CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application Serial Number 61/778,551 filed on March 13, 2013, the entire application being hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] This application relates to solar structures including direct-current powered buildings designed to operate completely off the grid and more particularly to building materials including hollow-core insulated planks and systems including building- integrated tracking photovoltaic systems especially useful for incorporation into same.

BACKGROUND OF THE INVENTION

[0003] Solar panels for use in commercial and residential environments are known. Solar panels are typically mounted on a mounting structure, which is supported on a mounting surface, such as a rooftop. However, fixed rooftop arrays are limited and less efficient due to their orientation to the sun. In addition, many mounting structures present too large a surface area to wind, and are therefore subject to strong wind uplift forces. [0004] Furthermore, building systems and structures that utilize solar-derived energy ideally should be as efficient as possible. However, current standard building materials do little to help make energy produced "off the grid" more feasible in terms of insulation capacity and strength for supporting solar panels and the like. SUMMARY OF THE INVENTION

[0005] The embodiments described herein relate to building materials and systems that are especially useful with curved structures that support and/or utilize photovoltaic panels.

[0006] In one embodiment, a roof material includes a curved plank of composite material having at least one hollow space within the plank and ends adapted to be joined with a further curved plank of composite material is disclosed.

[0007] In another embodiment, a building-integrated tracking photovoltaic (PV) array structure for a curved surface is disclosed. The array structure features, for example, a support structure having a pair of spaced apart sides joined by a pair of ends, with the sides defining a linear top piece joined to a pair of down pieces, each down piece being coupled to the top piece at an angle of less than ninety degrees, and a bottom piece forming a convex curve is disclosed. Each linear top piece and pair of ends further define a substantially rectangular mounting surface for a photovoltaic cell.

[0008] These and other aspects of the invention will be apparent upon reference to the following detailed description and figures. To that end, any patent and other documents cited herein are hereby incorporated by reference in their entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Fig. 1 schematically illustrates a side elevational view of a solar structure embodiment of the invention.

[0010] Fig. 2 depicts an enlarged view of the structure in Fig. 1 from line E to line G.

[0011] Fig. 3 depicts a simplified end elevational view of the structure in Fig. 1 to show the building- integrated tracking PV array, roof, floor and wall elements.

[0012] Fig. 4 illustrates an embodiment of a building-integrated PV tracking array support structure.

[0013] Fig. 5 shows an enlarged view of the array support structure featured in Fig. 4.

[0014] Fig. 6 depicts a side view of a roofing plank and supporting structure embodiment.

[0015] Fig. 7 illustrates an enlarged section taken at IB of Fig. 1.

[0016] Fig. 8 is an enlarged section taken at 2B of Fig. 1.

[0017] Fig. 9 depicts an individual roof plank embodiment.

[0018] Fig. 10 shows an alternate embodiment of a roof plank.

[0019] Figs. 11A and 1 IB illustrate further embodiments of a building-integrated tracking PV array system.

[0020] Fig. 12 depicts a roof plank manufacturing process. DETAILED DESCRIPTION OF THE INVENTION

[0021] Embodiments described herein relate to structures, building materials and systems designed to be especially useful with renewable energy such as a solar energy as opposed to traditional sources of energy, such as an electrical grid, natural gas pipelines, stored propane, and the like.

[0022] Consequently, embodiments herein relate to insulated concrete forms, for building structure walls up to the second floor level, Piekko Deltabeam™ (a type of steel form filled with concrete) flooring, and hollow core concrete planks for the second floor of building structures.

[0023] Other embodiments relate to full radius curved, open web triangular steel roof trusses located at certain intervals, such as 20 foot grid spacing.

[0024] Further embodiments relate to curved hollow core insulated roof materials, such as planks, made of a composite material such as alumina silica ceramic composite material and to manufacturing processes for same. [0025] Additional embodiments are directed to light weight (alumina silica ceramic or other composite material, including ceramic Matrix Composite (CMC) material) planks and to mechanized building-integrated tracking PV arrays, and support structures for such arrays, that can traverse the full curvature of a curved surface, such as a roof, of building, and that can be located on the centerlines of the grid/truss spacing.

[0026] A mechanized array may be driven by a series of gear motors, cables, counterweights and pulleys. Slip rings would allow transfer of DC power generated from the building-integrated tracking PV array to a fixed power distribution and management system. One or more computers can monitor and control the array and other systems.

[0027] Thus, a solar structure of the invention, i.e., a structure such as a silo or water tower that supports photovoltaic panels and/or a structure that both supports and utilizes at least a portion of the energy produced from the sun, will employ building materials that are especially useful for their strength, relatively light weight, stability, and/or insulating properties. [0028] To be completely independent of traditional energy supply sources, one or more of the following renewable energy technologies may be employed in addition to photovoltaic cells: Vertical Axis Wind Turbines (VAWT), Concentrated Solar Hydrogen Generators (CSHG), Fuel Cell Power Modules (converting H ₂ to DC power), and Hydrogen Generation Modules (electrolysis conversion of DC power to ¾) with low pressure storage.

[0029] With the combined sources of DC power and ¾ generation created from the sun and/or wind, the solar structure will consume the power on demand directly from a common battery buffer, with its operational power level maintained by the Energy Control Module (ECM). The ECM is a computer-based system that directs the excess power to be converted to ¾ and stored for future use when the sun does not shine and the wind does not blow. It will also direct the conversion of ¾ back into electricity on demand to maintain the batteries' operational levels. [0030] Additionally, the supply of H ₂ created and stored by the solar structure can be utilized as an energy source to power fuel cell vehicles and farm implements.

[0031] Turning to the figures, wherein like numerals depict like elements, Fig. 1 schematically illustrates a side elevational view of a solar structure 2 embodiment of the invention. The solar structure 2 may be a house or other structure. The solar structure includes photovoltaic panels 4 disposed atop a building-integrated tracking PV array support structure and system 6 (the support structure and system being described in more detail below).

[0032] Solar structure 2 also has hollow core insulated roof planks 8, steel forms filled with concrete floors, full radius curved open web triangular roof trusses 14, and insulated concrete forms 16 for lower wall construction. [0033] Fig. 2 depicts an enlarged view of the structure in Fig. 1 from line E to line G, whereas Fig. 3 depicts a simplified end-elevational view of the solar structure 2 in Fig. 1 to more clearly show the tracking array system 6, roof planks 8, floor 12 and wall elements 16.

[0034] The tracking array system 6 is comprised of photovoltaic panels 4 atop array support structure 20. In this embodiment, the array support structure 20 is seated within a track or groove 22 that contains suitable mechanization for moving the array 6 from approximately one end of the curved surface 24 to the opposite end. Such mechanization may include one or more DC gear motor drive trains, pulleys and counterweights, roller bearings, and slip rings/slip ring trip release for DC power transfer and disconnect.

[0035] For example, using a series of DC gear motors, a slow speed drive train will pull cables attached to the building-integrated tracking PV array. Supported by the trusses 14, pulleys and counterweights will offset the loads so that the amount of torque/horse power necessary to move the building-integrated tracking PV array is reduced to a minimum, providing an energy efficient operation.

[0036] Along the centerline of the trusses 14, roller guides (grooves or tracks 22) and bearings provide the low friction rolling efficiency. In that same path, a series of slip rings will allow the DC power generated from the PV panels to be transferred to fixed power strips. The slip rings will have a trip release capability so that the power coming from the PV panels can be shut off and isolated during periods of service for an additional lockout safety feature.

[0037] Following the full radiused curvature of the roof, the building- integrated PV tracking array will maintain the PV panel's orientation as perpendicular to the sun, following it from a 3:00 (east) relative position at sun up, to a 12:00 position at noon, to the final 9:00 (west) position at sunset.

[0038] In an embodiment, the roof planks 8 preferably are made of a composite material, are cast to be curved about 24 degrees, and contain ends that can interlock (described below). [0039] Turning to Fig. 4, an embodiment of the building-integrated PV tracking array support structure 20 is illustrated in greater detail. The tracking PV array support structure 20 is designed for a curved surface and includes a pair of spaced apart sides 26 joined by a pair of ends 28. The pair of sides 26 each defines a linear top piece 30 joined to a pair of down pieces 32, each down piece 32 being coupled to the top piece 30 at an angle of less than ninety degrees, and a bottom piece 34 forming a convex curve. Each linear top piece 30 and pair of ends 28 defines a substantially rectangular mounting surface for a photovoltaic cell.

[0040] The tracking PV array support structure may further include support ribs 40 running from linear top piece 30 to curved bottom piece 34. Moreover, the tracking PV array structure may also include spreader supports 42 disposed perpendicularly to the pair of spaced apart sides 26 and following the convex curve defined by the bottom piece 34. Spacer supports 44 perpendicular to the spreader supports 42 may also be employed.

[0041] Fig. 5 shows an enlarged view of the array structure featured in Fig. 4., while Fig. 6 depicts a side view of a roofing plank and supporting structure embodiment. [0042] Fig. 7 illustrates an enlarged section taken at IB of Fig. 1 in which concrete filling 50 is added to a floor plank 51 and steel plank 54 to form a composite floor. The floor may be topped with radiant heat coils 52.

[0043] Fig. 8 is an enlarged section taken at 2B of Fig. 1 and depicts building- integrated tracking PV array system mechanization components 60 for movement. The building-integrated tracking PV array is supported by support 62 which is seated in a track or groove capable of being a roller guide. A backer rod 66 and gasket 68 maintain the integrity of the roof 69. Pulleys 70 and counterweights 71 are present in the track area, which is atop a truss 72, or in the truss area. Insert fasteners 76, roller guide bearings 78, slip rings 80, and a trip release 82 are also present.

[0044] Fig. 9 depicts an individual roof plank embodiment 90, comprising a curved plank of composite material having at least one hollow space 95 within the plank and ends 94 and 96 adapted to be joined with a further curved plank of composite material. Preferably, the hollow space 92 runs transverse to a length of the plank 90. More than one hollow space that runs transverse to the length of the plank is especially preferred. [0045] In one embodiment, the plank 90 is made of aluminosilicate ceramic material. Moreover, the ends adapted to be joined are defined by a tongue at one end and a groove at an opposing end as shown in Figs. 9 and 10. Fig. 10 shows an alternate embodiment of the roof plank. [0046] Figs. 11A and 1 IB illustrate further embodiments of a building-integrated tracking PV array system especially adapted for use on spherical or cylindrical structures such as water towers, silos, and the like. In addition to tracking the sun from sunrise to sunset as shown by arrows Y, Fig. 1 IB shows that the tracking array may be rotatable around the sphere as designated by arrow 100. Thus, a dual-axis building-integrated tracking PV array provides maximum tracking efficiency and further provides shade to the underlying structure from the sun.

[0047] The roof planks may be produced from an aluminosilicate ceraminc composite material. The alumina (Aluminum Oxide or AI2O ₃ ) Silica (Silicon Dioxide or S1O2) ceramic composite material that has a high insulated value ( 90); thickness will vary. Other composite materials and ceramic matrix composites may also be utilized, with composite materials being materials made from two or more constituent materials with significantly different physical or chemical properties. [0048] CMCs can be produced using a number of fabrication processes: chemical vapor or liquid phase infiltration, hot press sintering techniques and polymer infiltration and pyrolysis (PIP). In one embodiment, continuous manufacturing of insulated roof planks is as follows (see Fig. 12). [0049] Foamed aluminum process generates specific volume to maintain throughput flow and cross sectional area (step 102). Multiple conduit/reinforcement tubes are aligned for foamed aluminum encasement (step 104). Foamed aluminum and tubes move down vertically thru the adjustable radius and thickness forming conveyor, cooling and setting the insulated roof plank to final cross section shape (step 106). Flying cutoff is used to separate the insulated roof plank from the continuous extrusion process above (step 108). Finished length insulated roof plank is transferred from vertical to horizontal orientation for post extrusion process (step 1 10). Insulated roof plank has both side edges prepared to final tongue & groove shape and size (step 1 12). Openings for operable skylight optionally are cut and prepared at programmed locations in the insulated roof plank (step 114). Single ply membrane roofing material is laminated to the insulated roof plank and operable skylights optionally are installed (step 1 16).

[0050] The alumina silica ceramic material used in the insulated roof planks can also provide heat sinking properties which may allow its use in the building-integrated tracking PV array's supporting framework. Heat buildup, a deterrent to the efficiency of PV's may be able to be shed by this material's properties.

[0051] The claims are not intended to be limited by the materials, methods, embodiments and examples described above.