Lightweight, self-ballasting photovoltaic roofing assembly

• US RE38,988 E1
• Filed: 04/15/2003
• Issued: 02/28/2006
• Est. Priority Date: 04/08/1996
• Status: Expired due to Term

• Current Assignee: Sunpower Corporation (Totalenergies Se)
• Original Assignee: Thomas L. Dinwoodie
• Inventors: Dinwoodie, Thomas L.
• Primary Examiner(s): DIAMOND, ALAN D
• Application Number:
  US10/414,347
• Time in Patent Office: 1,050 Days
• Field of Search: 136/251, 136/246, 136/291, 521/733
• US Class Current: 136/251
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 2025/6007 by using form-fitting connection means, e.g. tongue and groove
• CPC Class Codes: F24S 2080/015 Plastics
• CPC Class Codes: F24S 25/11 using shaped bodies, e.g. concrete elements, foamed elements or moulded box-like elements
• CPC Class Codes: F24S 25/16 Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
• CPC Class Codes: F24S 40/85 Arrangements for protecting solar collectors against adverse weather conditions F24S40/10 takes precedence
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: Y02B 10/12 Roof systems for PV cells
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• 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) 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) 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 insulation block (322) below the spacers (314, 314′, 315, 315′). The geometry of the pre-formed spacers (112, 114, 116, 118, 120, 122, 314, 314′, 315, 315′) is such that wind tunnel testing has shown its maximum effectiveness in reducing net forces of wind uplift on the overall assembly. Such construction results in a simple, lightweight, self-ballasting, readily assembled roofing assembly which resists the forces of wind uplift using no roofing penetrations.

Claims

1. A photovoltaic assembly comprising:

a building rooftop;

a photovoltaic module having sides and having upper and lower surfaces; and

a spacer secured to the lower surface of the photovoltaic module and supported by the building rooftop;

said spacer sized and configured to define;

an open region beneath said lower surface, said open region extending between and in contact with the lower surface and in direct contact with the building rooftop, and

including access openings formed therein for fluidly coupling said open region to said upper surface;

said access openings extending along at least two sides of said photovoltaic module;

whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to a support surface the building rooftop.

2. The assembly according to claim 1 wherein said photovoltaic module has at least three sides.

3. The assembly according to claim 2 wherein said spacer comprises multiple spacer elements, at least one said spacer element secured to said lower surface along each of said at least three sides.

4. The assembly according to claim 2 wherein said access openings extend along said at least three sides of said photovoltaic module.

5. The assembly according to claim 1 wherein said at least two sides comprise two opposite sides of said photovoltaic module.

6. The assembly according to claim 1 wherein said access openings extend along about 5% to 50% of the length of at least two said sides.

7. The assembly according to claim 1 wherein said spacer has a lower spacer surface and an upper spacer surface tapered relative to said lower spacer surface, said tapered upper spacer surface supporting said photovoltaic module so said open region is a tapered open region tapering between said access openings along two of said sides.

8. The assembly according to claim 7 wherein said tapered upper spacer surface is at an angle of about 5°

-12°

relative to the lower spacer surface so said photovoltaic module is oriented at an angle of about 5°

-30°

relative to the support surface building rooftop.

9. The assembly according to claim 7 wherein said photovoltaic module has an upper side, said photovoltaic module extending downwardly from said upper side, and further comprising a wind deflection surface having an upper edge near said upper side, said wind deflecting surface extending downwardly and outwardly away from said upper side.

10. The assembly according to claim 9 wherein said upper edge is about the same elevation as the upper side.

11. The assembly according to claim 1 further comprising an insulation member securable to the spacer when said spacer is situated between said photovoltaic module and said insulation member.

12. The assembly according to claim 11 wherein said spacer and insulation member forms a variable-height support structure for said photovoltaic module so that said open region is a tapered open region tapering between said access openings along two of said sides.

13. The assembly according to claim 12 wherein said photovoltaic module has an upper side, said photovoltaic module extending downwardly from said upper side, and wherein said insulation member comprises a wind deflection surface having an upper edge near said upper side, said wind deflection surface extending downwardly and outwardly away from said upper side.

14. The assembly according to claim 13 1 wherein said spacer comprises a plurality of elongate tapered spacers spaced apart from one another.

15. The assembly according to claim 11 wherein said photovoltaic module, insulation member, and spacer have a combined weight of about two to four pounds per square foot.

16. The assembly according to claim 11 wherein said photovoltaic assembly comprises means for interengaging said photovoltaic module, spacer, and insulation member to create an integral assembly for resisting the forces of wind uplift thus enabling lower installed weight per unit area.

17. The assembly according to claim 1 wherein said photovoltaic assembly comprises means for interlocking one said photovoltaic module assembly to another said photovoltaic module assembly.

18. The assembly according to claim 1 wherein said photovoltaic module and spacer have a combined weight of about two to four pounds per square foot.

19. A photovoltaic assembly, The assembly according to claim 1 further comprising:

a plurality of said spacer, said plurality of said spacer comprising spacers configured for disposal on top of a building roof the building rooftop;

and

a plurality of said photovoltaic module, said plurality of said photovoltaic module comprising photovoltaic modules having sides and disposed on top of said spacers to form a photovoltaic array; and

said spacers;

being arranged in a geometry which generally follows the sides of said photovoltaic modules; and

having openings that are between about 5% and 50% of the length of at least two sides of each photovoltaic module;

whereby said geometry enables said photovoltaic assembly to resist forces of wind uplift .

20. The assembly of claim 19 wherein said spacers have a top surface which is joined to said photovoltaic modules, forming an integral unit.

21. The assembly of claim 19 wherein said spacers are positioned adjacent to one another with said photovoltaic modules spaced apart from one another, whereby water may drain between said photovoltaic modules.

22. The assembly of claim 19 further comprising perimeter ties situated around the photovoltaic array and joined with said photovoltaic array to make an integral array assembly.

23. The assembly of claim 22 wherein said perimeter ties are joined with one another whereby the integral array assembly is tied together and strengthened.

24. The assembly according to claim 22 wherein said perimeter ties comprise a chosen one of concrete pavers and hollow metal flashing units.

25. The assembly of claim 19 wherein said assembly further comprises means for resisting forces of wind uplift sufficiently to eliminate the need for penetrations of a building roof the building rooftop.

26. The assembly of claim 19 wherein said spacers are preformed spacers.

27. The assembly of claim 19 wherein said spacers have a tapered profile for orienting the photovoltaic modules in a direction for increased sun exposure.

28. The assembly of claim 27 wherein said spacers have tapered profiles with first outwardly and downwardly tapered portions supporting said photovoltaic modules and defining a tapered air-space and second outwardly and downwardly tapered portions, whereby wind is caused to flow over the spacers and not underneath the photovoltaic modules,

whereby internal pressures within the tapered air-space created by the spacers offset external pressures which aids the overall assembly in resisting net forces of wind uplift.

29. The assembly of claim 19 wherein said spacers are sized to orient the photovoltaic modules at an angle of about 5°

-12° and

create a tapered air space beneath the photovoltaic modules.

30. The assembly according to claim 19 wherein said photovoltaic array has a weight of about two to four pounds per square foot.

58. The assembly according to claim 1 wherein said photovoltaic module and spacer have a combined weight of about 1.67-5.0 pounds per square foot.

67. The assembly according to claim 19 wherein said photovoltaic assembly comprises means for interlocking one said photovoltaic assembly to another said photovoltaic assembly.

73. The assembly according to claim 1 wherein said assembly further comprises means for resisting forces of wind uplift sufficiently to eliminate the need for penetrations of the building rooftop.

74. The assembly according to claim 19 wherein the photovoltaic assembly is mountable to a building roof without forming penetrations through the building rooftop.

31. A photovoltaic roofing assembly, comprising:

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

a plurality of spacers configured for disposal on top of said insulation blocks;

a plurality of photovoltaic modules having first, second, third and fourth sides and disposed on top of said spacers to form a photovoltaic array; and

said spacers;

being arranged in a geometry which generally follows the sides of said photovoltaic modules; and

having openings that are between 5% and 50% of the length of at least two each of the first, second, third and fourth sides of each photovoltaic module;

whereby said geometry enables said photovoltaic assembly to resist forces of wind uplift.

32. The assembly of claim 31 wherein each of said insulation blocks have adjoining sides with a joint disposed between said sides for water drainage.

33. The assembly of claim 31 wherein said insulation blocks have top surfaces which are joined to the spacers which in turn are joined to photovoltaic modules, forming three-part integral units.

34. The assembly of claim 31 wherein said spacers are sized to orient the photovoltaic modules at an angle of about 5°

-12° and

create a tapered air space beneath the photovoltaic modules.

35. The assembly according to claim 31 wherein said photovoltaic array has a weight of no more than about four pounds per square foot.

68. The assembly according to claim 33 wherein said photovoltaic roofing assembly comprises means for interlocking one said integral unit to another said integral unit.

75. The assembly according to claim 31 wherein the photovoltaic roofing assembly is disposed on the roofing membrane without forming penetrations through the roofing membrane.

36. A photovoltaic roofing assembly comprising:

a plurality of photovoltaic assemblies, each said photovoltaic assembly comprising;

a photovoltaic module having upper, lower, and lateral sides and having upper and lower surfaces; and

a variable-height spacer secured to the lower surface of the photovoltaic module so to orient said photovoltaic module at an angle with said lateral sides extending downwardly from said upper side to said lower side, said angle being about 5°

-30°

from horizontal;

said spacer sized and configured to define;

a tapered open region beneath said lower surface; and

access openings along said upper and lower sides fluidly coupling said open region to said upper surface;

whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to a support surface; and

means for interengaging adjacent photovoltaic assemblies into an array of photovoltaic assemblies, said array defining a perimeter.

37. The assembly according to claim 36 57 wherein said perimeter assembly comprises a concrete paver.

38. The assembly according to claim 36 wherein said photovoltaic assembly further comprises a wind deflection surface, having an upper edge near the upper side, extending downwardly and outwardly away from said upper side.

39. The assembly according to claim 38 wherein said spacer provides said wind deflection surface.

40. The assembly according to claim 36 wherein said array plurality of photovoltaic assemblies has a weight of no more than about four pounds per square foot.

57. The assembly according to claim 36 further comprising a perimeter assembly, along said perimeter, interlocking with said photovoltaic assemblies.

59. The assembly according to claim 36 wherein said photovoltaic module and spacer have a combined weight of about 1.67-5.0 pounds per square foot.

63. The assembly according to claim 36 wherein said photovoltaic module and spacer have a combined weight of about two to four pounds per square foot.

76. The assembly according to claim 36 wherein the photovoltaic assemblies are mountable to a building rooftop without forming penetrations through the building rooftop.

41. A method of making a photovoltaic roofing assembly, comprising the following steps:

joining a spacer to a photovoltaic module having first, second, third and fourth sides;

sizing and positioning said spacer to provide an open region beneath said photovoltaic module and openings into said open region on at least two , the openings extending along about 5% to 50% of each of the first, second, third and fourth sides of said photovoltaic module to reduce wind uplift forces on the photovoltaic module;

joining an insulation layer to said spacer to create a three-part integral assembly; and

installing in the field said three-part integral assembly as a layer on top of a roofing membrane without forming penetrations through a roof surface;

whereby the completed assembly resists the forces of wind uplift.

42. The method of claim 41 further comprising the step of sizing said openings to comprise about 5% to 50% of the length of at least two sides of said photovoltaic module.

43. The method of claim 41 further comprising the step of providing said openings on all sides of said photovoltaic module.

44. The method of claim 41 further comprising the step of configuring said spacer to have a tapered surface to which said photovoltaic module is joined, said tapered surface having an angle of about 5°

-30°

from horizontal thereby forming said open region as a tapered open region.

45. The method according to claim 41 further comprising the step of providing said integral assemblies assembly with interengagable lateral edges, and said installing step is carried out so that comprises installing a first said integral assembly and a second said integral assembly adjacent to one another with said lateral edges of adjacent integral units are said first integral assembly and said second integral assembly interengaged.

46. The method according to claim 41 further comprising the steps of:

installing a plurality of said integral assemblies assembly to form an array of said integral assemblies, said array having a periphery; and

joining perimeter ties to said periphery to stabilize said array.

47. A method of making a photovoltaic roofing assembly, comprising the following steps:

joining a spacer to a photovoltaic module to create a two-part integral assembly;

sizing and positioning said spacer to provide an open region beneath said photovoltaic module and openings into said open region to reduce wind uplift forces on the photovoltaic module;

configuring said spacer to support said photovoltaic module in a manner to form said open region as a tapered open region;

positioning said openings on at least two sides of said photovoltaic module, said two sides being opposite sides of said photovoltaic module, said tapered open region tapering between said openings on said two opposite sides;

installing in the field said two-part integral assembly as a layer above a roofing membrane;

whereby the completed assembly resists the forces of wind uplift.

48. The method of claim 47 further comprising the step of joining an insulation layer to said spacer to create a three-part integral assembly.

49. The method of claim 47 wherein said spacer configuring step is carried out so that said as to provide a tapered surface has having an angle of about 5°

-30°

.

50. The method of claim 47 wherein said installing step is carried out without forming penetrations through, or adhering the unit to, a roof surface.

51. The method according to claim 47 further comprising the steps of:

installing a plurality of said integral assemblies assembly to form an array of said integral assemblies, said array having a periphery; and

joining perimeter members to said periphery to stabilize said array.

60. The assembly according to claim 47 further comprising limiting the two-part integral assembly to a combined weight of about 1.67-5.0 pounds per square foot.

64. The assembly according to claim 47 further comprising limiting the two-part integral assembly to a combined weight of about two to four pounds per square foot.

69. The method according to claim 47 wherein the installing step comprises interengaging adjacent integral assemblies.

77. The method according to claim 47 wherein the installing step is carried out without forming penetrations through the roofing membrane.

52. A photovoltaic assembly comprising:

an array of interlocking photovoltaic units, said array having a perimeter, each said photovoltaic unit comprising;

a photovoltaic module having an upper surface and first, second, third and fourth sides;

an insulation layer;

a spacer coupling the photovoltaic module and the insulation layer and defining an open region therebetween, the spacer extending along each of the first, second, third and fourth sides; and

an access opening fluidly coupling said upper surface of said photovoltaic module and the open region, the openings extending along about 5% to 50% of each of the first, second, third and fourth sides; and

said array having a weight of about two to four pounds per square foot;

whereby the configuration of the photovoltaic assembly resists wind uplift without the need for roof surface penetrating elements.

53. The photovoltaic assembly according to claim 52 further comprising a perimeter assembly joined to said perimeter of said array.

54. A method for making a photovoltaic roofing assembly comprising the following steps:

selecting a photovoltaic unit having an outer photovoltaic module, an insulation layer, and a spacer coupling the photovoltaic module and insulation layer to define an open region therebetween, the outer photovoltaic module having an outer surface and first, second, third and fourth sides;

the selecting step comprising the step of selecting a photovoltaic unit weighing no more than about four pounds per square foot;

placing a plurality of said photovoltaic units on a roof surface without securing the units to the roof surface to form an array of said photovoltaic units;

said selecting and placing steps further comprising the step of providing at least one access opening extending along about 5% to 50% of each of the first, second, third and fourth sides for each said photovoltaic unit thereby fluidly coupling the outer surface of said photovoltaic module and said open region; and

surrounding the array with a perimeter assembly without securing the perimeter assembly to the roof surface.

70. The method according to claim 54 wherein the placing step comprises interengaging adjacent photovoltaic units.

55. A photovoltaic assembly comprising:

a photovoltaic module having sides and having upper and lower surfaces; and

a spacer secured to the lower surface of the photovoltaic module, the spacer being mountable directly to a building rooftop;

said spacer sized and configured to define;

an open region beneath said lower surface, said open region extending between and in contact with the lower surface and in direct contact with the building rooftop, and

including access openings formed therein for fluidly coupling said open region to said upper surface;

said access openings extending along at least two sides of said photovoltaic module;

whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to the building rooftop.

61. The assembly according to claim 55 wherein said photovoltaic module and spacer have a combined weight of about 1.67-5.0 pounds per square foot.

65. The assembly according to claim 55 wherein said photovoltaic module and spacer have a combined weight of about two to four pounds per square foot.

71. The assembly according to claim 55 wherein said photovoltaic assembly comprises means for interlocking one photovoltaic assembly to an adjacent photovoltaic assembly.

78. The assembly according to claim 55 wherein the photovoltaic assembly is mountable to the building rooftop without forming penetrations through the building rooftop.

56. A photovoltaic/building rooftop assembly comprising:

a building rooftop;

a photovoltaic module having sides and having upper and lower surfaces; and

a spacer secured to the lower surface of the photovoltaic module to create a photovoltaic assembly, the spacer being mounted directly to the building rooftop to create a photovoltaic/building rooftop assembly;

said spacer sized and configured to define;

an open region beneath said lower surface, said open region extending between and in contact with the lower surface and in direct contact with the building rooftop, and

including access openings formed therein for fluidly coupling said open region to said upper surface;

said access openings extending along at least two sides of said photovoltaic module;

whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to the building rooftop.

62. The assembly according to claim 56 wherein said photovoltaic module and spacer have a combined weight of about 1.67-5.0 pounds per square foot.

66. The assembly according to claim 56 wherein said photovoltaic module and spacer have a combined weight of about two to four pounds per square foot.

72. The assembly according to claim 56 wherein said photovoltaic/building rooftop assembly comprises means for interlocking one said photovoltaic assembly to another said photovoltaic assembly.

79. The assembly according to claim 56 wherein the photovoltaic assembly is mounted to the building rooftop without forming penetrations through the building rooftop.

80. A photovoltaic assembly comprising:

a building rooftop;

a photovoltaic module having sides and having upper and lower surfaces; and

a plurality of spacers secured to the lower surface of the photovoltaic module and supported by the building rooftop;

said spacers sized and configured to define;

an open region beneath said lower surface, said open region extending between and in contact with the lower surface and in direct contact with the building rooftop, and

including access openings formed therein for fluidly coupling said open region to said upper surface;

said access openings extending along at least two sides of said photovoltaic module;

whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to the building rooftop.