FIELD OF THE INVENTION

[0001] The present invention relates to solar panel modules, and more particularly a novel solar panel module configured to be usable as a load- bearing structural member for a residence or commercial building.

BACKGROUND

[0002] Traditional solar or photovoltaic panels are not integrated into the roofs structure and instead must be affixed to the exterior of a building's roofing structure. To many, this is not aesthetically desirable. Additionally, since traditional, non-integrated solar or photovoltaic panels cannot otherwise contribute in a load-bearing fashion to the roofing structure, the material roofing costs are not offset by the use of such solar paneling. Moreover, the cost of adding traditional solar photovoltaic or thermal solutions to a building's roofing structure also has hidden costs associated with the additional engineering of the roof cavity to make sure that the structure of the roof can handle the new loads being imposed onto the original engineering of the roof framing (snow loads, snow drifting, wind and wind up lift). Still additional drawbacks associated with traditional, non-integrated solar or photovoltaic panels include having to uninstall such panels whenever the building needs to be re-roofed, for example, or when the panels reach their natural technological end of life, e.g., 17 - 20 years. Thus, there is a need in the art for solar panel modules configured as load-bearing structural roofing members which are both more aesthetically and economically desirable by virtue of being integral with the roof. SUMMARY OF THE INVENTION

[0003] Disclosed and claimed herein is a load-bearing solar panel module for integration with a building roofing structure which includes a first extruded structural rail and a second extruded structural rail aligned parallel to the first extruded structural rail. The solar panel module further includes a first extruded cross beam coupled to a first end of each of the first and second extruded structural rails, such that the first extruded cross beam is aligned perpendicular to and between such first and second extruded structural rails. In addition, a second extruded cross beam is coupled to a second end of each of the first and second extruded structural rails, such that the second extruded cross beam is also aligned perpendicular to and between such first and second extruded structural rails.

[0004] The solar panel module further includes at least one middle component aligned perpendicular to and coupled to each of the first and second extruded structural rails and between the first end and the second end of the first and second extruded structural rails. The solar panel module is configured such that the first and second extruded structural rails, the first and second extruded cross beams and the at least one middle component are coupled together into a structural encasement which exhibits load-bearing properties when integrated into a roofing structure of a commercial or residential building. Finally, the solar panel module includes at least one of a plurality of solar photovoltaic cells and a plurality of thermal vacuum tubes disposed within the above structural encasement.

[0005] Other aspects, features, and techniques of the invention will be apparent to one skilled in the relevant art in view of the following description of the exemplary embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The features, objects, and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout, and wherein:

[0007] FIG. 1 illustrates an exploded view showing the individual components of a solar panel module configured in accordance with the principles of the invention;

[0008] FIG. 2 illustrates an assembled view of the solar panel module of FIG. 1; and

[0009] FIG. 3 illustrates another example of a thermal vacuum tube assembly usable in combination with the solar panel module of FIGs. 1 and 2.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Overview of the Disclosure

[0010] Disclosed herein is a prefabricated structural solar roof panel module, configured to function as a load-bearing structural member of the roofing structure of a residence or commercial building. In certain embodiments, the solar panel modules disclosed herein are capable of generating electric power for general power usage and hot water for air conditioning and space heating.

[0011] One aspect of the invention is to provide a novel prefabricated solar panel module that substantially enhances the building structural soundness by virtue of being integral with the overall structural system of the building, while at the same time providing for an efficient renewable source of energy. A panel module so configured may save time, labor, and costs of roof installation by accurate spaced alignment, with the built-in rafter/rails providing the main structural strength and stiffness. To that end, the solar panels may preferably be designed and built to meet the requirements for structural loadings, as specified in the International Building Code (IBC) and/or the International Residential Code (IRC), including the ability to handle snow loads, wind and wind uplift.

[0012] By virtue of being integral with the roofing structure, the novel solar panel module disclosed and claimed herein effectively replaces traditional construction methods and materials used to complete a building's roofing structure. As such, the cost associated with the presently disclosed novel solar panel module to be installed into the cavity of a roof as a load- bearing structural component may be roughly equal to the same cost associated with building out the same roof cavity using traditional framing material and the labor costs.

[0013] Still another aspect of the novel solar panel modules disclosed and claimed herein is that they are fully upgradable, as technology evolves, without having to be un-installed, and that they have an expected life that approximates that of a typical residential or commercial roof structure.

[0014] It should further be appreciated that the novel solar panel modules disclosed and claimed herein may be customized on a regional or customer- specific basis for purposes of hurricane resistance and snow load allowances.

Additionally, the novel solar panel modules disclosed and claimed herein may be customized for local climate to be fully thermal or fully photovoltaic based on HVAC needs of the installer, all while satisfying all load-bearing requirements, e.g., IBC and IRC requirements.

[0015] As used herein, the terms "a" or "an" shall mean one or more than one. The term "plurality" shall mean two or more than two. The term "another" is defined as a second or more. The terms "including" and/or "having" are open ended (e.g., comprising). Reference throughout this document to "one embodiment", "certain embodiments", "an embodiment" or similar term means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner on one or more embodiments without limitation. The term "or" as used herein is to be interpreted as inclusive or meaning any one or any combination. Therefore, "A, B or C" means "any of the following: A; B; C; A and B; A and C; B and C; A, B and C". An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.

Description of an Exemplary Embodiments

[0016] Referring now to FIG. 1, depicted is an exploded view of a solar panel module 100, configured as a hybrid photovoltaic and solar-thermal panel in which both photovoltaic cells and an array of thermal pipe vacuum tube solar thermal collectors may be integrated into a residential or commercial roofing structure. However, it should be appreciated that in other embodiments, the solar panel module 100 may be configured as only a solar- photovoltaic system or as a solar-thermal system, rather than a hybrid system of both. [0017] As shown, the panel module comprises various individual components which contribute to both its energy producing and load-bearing properties. In particular, the panel comprises a first extruded structural rail 105 (depicted as the female component) and a second extruded structural rail 110 (depicted as the male component). In the embodiment of FIG. 1, the first and second extruded structural rails 105 and 110 form the two longitudinal sides of the module 100. The first and second extruded structural rails 105 and 110 may be preferably fabricated from sheet metal material, such as zinc coated steel sheet or aluminum having a minimum thickness, e.g., 1/8 inch. The thickness of the material used to fabricate the extruded structural rails 105 and 110 may be a function of the strength of the material used and the

IBC or IRC requirements for the particular building to be constructed.

[0018] Module 100 further comprises a first extruded cross beam 115a and a second extruded cross beam 115b, which serve as end enclosures for the module 100 in its assembled form. The first and second extruded cross beams 115a and 115b are oriented essentially perpendicular to the first and second extruded structural rails 105 and 110. Disposed between the first and second extruded cross beams 115a and 115b, and also oriented essentially perpendicular to the first and second extruded structural rails 105 and 110, is a middle component 120. The first and second extruded cross beams 115a and 115b, together with the middle component 120, function to provide lateral stability to the module assembly. As with the first and second extruded structural rails 105 and 110, the first and second extruded cross beams 115a and 115b and middle component 120 may be fabricated from sheet metal material, such as zinc coated steel sheet or aluminum having a minimum thickness, e.g., 1/8 inch, where the thickness of the material used is a function of both the properties of the material itself and the IBC or IRC requirements for the particular building to be constructed. [0019] Continuing to refer to FIG. 1, module 100 may further comprise certain insulation-related components, such as a polystyrene insulation component 125, which may be situated between two stone fiberboard panels 130a and 130b. An insulation subassembly comprised of the polystyrene insulation component 125 and fiberboard panels 130a and 130b, together with an APA plywood sheathing (exposure 1) 135, may be used to provide the insulation requirement for the roof, and the finish surface for the underside of the roof.

[0020] Disposed above the insulation subassembly may be a sun-heated vacuum tube subassembly comprised of a metal reflector 140, a tube stabilizer/support component 145, thermal vacuum tubes 150, and a manifold 155. The metal reflector is configured to improve the system's ability to capture heat energy by focusing more direct and ambient sunlight onto the vacuum tubes 150, while the tube stabilizer/support component 145 supports one end of the vacuum tubes 150 within the first and second extruded structural rails 105 and 110. A manifold 155 is provided on the opposite end of the vacuum tubes 150 as a means to facilitate the flowing of the heated water to an external tank or water distribution system (not shown). In this fashion, the solar irradiance on the vacuum tubes 150 may heat the water contained within the manifold 155 such that the water in the manifold 155 may reach temperatures between 155 °F and 195 °F, and may preferably reach a temperature of approximately 195 °F.

[0021] Since the embodiment of FIG. 1 depicts the solar panel module 100 as a hybrid photovoltaic and solar-thermal panel, it is further depicted as including a hybrid solar can 160 which houses one or more solar cell strings

(not shown). Additionally, the hybrid solar can 160 may further comprise a diurnal tracking system, such as the system disclosed and claimed in U.S. Publication No. 2010/0275902, entitled "Photovoltaic and Thermal Energy System." In particular, and as disclosed in U.S. Publication No. 2010/0275902, the hybrid solar can 160 may be configured to track the sun throughout the day in order to maximize the amount of power generated by the system. [0022] Rather than allowing the elevated temperatures of and around the solar cell string to degrade the efficiency of the system, as would typically occur, heat may be drawn away from the cells by using a cold water inflow 165 and a hot water outflow 170 for piping cold and hot water, respectively. In particular, the cold water inflow 165 is configured to pipe cold/cool water to cool the solar cell assembly, while the hot water outflow 170 removes the resulting heated water for potential use in a separate power generation system and/or for hot water consumption.

[0023] Finally, a single-ply tempered glass plate 175 may be used to cover the module 100 to protect the module 100 from the environment, while still allowing sun rays to reach both the vacuum tubes 150 and the solar photovoltaic cells (not shown) within the hybrid solar can 160. The assembled module 100 may then be integrated into the roofing structure of a building during the original construction process and in place of the standard roofing materials which would otherwise be used to form the roof.

[0024] It should also be appreciated that, while the module 100 of FIG. 1 has been depicted as a hybrid photovoltaic and solar-thermal panel having both photovoltaic cells and an array of heat pipe (thermal) vacuum tubes, the solar panel module 100 may alternatively be configured as only a solar- photovoltaic system or as a solar-thermal system, rather than a hybrid system of both. However, in such cases the module 100 would exhibit the same load-bearing properties described above, and as required to meet any IBC or IRC requirements.

[0025] Referring now to FIG. 2, depicted is an assembled view of the solar panel module 100 of FIG. 1. In particular, FIG. 2 shows the assembled solar panel module 200 having both a solar portion 210 and a thermal portion 220. As described above with reference to FIG. 1, the solar portion 210 may be comprised of a hybrid solar can 230 which houses one or more solar cell string(s) 240, and which uses water piping 250 to remove heat from the area around the cell string(s) 240. The thermal portion 220 contains the heat transfer components referenced above, including vacuum tubes 260. [0026] The solar portion 210 and the thermal portion 220 are then housed in an extruded, structural encasement comprised of first and second extruded cross beams 270a and 270b, along with middle component 280a, all situated between and perpendicular to first and second extruded structural rails 290a and 290b which form the two longitudinal sides of the module 200.

Additionally, it should be appreciated that the module 200 may also include a secondary middle component 280b in the event additional lateral strength is required.

[0027] As described above with reference to FIG. 2, the components which form the extruded, structural encasement of the module 200 may preferably be fabricated from sheet metal material, such as zinc coated steel sheet or aluminum having a minimum thickness, e.g., 1/8 inch, which is a function of both the strength of the material used and the IBC or IRC requirements for the particular building to be constructed.

[0028] It should be appreciated that the above-described components may be connected using various approaches, including, for example, interlocking joints, blind fasteners, snap-fit joints, and conventional screws. Additional connectors may be provided at both the eave and the ridge to secure the solar panel modules to each other and/or to make them integral with the structural roofing system. For aesthetic purposes, it may be preferable for the modules

200 to be connected together and to the roofing system so as to form an essentially flush exterior.

[0029] Numerous variations to the above-identified components are similarly within the scope of the invention. For example, FIG. 3 shows a vacuum tube arrangement 300 which, rather than utilizing the ten-tube configuration of FIGs. 1 and 2, instead utilizes 13 tubes having a close spacing, e.g., spacing 310. In certain embodiments, spacing 310 may be approximately equal to the outside diameter of the vacuum tubes plus approximately 1/8 inch. In any event, this closer spacing may allow the replacement of the corrugated metal reflector (e.g., reflector 140 of FIG. 1) with the sheet of flat reflective aluminum 320, as shown in FIG. 3. Moreover, since the module is preferably sealed, the aluminum need not be anodized. The closer spacing may also eliminate the need to use rubber grommets. With wider spacing, such as the case with FIG. 1 and 2, rubber grommets may be needed to hold the vacuum tubes in place.

[0030] It should further be appreciated that closer spacing between the vacuum tubes may also minimize the lost solar irradiance that would otherwise pass between the tubes. The rear flat reflector 320 of FIG. 3 may direct the remaining solar irradiance that passes through the narrower gap to the sides and rear of the tube absorbers.

[0031] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.