Form-fitting solar panel for roofs and roof vents

• US 8,607,510 B2
• Filed: 10/24/2007
• Issued: 12/17/2013
• Est. Priority Date: 10/25/2006
• Status: Active Grant

• Current Assignee: O'Daniels LLC
• Original Assignee: Gregory S. Daniels
• Inventors: Daniels, Gregory S.
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): Ference, James
• Application Number:
  US11/923,456
• Publication Number:
  US 20080098672A1
• Time in Patent Office: 2,246 Days
• Field of Search: 521/733, 521/98, 523/021, 527/481, 524/60, 524/61, 524/62, 126/622, 126/621, 126/623, 136/245, 136/251, 136/244, 136/206, 136/232
• US Class Current: 52/173.3
• CPC Class Codes: E04D 1/2918 the fastening means taking hold directly on adjacent elements of succeeding rows
• CPC Class Codes: E04D 1/30 Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles E04D3/40 takes precedence
• CPC Class Codes: E04D 2001/309 Ventilation tiles
• CPC Class Codes: H02S 20/25 Roof tile elements
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A roof of a building is provided. The roof comprises a roof frame, a layer of curved roof cover elements (e.g., tiles) above the roof frame, and a solar panel secured to one or more of the roof cover elements. The solar panel substantially conforms to one or more curved surfaces of the one or more roof cover elements. Another aspect provides a roof comprising a roof frame, a layer of curved roof cover elements (e.g., tiles) above the roof frame, a vent member within the roof cover element layer, and a solar panel. The vent member has a curved surface and is sized and shaped to mimic the appearance of one or more of the roof cover elements. The vent member also has an opening allowing a ventilation airflow from the building interior toward an airspace above the vent member and the roof cover element layer. The solar panel is secured to and substantially conforms to the curved surface of the vent member.

Claims

1. A roof member configured to form a portion of the top surface of a roof, the roof member comprising:

a roof member body having a curved surface, wherein the body comprises a roof tile or shingle, the roof tile or shingle supported on one or more battens, the roof tile or shingle overlapping a portion of an adjacent roof tile or shingle; and

a solar panel secured to and substantially conforming to the curved surface, wherein the solar panel comprises a cushioned-backing material adhered to the curved surface of the body, a flexible sheet on the cushioned-backing material, and a solar cell on the flexible sheet, wherein the solar cell, flexible sheet, and cushioned-backing material each conform to the curved surface and are each flexible to cooperatively bend while joined together, to stably conform to different curved shapes of roof tiles or shingles, including curved shapes of S-shaped tiles and M-shaped tiles.

2. The roof member of claim 1, wherein the body comprises a roof tile.

3. The roof member of claim 1, wherein the roof tile is S-shaped or M-shaped.

4. The roof member of claim 1, wherein the body comprises a portion of a vent which comprises:

a primary vent member having an opening allowing a ventilation airflow between regions below and above the primary vent member; and

a secondary vent member forming at least a portion of the body, the secondary vent member having a curved surface, the secondary vent member being positioned above the primary vent member to prevent ingress of water through the opening while allowing said ventilation airflow to travel from the region below the primary vent member through the opening toward an airspace above the secondary vent member.

5. The roof member of claim 1, wherein the flexible sheet comprises a flexible stainless steel sheet.

6. The roof member of claim 1, wherein the flexible sheet and the solar cell are encapsulated in a polymer, and bonded to the cushioned backing material.

7. A roof member configured to form a portion of the top surface of a roof, the roof member made by a method comprising:

providing a roof member body having a surface, wherein the body comprises a roof tile or shingle, the roof tile supported on one or more battens, the roof tile or shingle overlapping a portion of an adjacent roof tile or shingle;

providing a flexible, form-fitting solar panel, wherein the solar panel comprises a cushioned-backing material, a flexible sheet on the cushioned-backing material, and a solar cell on the flexible sheet, wherein the solar cell, flexible sheet, and cushioned-backing material of the solar panel are each flexible to cooperatively bend while joined together, to stably conform to different curved shapes of roof tiles or shingles, including curved shapes of S-shaped tiles and M-shaped tiles; and

securing the cushioned-backing material of the solar panel to the surface of the roof member body such that the solar panel substantially conforms to the surface.

8. The roof member of claim 7, wherein the surface is curved.

9. The roof member of claim 7, wherein the surface is flat.

10. The roof member of claim 7, wherein providing the solar panel comprises encapsulating the flexible sheet and the solar cell in a polymer, and bonding the flexible sheet and the solar cell to the cushioned backing material.