints between the integral modules, onto and over the roofing membrane below.

Claims

1. A photovoltaic roofing assembly, comprising:

a roofing membrane;

a plurality of photovoltaic modules disposed as a layer on top of said roofing membrane, and

means for regulating the temperature of said photovoltaic modules.

2. The assembly of claim 1 wherein said means of temperature regulation includes a plurality of pre-formed spacers located below said photovoltaic modules, whereby said photovoltaic modules are separated from said roofing membrane by a pre-determined distance, thus enabling heat transfer from the backside of said photovoltaic modules to a convecting fluid.

3. The assembly of claim 2 wherein said spacers have a top surface which is joined to said photovoltaic modules, forming integral units.

4. The assembly of claim 3 wherein said integral units have adjoining sides and a joint is disposed between the photovoltaic modules of said integral units, whereby water may drain between said photovoltaic modules and whereby the pressure differential between the top and bottom sides of said photovoltaic modules due to windflow over the top of said photovoltaic modules is reduced.

5. The assembly of claim 4 wherein said integral units have a tapered profile, and the photovoltaic modules which are the top side of said integral units have a top surface which can be installed so as to face in a direction of increased sun exposure.

6. The assembly of claim 1 wherein said means of temperature regulation includes a phase change material together with a container for containing said phase change material, disposed as a layer below said plurality of photovoltaic modules.

7. The assembly of claim 6 wherein said container which contains said phase change material has a top surface which is joined to its respective photovoltaic module, forming a three-pan integral unit.

8. The assembly of claim 7 wherein each three-part integral unit has adjoining sides with a joint disposed between said sides for water drainage and for pressure equalization between the bottom and top sides of said three-part integral units.

9. The assembly of claim 8 wherein each of said three-pan integral units includes a container which is pre-formed to enable fluid convection along at least one surface to facilitate heat transfer away the phase change material which it contains.

10. The assembly of claim 9 wherein said three-pan integral unit has a tapered profile, and the photovoltaic module disposed as the top side of said three-part integral unit has a top surface which can be installed so as to face in a direction of increased sun exposure.

11. The assembly of claim 7 further including spacers which are joined on their top side to the bottom surface of said three-part integral units, with the bottom of said spacers resting on the roofing membrane.

12. The assembly of claim 11 wherein said three-part integral units with supporting spacers have adjoining sides and a joint disposed between said sides for water drainage and for pressure equalization between the bottom and top sides of said three-part integral units.

13. The assembly of claim 12 wherein said three-part integral units with supporting spacers have a tapered profile and the photovoltaic module disposed as the top side of said thru-part integral units has a top surface which can be installed so as to face in a direction of increased sun exposure.

14. The assembly of claim 12 wherein the container portion of said three-part integral units is an aluminum honeycomb.

15. The assembly of claim 14 wherein said three-part integral units have a tapered profile, and the top surface of said three-part integral units can be installed so as to lace in a direction of increased sun exposure.

16. A method of making a solar roofing assembly comprising:

assembling photovoltaic modules having a bottom surface bonded to supporting spacers, thereby forming integral units;

installing a roofing membrane over a roof;

installing said integral units as a layer on top of said roofing membrane, whereby the completed assembly limits the temperatures experienced by the photovoltaic modules and eliminates the need for roofing penetrations for hold-down of said integral units.

17. A method of making a photovoltaic roofing assembly, comprising installing in the field a roofing membrane;

installing in the field pre-formed spacers in substantially straight lines; and

installing photovoltaic modules on top of said pre-formed spacers;

whereby the completed assembly limits the temperatures experienced by the photovoltaic modules and eliminates the need for roofing penetrations for hold-down of any of its components.

18. A method of making a solar roofing assembly comprising:

assembling photovoltaic modules having a bottom surface bonded to a container containing a phase change material, thereby forming three-part integral units;

installing a roofing membrane over a roof;

installing said integral units as a layer on top of said roofing membrane using supporting spacers;

whereby the completed assembly has predetermined dimensions and edge connections which limit the temperatures experienced by the photovoltaic modules and eliminate the need for roofing penetrations for hold-down of its components.

19. A photovoltaic roofing assembly, comprising:

a roofing membrane;

a plurality of insulation blocks disposed as a layer on top of said roofing membrane;

a plurality of photovoltaic modules disposed as a layer on top of said insulation blocks; and

means for regulating the temperature of said photovoltaic modules.

20. The assembly of claim 19, wherein said means of temperature regulation includes pre-forming said insulation blocks with pre-determined grooves on their top surface, whereby a layer is formed on the top side of said insulation blocks which enables convective fluid flow for heat transfer away from the backside of said photovoltaic modules and allows pressure equalization between the bottom and top sides of said photovoltaic modules.

21. The assembly of claim 20 wherein each of said insulation blocks have adjoining sides with a joint disposed between said sides for water drainage.

22. The assembly of claim 21 wherein each of said insulation blocks has a top surface which is joined to its respective photovoltaic module, forming a two-part integral unit.

23. The assembly of claim 22 wherein each of said insulation blocks has a tapered profile, and said photovoltaic module disposed above said insulation block has a top surface which can be installed so as to face in a direction of increased sun exposure.

24. The assembly of claim 19 wherein said means of temperature regulation includes a plurality of pre-formed spacers which separate said photovoltaic modules from said insulation block, thus enabling heat transfer from the backside of said photovoltaic modules to a convecting fluid.

25. The assembly of claim 24 wherein each of said spacers has a top surface which is joined to its respective photovoltaic module, thus forming a two-part integral unit.

26. The assembly of claim 25 wherein each of said two-part integral units are attached on their bottom sides to the top surface of the insulation blocks, with a joint disposed between the sides of said two-part integral units for water drainage and for pressure equalization between the bottom and top sides of said two-part integral units.

27. The assembly of claim 26 wherein said two-part integral units have a tapered profile, and the photovoltaic module on the top side of said two-part integral units have a top surface which can be installed so as to face in a direction of increased sun exposure.

28. The assembly of claim 25 wherein each of said two-part integral units have adjoining sides with a joint disposed between said sides for water drainage and for pressure equalization between the bottom and top sides of the two-part integral units.

29. The assembly of claim 28 wherein each of said two-part integral units has a tapered profile, and the photovoltaic module on the top side of said two-part integral unit has a top surface which can be installed so as to lace in a direction of increased sun exposure.

30. The assembly of claim 19 wherein said means of temperature regulation includes a phase change material together with a container for containing said phase change material, disposed as a layer below said plurality of photovoltaic modules.

31. The assembly of claim 30 wherein said container has a top surface which is joined to its respective photovoltaic module, forming a two-part integral unit.

32. The assembly of claim 31 wherein said two-part integral units have adjoining sides with a joint disposed between said sides for water drainage and for pressure equalization between the bottom and top sides of said two-part integral units.

33. The assembly of claim 32 wherein the container portion of said two-part integral units is pre-formed to enable fluid convection along at least one surface to facilitate heat transfer away from the phase change material which it contains.

34. The assembly of claim 33 wherein said container has a tapered profile, and the photovoltaic module disposed above said container has a top surface which can be installed so as to face in a direction of increased sun exposure.

35. The assembly of claim 32 further including spacers which elevate said two-part integral units above said roofing membrane.

36. The assembly of claim 35 wherein said spacers have a tapered profile, and said two-part integral units disposed above said spacers have a top surface which can be installed so as to face in a direction of increased sun exposure.

37. The assembly of claim 35 wherein the container portion of said two-part integral units is an aluminum honeycomb which contains said phase change material.

38. The assembly of claim 37 wherein said spacers have a tapered profile, and said two-part integral units disposed above said spacers have a top surface which can be installed so as to face in a direction of increased sun exposure.

39. A method of making a solar roofing assembly comprising:

pre-forming an insulation block to include channels on its top surface;

assembling a photovoltaic module having a bottom surface bonded to said insulation block, thereby forming a two-part integral unit;

installing a roofing membrane over a roof;

installing said two-part integral units as a layer on top of said roofing membrane;

installing roofing pavers around the perimeter areas of said two-part integral units;

whereby the completed assembly limits the temperatures experienced by the photovoltaic modules and eliminates the need for roofing penetrations for hold-down of its components.

40. A method of making a photovoltaic rooting assembly, comprising installing in the field a roofing membrane over a roof;

installing in the field a plurality of insulation blocks disposed as a layer on top of said roofing membrane;

installing pre-formed spacers in substantially straight lines as a layer on top of said insulation blocks;

installing photovoltaic modules on top of said pre-formed spacers;

whereby the completed assembly limits the temperatures experienced by the photovoltaic modules and eliminates the need for roofing penetrations for hold-down of its components.

41. A method of making a photovoltaic roofing assembly, comprising assembling a photovoltaic module having a bottom surface attached to pre-formed spacers forming two-part integral units;

installing in the field a roofing membrane over a roof;

installing in the field a plurality of insulation blocks disposed as a layer on top of said roofing membrane;

installing said two-part integral units as a layer on top of said insulation blocks;

whereby the completed assembly limits the temperatures experienced by the photovoltaic modules and eliminates the need for roofing penetrations for hold-down of its components.

42. A method of making a solar roofing assembly comprising:

assembling a photovoltaic module having a bottom surface bonded to a container which contains a phase change material, thereby forming a three-part integral unit;

installing a roofing membrane over a roof;

installing a plurality of insulation blocks as a layer on top of said roofing membrane;

installing said three-part integral units as a layer on top of said insulation blocks;

whereby the completed assembly eliminates the need for roofing penetrations for hold-down of its components and limits the temperatures experienced by the photovoltaic modules.

43. A method of making a solar roofing assembly comprising:

assembling a photovoltaic module having a bottom surface bonded to a container which contains a phase change material, thereby forming a three-part integral unit;

installing a roofing membrane over a roof;

installing a plurality of insulation blocks as a layer on top of the roofing membrane;

installing spacers as a layer on top of said insulation blocks;

installing said three-part integral units as a layer on top of said spacers;

whereby the completed assembly eliminates the need for roofing penetrations for hold-down of its components and limits the temperatures experienced by the photovoltaic modules and roofing membrane.