WO2013092682A2 - Structurally integrated solar building element - Google Patents
Structurally integrated solar building element Download PDFInfo
- Publication number
- WO2013092682A2 WO2013092682A2 PCT/EP2012/076109 EP2012076109W WO2013092682A2 WO 2013092682 A2 WO2013092682 A2 WO 2013092682A2 EP 2012076109 W EP2012076109 W EP 2012076109W WO 2013092682 A2 WO2013092682 A2 WO 2013092682A2
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- WO
- WIPO (PCT)
- Prior art keywords
- structurally
- integrated solar
- solar building
- building element
- profile
- Prior art date
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/36—Connecting; Fastening
- E04D3/365—Connecting; Fastening by simple overlapping of the marginal portions with use of separate connecting elements, e.g. hooks or bolts for corrugated sheets
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/36—Connecting; Fastening
- E04D3/366—Connecting; Fastening by closing the space between the slabs or sheets by gutters, bulges, or bridging elements, e.g. strips
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/38—Devices for sealing spaces or joints between roof-covering elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
- F24S25/634—Clamps; Clips
- F24S25/636—Clamps; Clips clamping by screw-threaded elements
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
- H02S20/20—Supporting structures directly fixed to an immovable object
- H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
- H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S20/00—Solar heat collectors specially adapted for particular uses or environments
- F24S20/60—Solar heat collectors integrated in fixed constructions, e.g. in buildings
- F24S20/66—Solar heat collectors integrated in fixed constructions, e.g. in buildings in the form of facade constructions, e.g. wall constructions
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S20/00—Solar heat collectors specially adapted for particular uses or environments
- F24S20/60—Solar heat collectors integrated in fixed constructions, e.g. in buildings
- F24S20/67—Solar heat collectors integrated in fixed constructions, e.g. in buildings in the form of roof constructions
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S20/00—Solar heat collectors specially adapted for particular uses or environments
- F24S2020/10—Solar modules layout; Modular arrangements
- F24S2020/13—Overlaying arrangements similar to roof tiles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S2025/01—Special support components; Methods of use
- F24S2025/022—Sealing means between support elements, e.g. overlapping arrangements; Gap closing arrangements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S2025/80—Special profiles
- F24S2025/804—U-, C- or O-shaped; Hat profiles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/20—Solar thermal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the invention addressed herein refers to a building element or construction element including a photovoltaic element.
- Construction Element in the context of this disclosure addresses a construction part basically exhibiting an essentially plane, plate shape with a front and a back surface and a thickness.
- the thickness in the third dimension is in most cases less than the length and the width of the plate.
- the edges of the plate shaped building element will preferably be pairwise parallel, such as a rectangular, square or trapezoidal design.
- SEC Small Energy Converter
- SE Structure Element
- SISBE incorporates besides the functional purpose of converting solar radiation into electrical energy also at least one of structural, protective, insulating, architectural and/or decorative purposes.
- a SISBE is understood as a unit, integrating and exhibiting at least two of the mentioned qualities, e. g. a SEC and a SE.
- BIPV Building Integrated Photovoltaics
- SISBE Construction Element with a Solar Energy Converter
- Solar panels or photovoltaic panels are being understood in the context of this disclosure as essentially flat, plane arrangements of solar cell(s), irrespective of the solar technology (bulk crystalline Si, thin film
- Thin film solar cell panels are photovoltaic panels, wherein the photoelectric conversion takes place in thin semiconductor film layers instead of bulk semiconductor. Such thin films are being deposited layer by layer on substrates like, glass, steel, plastic or flexible substrates by deposition technologies such as vacuum deposition. Thin film solar cell panels are known in the art .
- Photovoltaic panels preferably shall be installed in a way allowing them to use as much as possible of the incident light. Thus they need to be either actively guided (tracking the path of the sun) or installed without tracking means in locations where solar light can impinge on such panels as unrestricted as possible.
- roof tops are the preferred location for solar panel installations on buildings.
- Most of the systems commercially available however need an additional fixation structure that is fixed on the existing (e.g. roof-) construction. From a cost perspective this is a disadvantage, because two supporting structures are planned individually, built separately and stacked on each other. In most cases the second structure (for the photovoltaic panels) even will add weight, complexity and maintenance needs to the first structure (the roof, wall or generally building
- PCT publication WO 2011/073303 refers to a substantially two- dimensional construction element with a solar energy converter member extending along and defining one surface of said construction element and providing for solar energy conversion and a building construction member extending along and
- a Structurally Integrated Solar Building Element 10 SISBE comprises at least one Solar Energy Converter SEC 11 and at least one Structural Element 15.
- the Structural Element 15 has the shape of a stretched wedge (in a cross section along one edge) , with the thickness of the
- Structural Element 15 being thicker at one edge (A) compared to the other (A' ) .
- the Structural Element 15 comprises at least two sub elements 12, 13, wherein the element 12 arranged closer to the SEC 11 exhibits the shape of the stretched wedge, whereas the second sub element 13 has the shape of a plate with parallel surfaces (surface facing the SEC) . Further additional sub-elements would follow essentially the shape of sub-element 13.
- An object of the present invention is to improve on the structurally integrated solar building elements of the prior art .
- a structurally-integrated solar building element assembly comprising at least two structurally-integrated solar building elements disposed mutually adjacently and separated by a gap.
- Each structurally-integrated solar building element comprises at least one solar energy converter such as a photovoltaic module, situated upon at least one structural element, i.e. an element giving structural strength to the SISBE.
- Said assembly further comprises a profile element disposed in said gap, said profile element having a substantially flat bottom section and two side walls and can be considered as being substantially capital-Omega ( ⁇ ) shaped.
- the top portion of profile element comprises two projecting flanges respectively overlapping edge portions of two mutually adjacently disposed structurally- integrated solar building elements.
- the profile element is adapted to be attached to a support structure by means of at least one fixation element such as a screw, a bolt, a pin, adhesive or similar so as to hold the structurally-integrated solar building element assembly in place on said support structure.
- fixation element such as a screw, a bolt, a pin, adhesive or similar
- the bottom section and the two side walls of the profile element define a conduit adapted to receive at least one cable connecting solar energy
- the profile element comprises at least one lateral opening
- insulating material is disposed inside the channel. The overall insulation of the assembly is thus improved.
- the height of the side walls of the channel are at least the thickness of the at least one structural element or of at least one sub-element thereof.
- a profile seal is arranged between the surface of each solar energy converter and each respective projecting portion, so as to seal the assembly from the weather.
- the profile seal may comprise a base portion and at least one of the following features, which help ensure good sealing between the profile and the adjacent SEC:
- ⁇ one or more projecting seal portions extending from a side edge of the base portion, e.g. so as to contact the side wall of the profile element; • a plurality of crenellations, i.e. ribs or ridges, extending from a bottom surface of the base portion for sealing to the upper surface of a solar energy converter;
- a top cover is arranged on the open end of profile element, the top cover being held in place by fixing means such as clips, screws, or glue. The interior of the profile element is thus protected from the weather.
- the structurally-integrated solar building element assembly is adapted to be attached to a support structure such as roof beams or structural panels by means of the profile element.
- a support structure such as roof beams or structural panels.
- the SISBEs themselves thus do not require holes, clips or similar to attach them to the support structure.
- each side wall comprises at a male end a cutout in each side wall and a pair of tabs, the outer surface of each tab being flush with the inner surface of the adjacent side wall, and wherein the profile element comprises at a female end a pair of further cutouts formed by cutting away the ends of the projecting portions an adjacent section of each respective side wall.
- the male end of a profile element can be inserted into the female end of the subsequent profile element such that they fit together.
- kit of parts for assembling a structurally-integrated solar building element assembly according to any of the above assembly embodiments, the kit of parts comprising:
- each structurally-integrated solar building element comprising at least one solar energy converter such as a photovoltaic cell situated upon at least one
- the top portion of the profile element comprising two projecting flanges adapted respectively to overlap edge portions of two mutually adjacently disposed structurally-integrated solar building elements, which form can be considered as being
- kit of parts for assembling the SISBE assembly is provided .
- the substantially flat bottom section and the two side walls of the profile element define a conduit or channel adapted to receive at least one cable connecting solar energy converters of adjacent
- the profile element comprises at least one lateral opening provided in the side wall of the profile element for the passage of said at least one cable.
- the kit further comprises
- insulating material adapted to be positioned inside the channel, for improving the overall insulation of the assembled assembly.
- the height of the side walls of the profile element is at least the thicknesses of said at least one structural element or of at least one sub- element thereof.
- the. kit further comprises
- the profile seal may comprise a base portion and at least one of the following features:
- ⁇ one or more projecting seal portions extending from a top surface (178) of the base portion, e.g. so as to contact the underside of a solar energy converter;
- the kit further comprises
- top cover adapted to be arranged on the open end of the profile element, the top cover being arranged to be held in place by fixing means such as clips, screws, or glue. Water can thus be prevented from entering into the profile element when the assembly is assembled.
- the structurally- integrated solar building element assembly is adapted to be attached to a support structure such as roof beams or
- SISBEs themselves thus do not require holes, clips or similar to attach them to the support structure.
- the profile element comprises at a male end a cutout in each side wall and a pair of tabs, the outer surface of each tab being flush with the inner surface of the adjacent side wall, and wherein the profile element comprises at a female end a pair of further cutouts formed by cutting away the ends of the projecting portions an adjacent section of each respective side wall.
- the object of the invention is likewise attained by a
- structurally-integrated solar building element comprising at least one solar energy converter situated upon at least one structural element, wherein the at least one structural element is wedge shaped and comprises a thicker edge and a thinner edge, said thicker edge and said thinner edge being opposite- edges . Since one edge is thicker than the opposite edge, when the SISBEs are laid together thick-end-to- thin-end, the thick end of one SISBE will sit proud above the thin end of the adjacent SISBE, rendering mounting and
- the at least one structural element comprises at least one first sub-element situated closest to the at least one solar energy converter, and at least one second sub- element situated on the side of the least one first sub- element opposite to the at least one solar energy converter.
- the mechanical and insulating properties of the SISBE can thus be optimised, e.g. by choosing different materials for each of the sub-elements. For instance, one sub-element may give the SISBE structural strength while the other gives it good insulating properties.
- the at least one first sub-element is conformed so as to give the at least one structural element its wedge shape, the at least one second sub-element being of substantially constant cross-section.
- the second sub-element projects over the first sub- element at the thinner edge of the at least one structural element and is recessed from the first sub-element at the thicker edge of the structural element. This results in a staggered, stepped structure which contributes to the
- the at least one solar energy converter projects over the least one structural element at said thicker edge (A) thereby defining a projecting portion, and wherein the at least one solar energy converter is recessed from the at least one structural element at said thinner edge thereby defining a recess area, i.e. an area of exposed structural element upon which no solar energy converter is situated.
- a recess area i.e. an area of exposed structural element upon which no solar energy converter is situated.
- the structural element comprises at least one curved or bevelled (i.e. angled) portion at its thicker end and at least one substantially corresponding oppositely-curved or oppositely-bevelled portion at its thinner end.
- the curved or bevelled portion is arranged so as to substantially fit together with the oppositely-curved or oppositely-bevelled portion of an adjacent structurally-integrated solar building element.
- the at least one curved or bevelled portion at the thicker end of the structural element underhangs the solar energy
- the first sub-element comprises a first bevelled portion
- the second sub-element comprises a second
- the first bevelled portion has a steeper bevel than the second bevelled portion.
- the second bevelled portion is more acute than the first bevelled portion.
- the difference in thickness between the thicker edge and the thinner edge is arranged such that the projecting portion of a first structurally-integrated solar building element is arranged to overhang the recess area of a second structurally-integrated solar building element.
- the solar energy converter is attached to the at least one structural element by at least one of: adhesive bonding; welding; clamping; riveting; screws; bolts.
- the structural element and/or at least one sub- element thereof comprises at least one of the following materials in a foam and/or fibrous form: polypropylene, PMI (polymethacrylimide) , PUR (polyurethane) , PIR
- polyetheretherketone polyetheretherketone
- PS styrene-based
- foam glass glass wool (whether compressed or not)
- glass wool whether compressed or not
- rock wool- based material whether compressed or not
- the object of the invention is likewise attained by a
- structurally-integrated solar building element assembly comprising at least two structurally-integrated solar building elements according to any of the above embodiments thereof disposed mutually adjacently such that the thinner end of a first structurally-integrated solar building element abuts or is adjacent to the thicker end of a second structurally- integrated solar building element.
- the assembly comprises at least two
- structurally-integrated solar building element assembly further comprises a stabilising beam and a seal positioned within an interspace formed between the projecting portion of the solar energy converter of the first structurally- integrated solar building element and the structural element of the second structurally-integrated solar building element, the seal being in contact with the stabilising beam and in contact with the overhanging portion of the solar energy converter of the first structurally-integrated solar building element.
- the stabilising beam substantially fills the recess area, further assisting in assuring structural integrity and structural strength.
- the SISBE assembly further comprises an additional sealing film placed extending from the limit of the pv active cells of the solar energy converter (typically about 1cm from the edge of the solar energy converter glass) of the second structurally-integrated solar building element up to the beginning of the structural element of the first structurally- integrated solar building element.
- the seal has a hardness of 20-90 Shore, particularly 35-70 Shore, further particularly 40-60 Shore, yet further particularly substantially 50 Shore.
- the seal may be ⁇ shaped, i.e. may comprise a flat portion for contacting at least the stabilising beam, and a tubular portion joined to the flat portion adapted to contact the underside of the projecting portion of the solar energy converter of the first structurally-integrated solar building element and to contact the surface of the solar energy converter of the second structurally-integrated solar building element.
- the tubular portion of the seal may comprise one or more ribs for contacting the underside of the projecting portion of the solar energy converter of the first structurally-integrated solar building element. Good sealing between the SISBEs is thus achieved.
- this structurally-integrated solar building element assembly and the first-mentioned structurally- integrated solar building element assembly may be combined so as to form a structurally-integrated solar building element assembly comprising a plurality of structurally-integrated solar building element assemblies according to the first- mentioned embodiments thereof, arranged such that the
- structurally-integrated solar building elements form an at least 2x2 matrix of structurally-integrated solar building elements, each adjacent pair of structurally-integrated solar building elements arranged in a direction parallel to the profile element (50) forming a structurally-integrated solar building element assembly according to the second-mentioned embodiments thereof.
- the object of the invention is likewise attained by a building comprising any combination of the above-mentioned embodiments.
- Figure 1 a longitudinal cut through a SISBE on line A-A' of fig. 3;
- Figure 2 a cross-section of SISBE on line B-B' of fig. 3;
- Figure 3 a SISBE mounted on a support structure
- Figure 4 three SISBES mounted on a support structure
- Figure 5 a 3x3 matrix of SISBES mounted on a support
- Figure 6 a longitudinal cut along D-D' of Figure 5;
- Figure 7 a cross-section along E-E' of figure 5;
- Figure 8 shows an arrangement of SISBEs with their junction boxes connected by cables
- Figure 9 a wireframe isometric view of a SISBE
- Figure 10 an isometric view from above on a crossing point of four SISBEs when mounted;
- FIG 11 the situation of Figure 10 with further mounting parts attached
- Figure 12 The situation of Figure 11 with all mounting parts attached
- Figure 13 an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6
- Figure 14 an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6;
- Figure 15 an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6;
- Figure 16 a cross-section of a variant of the seal shown in figure 6;
- Figure 17 a cross-section of a variant of the profile seal shown in figure 7;
- Figure 18 a perspective view of the profile seal of figure 17;
- Figure 19 an isometric view of a male end of a profile element
- Figure 20 an isometric view of a female male end of a profile element.
- Figure 9 shows a Structurally Integrated Solar Building
- SISBE Solar Energy Converter
- SE Structural Element
- the SE is being shown here as made from two sub-parts, but this embodiment shall not be limiting.
- a longitudinal cut shall mean a plane defined by arrows A-A' and C-C .
- a cross-section shall be defined by the plane B-B' and C-C. If the thickness of one of the features shown in the figures is addressed, the
- FIG. 9 The dimensioning in Figure 9 has been adapted to a standard size of one type of SEC 11, 1100mmxl300mm.
- the size of the SEC may vary and the respective other dimensions will adjust respectively.
- the SEC may be a flat, plate shaped photovoltaic panel as known in the art, preferably a thin film solar panel.
- Figure 1 shows a longitudinal cut through a SISBE 10.
- a Structurally Integrated Solar Building Element 10 comprises at least one Solar Energy Converter SEC 11 and at least one Structural Element 15; the Structural Element may have an uneven thickness.
- the Structural Element 15 has the shape of a stretched wedge, with the thickness of the Structural Element 15 being thicker at one edge (A) compared to the other (A' ) .
- Structural Element 15 is shown as being composed of a first substructure 12 and second substructure 13, which represents a further embodiment of the invention.
- Structural Element 15 may comprise a plurality of sandwiched layers.
- Figure 2 shows a cross-section of SISBE 10.
- Structural Element 15 is shown as including two sub-layers 12 and 13. In the context of this disclosure in a basic
- SE 15 could be realized with sub-layer 12 alone.
- the dimensions in the direction B-B' of SE 15 (or 12, respectively) and SEC 11 would be the same, in other words SEC 11 will, preferably, not be recessed from nor project over SE 15 (12) .
- Figures 3 and 4 show how individual SISBES can be mounted to form a larger surface. Due to the combination of SE 15 with SEC 11 only a limited support area needs to be provided. This may be beams (17, 17', 17", 17'") positioned below and along edges B. These beams could be wood, steel, concrete or any other supporting material.
- a closed surface is being shown as support surface. In another embodiment said closed surface is not necessarily an overall carrying surface, but could be e.g. moisture barrier (foil) and/or part of the inner wall mounting supported by a beam structure.
- moisture barrier fin
- said closed surface could be totally avoided and SISBEs could be directly fixed on said beams: in such case the rear side of the larger surface would directly show the rear SISBEs surface between the beams.
- beams arranged orthogonally to beams 17, 17', ... can be used.
- Figure 5 shows a 3 x 3 arrangement of readily mounted SISBEs 10, 20, 30, ... already with further fixtures explained in the subsequent figures.
- Figure 6 shows a longitudinal cut along D-D' (marked as reference 23 in Figure 5) through the overlap area between two SISBEs 30 and 40.
- the SECs 11, 11', the SE sub-layers 12, 13 and 12', 13' belong to SISBEs 40 and 30 respectively. Due to the wedge-like design of SE 15 a projecting portion 41 of SISBE 40 will overlap recess area 31 of SISBE 30.
- the functionality of sublayer 13, 13' of SE 15 may be omitted to explain the mounting principle.
- the difference of thicknesses of the adjoining edge portions of references 12 and 12' are calculated such that they allow for arranging stabilizing beam 22 and a seal 23. Further, between beam 22 and seal 23 an additional sealing film can be placed extending from the lower SEC s 11' upper limit of the pv active cells (about 1 cm away from the SEC s 11' upper limit) up to the beginning of the adjacent SE sublayer 12. As is visible in Figure 5 and 6, stabilizing beam 22 fills a pocket or gap present in recess area 31.
- stabilizing beam advantageously extends across several SISBEs and can be made from any suitable material, light metal, plastic or alike. For cost and weight reasons a hollow profile may be used.
- Seal 23 blocks dust, dirt, water, insects from entering the connecting area of SISBEs 30, 40.
- the seal may be designed according to state of the art techniques with . one or more sealing lips, which may be formed as hollow profile, sealing edges or a combination thereof.
- FIG 7 shows a cross-section along E-E' (marked as reference 24 in Figure 5) through the overlap area between two SISBEs 20 and 30.
- the SECs 11", 11', the SE sub-layers 12", 13" and 12', 13' belong to SISBEs 20 and 30 respectively.
- the functionality of sublayer 13", 13' of SE 15 may be omitted to explain the mounting principle.
- SEC 11", 11' and SE 12, 12' do not protrude or recess. Therefore a specially designed profile 50 can be used to fill the gap between SISBEs 20 and 30.
- a fixation element 51 like a clamp, a clip, a screw or a nail is being used to fasten profile 50 to the support structure, e. g. beam 17".
- Profile 50 has a flat bottom section 59 and two side walls 60, 61.
- the height of the side walls 60, 61 is construed to be at least the thicknesses of SE 15 (or sub-layer 12', 12" - as shown) plus SEC 11', 11". It is important to note that due to the lengthwise wedge-like shape of SE 15 (sub layer 12, respectively) the side walls 60, 61 preferably have to conform to those dimensions. In case the side walls 60, 61 do not conform the wedge shape, the remaining space between sublayers 13 and 13' could be filled with a dummy material such as plastic, foam or just left with air if sealed properly or according to the incumbent building requirements.
- the top portion of profile 50 includes two projecting portions 57, 58 overlapping edge portions of SISBEs 30, 20
- a profile seal 170 may be arranged between SEC 11' and projecting portion 57 and SEC 11" and projecting portion 58 respectively for blocking environmental influences from entering the area between SISBEs 20 and 30.
- Interspace or channel 62 can accept cables 55 connecting adjacent panels (entering the channel e. g. through lateral opening 56), sensors (temperature, humidity or alike) , insulating material 52. Easy access, e.g. for maintenance, is possible by removing a top cover 54 which is being held in place e. g. by clips 53. Alternatively screws or gluing could be used.
- Figure 8 shows an arrangement of SISBE' s 10, 20, 30 with their junction boxes 19, 29, 39 connected by cables. Junction boxes connect the photovoltaically active layer stacks with the grid. SISBEs 10, 20, 30 are shown side by side, separated by channels 65, 66. Connectors are being placed in the channels, thus being kept in a protected environment.
- Figure 10 is a view from above on a crossing point of four SISBEs when mounted (certain parts omitted, as explained below).
- two SISBEs 70 and 73 mounted side by side with a profile 50' (corresponds to profile 50 in Fig. 6) .
- Stabilizing beam 22 is being arranged to overlap the edge part of SISBE 70 and 73, whereas seals 23 and 23' are arranged over beam 22.
- the projecting part of SISBE 71 and 72 over SISBE' s 70, 73 has been omitted to allow this view (analogy: projecting portion 41 in Figure 6) .
- the end part of profile 50 arranged between SISBEs 71, 73 shows cutouts allowing beam 22 to be arranged in the overlapping manner described.
- Figure 11 shows the situation of Figure 10 with further mounting parts attached. References in Figure 11 have the same meaning as in Figure 10. Again the projecting portion of
- Top covers 54, 54' have been arranged over profiles 50, 50', in analogy to the situation displayed in Figure 7. It has to be noted that the colours of these covers 54, 54' can be adapted to the look of SISBE's 70- 73, thus resulting in a homogeneous look over the whole covered area. However, those covers could also be coloured differently in order to create a special look or design. For large areas such graphic patterns can be arranged, be them artistic, letter-like, logos or alike.
- Figure 12 shows the finalized situation with all mounting parts attached to the crossing point of SISBEs 70, 73, 74, 75.
- SISBE's 74, 75 now are shown to the full surface extent covering the seal portion 23, 23' , which was still visible in Fig. 11.
- a small front cover 78 closes the front portion of cover 54.
- cover 78 may form an integral part of cover 54, too.
- Areas 76, 77 may receive also front faceplates, if necessary.
- colour design for parts 76, 77, 78 the same is valid as stated for parts 54, 54' .
- Figure 13 illustrates in cross-section parallel to D-D' of figure 5 a further variation of the shape of the structural element 15, facilitating mounting and dismounting of the SISBEs.
- Figure 13 illustrates a first SISBE placed adjacent to a second, substantially identical SISBE 10' .
- Beam 22 and seal 23 of figure 6 have been omitted from the drawing for simplicity.
- Structural element 15 is illustrated here as comprising a first sub element 12 and the second sub element 13, however structural element 15 may be composed of a single element.
- the thinner end of structural element 15 comprises a bevelled portion 15 b i
- the thicker end of structural element 15 comprises a substantially corresponding oppositely-bevelled portion 15 2 .
- the bevel angle is constant throughout both sub elements 12, 13.
- These bevelled portions 15 b i, 15 b2 are arranged such that, when two SISBEs 10, 10' are placed adjacently as illustrated, the bevelled portion 15' b i at the thinner end of the structural element 15' of one SISBE 10' substantially fits together with the oppositely-bevelled portion 15 b2 of the thicker end of the structural element 15 of the adjacent SISBE 10.
- the sharp end of the bevel may also be squared off or rounded off.
- the bevelled ends of the structural elements 15, 15' do not impinge upon each other as the SISBES are rotated into position.
- the adjacent SISBES in the direction parallel to D-D' of figure 5 can be fitted together with higher tolerances due to less clearance being reguired to prevent the ends of the structural elements 15, 15' from impinging upon each other during mounting as is the case with the squared, stepped ends of the sub elements 12, 13 of the structural element 15 as illustrated in figure 6.
- Figure 14 illustrates a further variation on the shape of structural element 15, which differs from that of figure 13 in that, instead of both sub elements 12, 13 being bevelled at the same angle, first sub element 12, which is nearest the solar energy converter 11, has a steeper bevel than the second sub element 13.
- first sub element 12 which is nearest the solar energy converter 11 has a steeper bevel than the second sub element 13.
- bevelled portion 12 b i of first sub element 12 intersects a plane defined by the solar energy converter 11 at an angle greater than the angle of intersect of a plane defined by the bevelled portion 13 b i of second sub element 13 with the plane defined by the solar energy converter 11.
- the plane defined by the bevelled portion 12 b i of first sub element 12 intersects the plane defined by the bevelled portion 13 b i of second sub element 13 at an angle of less than 180°.
- the acute angle between the bevelled surface of bevelled portion 12 b i of first sub element 12 and its adjacent surface is greater than the acute angle between the bevelled surface of bevelled portion 13 b i and its adjacent surface.
- bevelled portion 12' i of one SISBE 10' fits together with oppositely- bevelled portion 12 b2 of an adjacent SISBE 10, and likewise bevelled portion 13' b i of one SISBE 10' fits together with oppositely-bevelled portion 13 b2 of adjacent SISBE 10.
- This arrangement presents the same advantages as for figure 13.
- Figure 15 illustrates a further variation on the shape of structural element 15, which differs from that of figures 13 and 14 in that, rather than being bevelled, the thinner end of structural element 15 is concave curved, defining a concave curved portion 15 c i.
- the thicker end of structural element 15 likewise comprises an oppositely-curved portion 15 c2 , which is convex and substantially fits together with concave curved portion 15' c i of an adjacent SISBE 10'.
- the curved portions 15 c i, 15' c i, 15 c2 are illustrated in figure 15 as a single curve, the curve may also be discontinuous, e.g. with a different curvature for each of sub elements 12 and 13, or the same curvature with a discontinuity at the junction between sub elements 12 and 13. This arrangement presents the same advantages as for figures 13 and 14.
- Figure 16 illustrates in schematic cross-sectional view a seal 23' which is a variation of a seal 23 of figure 6, adapted to seal the gap between the underside of overhanging solar energy converter 11 of one SISBE and the top side of the adjacent solar energy converter 11' of the neighbouring SISBE.
- Seal 23' comprises a flat portion 161 which joins a tubular portion 162. In the illustrated example, these two portions join tangentially, however this does not have to be the case.
- the shape can be described as that of a lowercase Greek letter Sigma ( ⁇ ) .
- a plurality of ribs 163 are provided on the exterior of the tubular portion 160 to
- Seal 23' has a hardness of 20-90 Shore, particularly 35-70 Shore, further particularly 40-60 Shore, yet further particularly substantially 50 Shore.
- Figure 17 and 18 illustrate a variation of a profile seal 170 of figure 7, intended to be placed between each of the
- Profile seal 170 comprises a base portion 171 provided with a pair of through holes 172.
- Four projecting portions 173, 174, 175 and 176 project from the base portion 171, side projecting portion 176 extending from a side edge 177 of base portion 171 and destined to be
- Cutouts 173a, 174a, 175a are provided at the root of each projecting portion 173, 174, and 175 to provide clearance to allow the projecting portions to bend under pressure applied by the projecting portion 57, 58 of the profile element 50. This arrangement provides good sealing of the profile element 50 to the solar energy converters 11' ,
- Suitable Shore hardness of profile seal 170 is between 20-90, particularly 40-80, further particularly 50-70, even further particularly substantially 60.
- Figure 19 illustrates the male end of a profile element 50 adapted to interface with the end of an adjacent profile element.
- the profile element 50 is partially undercut leaving a pair of cutouts 192 and 193 under each projecting portion 57, 58 respectively.
- a pair of tabs 190, 191 respectively are provided, the outer surface of each tab 190, 191 being
- each profile element 50 is provided with further cutouts 201, 202 respectively, formed by cutting away the ends of the projecting portions 58 and 57 respectively, along with an adjacent section of each
- a plurality of profile elements 50 can fit together by asserting the male end of one profile element 50 into the female end of an adjacent profile element 50.
- Thin film solar cells as defined above commonly are being deposited on glass substrates. After deposition, quality control and electrical contacting the thin film solar cell needs to be encapsulated in order to avoid degradation of the thin film materials due to environmental influences such as moisture, oxidation, mechanical stress and dirt. Therefore usually a second glass substrate is being used as back
- a lamination layer e.g. a PVA or PVB foil arranged in between the two glass substrates with their flat sides facing each other this environmental protection can be accomplished.
- the advantages of glass such as gasproofness, rigidity, availability are gained by increased weight and fragility.
- a glass-glass laminate is not sufficient to allow for the required stability.
- the Structural Element SE will provide for sufficient stability as described above, the disadvantages of the second glass laminate may be overcome at the same time.
- the second reinforcing glass could be omitted and replaced by a purely protective barrier layer. This could e.g. a laminate of thin plastic foil plus an aluminium foil. These are able to provide for electrical insulation as well as excellent moisture barrier.
- the invention advantageously includes a solar module with at least two different material layers (described above as layers 12 and 13) at its backside in order to form a sandwich
- said two material layers may each comprise a core material layer and a back surface sandwich material layer.
- a dedicated one has to be introduced into the SISBE between module and core material layer.
- Such a sandwich structure applicable to all market available solar modules includes for example a front fibre reinforced thermoplastic or thermoset laminate that can be applied to the backside of a module by different means as for example gluing or by simply heating up the thermoplastic or thermoset
- the components of the sandwich structure may be simply clamped together, e.g. by clamping elements or by the profile elements (50) upon mounting the structurally-integrated solar building element to a structure.
- the core material layer of the sandwich may preferably comprise foam-like and/or fibrous- form material and on the back side the sandwich may comprise the same or similar fibre reinforced thermoplastic or resin laminate used for said front side sandwich material layer.
- front and the back side sandwich material layers used in said sandwich structure may differ from one another.
- the solar module may only have a front glass and therefore the sandwich structure may be directly laminated on the backside of the back glass-free module. It is obvious that in such a configuration the module itself needs to fulfil the already mentioned electrical and chemical insulating parameters.
- the front side sandwich material layer structure may comprise to a large extent the solar module itself.
- the foam-like and/or fibrous-form material may be attached in a different way to the solar module as for example by gluing. This may also work if the solar module has only a front glass and not a double glazed structure.
- the foam and/or fibre may be directly applied by gluing on the back electrode or on the back reflector of a PV module (SEC, as described above) . It is obvious that in such a configuration the solar module itself needs to fulfil the electrical and chemical insulating
- front side sandwich material layer may be used composite materials as glass fibre plus polypropylene, epoxy resin, polyester resin, vinylester resin. Also bulk materials as for example polypropylene or aluminium may be applied. The expert will define the necessary thickness based on the standards and regulations required. Also other materials with comparable properties may be used within the context of this invention.
- foams and/or fibrous materials based on both organic and/or inorganic materials
- PMI polymethacrylimide
- PUR polyurethane
- PIR polyisocyanurate
- expanded perlite PEEK (polyetheretherketone)
- PS styrene-based
- honeycomb-structured material may be used, reinforced with layer materials as mentioned.
- high modulus foams can also act as front and/or rear side sandwich material layers depending also on the specific application of the SISBEs. All said materials may be combined with each other to form a multilayer / composite core material / sandwich material.
- a back side sandwich layer may be used which provides a further reinforcement. Materials as for the front sandwich material layer can be used.
- the layers described above may be integrated to a respective
- SISBE unit by gluing, thermal welding, laminating or other methods suitable to durably bond said materials.
- these layers may simply be clamped together to form the respective SISBE unit, e.g. by dedicated clamping elements or by the profile elements (50) upon mounting the structurally-integrated solar building element to a structure.
- the insulating properties of foams described above are well known. A man skilled in the art will, depending on the
- Transport systems can be designed to match SISBEs of different thicknesses, tools and handling systems in the manufacturing plant as well as on the construction site may be standardized.
- Thicknesses of the various layers may vary. As a coarse rule one can mention that reinforcement layers can be designed advantageously to range from 0.5mm to 2.5mm, whereas the core sandwich and insulating layers may be 50mm to 30cm thick.
- the invention describes the use of insulating materials as part of a SISBE. Since PV modules such as SECs exhibit dark colours they will considerably heat up. Increased operating temperatures may be of advantage for certain types of SEC, but not for all. In this case, cooling structures may be
- thermoelements could be integrated close to the backside of the SEC to convert the thermal loads of the SEC into additional electrical energy.
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Abstract
A structurally-integrated solar building element (10) according to the invention comprises a solar energy converter (11) on a wedge-shaped structural element (15). Furthermore, a structurally-integrated solar building element assembly according to the invention comprises at least two structurally-integrated solar building elements (10) mounted mutually adjacently by means of an omega-shaped profile element arranged to be attached to an underlying support structure (17).
Description
STRUCTURALLY INTEGRATED SOLAR BUILDING ELEMENT
The invention addressed herein refers to a building element or construction element including a photovoltaic element.
DEFINITIONS
- The term "Construction Element" in the context of this disclosure addresses a construction part basically exhibiting an essentially plane, plate shape with a front and a back surface and a thickness. The thickness in the third dimension is in most cases less than the length and the width of the plate. The edges of the plate shaped building element will preferably be pairwise parallel, such as a rectangular, square or trapezoidal design.
- A "Structurally Integrated Solar Building Element"
(SISBE)" addresses in the context of this disclosure a Construction Element comprising at least a Solar Energy Converter and a Structural Element.
- A "Solar Energy Converter" (SEC) means any device capable of converting all or fractions or certain spectral portions of solar radiation into electrical energy. A prominent example of a solar energy converter is a photovoltaic panel or solar panel based on an arrangement of solar cells.
- A "Structural Element" (SE) means a part, device or
structure which is able to support itself at least partially, and/or to support another part.
- "Integrated" in SISBE essentially means that a SISBE
incorporates besides the functional purpose of converting solar radiation into electrical energy also at least one of structural, protective, insulating, architectural and/or decorative purposes. In the context of this disclosure and to the extent described herein a SISBE is
understood as a unit, integrating and exhibiting at least two of the mentioned qualities, e. g. a SEC and a SE. "Building Integrated Photovoltaics" (BIPV) means, as understood in the photovoltaic industry, a Construction Element with a Solar Energy Converter (SISBE) designed to be used for construction purposes in houses, industrial structures and alike.
Solar panels or photovoltaic panels are being understood in the context of this disclosure as essentially flat, plane arrangements of solar cell(s), irrespective of the solar technology (bulk crystalline Si, thin film
technologies, flexible modules, organic, or hybrids of solar photovoltaic and solar thermal collectors)
Thin film solar cell panels are photovoltaic panels, wherein the photoelectric conversion takes place in thin semiconductor film layers instead of bulk semiconductor. Such thin films are being deposited layer by layer on substrates like, glass, steel, plastic or flexible substrates by deposition technologies such as vacuum deposition. Thin film solar cell panels are known in the art .
TECHNICAL FIELD
Solar energy is today widely accepted as one of the key elements able to reduce mankind's dependency on fossil fuels, and are already in use widely today.
Photovoltaic panels preferably shall be installed in a way allowing them to use as much as possible of the incident light. Thus they need to be either actively guided (tracking the path of the sun) or installed without tracking means in locations where solar light can impinge on such panels as unrestricted as possible. No surprise, roof tops are the preferred location for solar panel installations on buildings. Most of the systems commercially available however need an
additional fixation structure that is fixed on the existing (e.g. roof-) construction. From a cost perspective this is a disadvantage, because two supporting structures are planned individually, built separately and stacked on each other. In most cases the second structure (for the photovoltaic panels) even will add weight, complexity and maintenance needs to the first structure (the roof, wall or generally building
structure) . It is therefore a goal of the invention to simplify the overall complexity of the building structure, to allow for broader and easier application of photovoltaic panels in BIPV, a standardization of construction elements, tools and spare parts and thus in generally to lower the financial and
constructional efforts.
RELATED ART
PCT publication WO 2011/073303 refers to a substantially two- dimensional construction element with a solar energy converter member extending along and defining one surface of said construction element and providing for solar energy conversion and a building construction member extending along and
defining the second surface of said construction element and providing for construction requirements.
SUMMARY OF THE INVENTION
A Structurally Integrated Solar Building Element 10 SISBE comprises at least one Solar Energy Converter SEC 11 and at least one Structural Element 15. In a preferred embodiment the Structural Element 15 has the shape of a stretched wedge (in a cross section along one edge) , with the thickness of the
Structural Element 15 being thicker at one edge (A) compared to the other (A' ) . In a further embodiment the Structural Element 15 comprises at least two sub elements 12, 13, wherein
the element 12 arranged closer to the SEC 11 exhibits the shape of the stretched wedge, whereas the second sub element 13 has the shape of a plate with parallel surfaces (surface facing the SEC) . Further additional sub-elements would follow essentially the shape of sub-element 13.
BRIEF DESCRIPTION OF THE INVENTION
An object of the present invention is to improve on the structurally integrated solar building elements of the prior art .
In a first aspect of the invention, this is attained by a structurally-integrated solar building element assembly comprising at least two structurally-integrated solar building elements disposed mutually adjacently and separated by a gap. Each structurally-integrated solar building element comprises at least one solar energy converter such as a photovoltaic module, situated upon at least one structural element, i.e. an element giving structural strength to the SISBE. Said assembly further comprises a profile element disposed in said gap, said profile element having a substantially flat bottom section and two side walls and can be considered as being substantially capital-Omega ( Ω) shaped. The top portion of profile element comprises two projecting flanges respectively overlapping edge portions of two mutually adjacently disposed structurally- integrated solar building elements. The profile element is adapted to be attached to a support structure by means of at least one fixation element such as a screw, a bolt, a pin, adhesive or similar so as to hold the structurally-integrated solar building element assembly in place on said support structure. As a result, mounting of SISBEs is rendered
extremely fast and simple.
In an embodiment of the assembly, the bottom section and the two side walls of the profile element define a conduit adapted to receive at least one cable connecting solar energy
converters of adjacent structurally-integrated solar building elements. Cabling of the electrical connections of the SISBEs is thus simplified, since the cabling can be disposed inside the profile elements rather than on the backside of the
SISBEs, rendering access easier. In a further embodiment, the profile element comprises at least one lateral opening
provided in the side wall of the profile element for the passage of said at least one cable.
In an embodiment of the assembly, insulating material is disposed inside the channel. The overall insulation of the assembly is thus improved.
In an embodiment of the assembly, the height of the side walls of the channel are at least the thickness of the at least one structural element or of at least one sub-element thereof.
In an embodiment of the assembly, a profile seal is arranged between the surface of each solar energy converter and each respective projecting portion, so as to seal the assembly from the weather. The profile seal may comprise a base portion and at least one of the following features, which help ensure good sealing between the profile and the adjacent SEC:
• one or more projecting seal portions extending from a top surface (178) of the base portion, e.g. so as to contact the underside of a solar energy converter;
· one or more projecting seal portions extending from a side edge of the base portion, e.g. so as to contact the side wall of the profile element;
• a plurality of crenellations, i.e. ribs or ridges, extending from a bottom surface of the base portion for sealing to the upper surface of a solar energy converter;
• one or more through-holes extending along the major length of the base portion for increasing the flexibility of the base portion.
In an embodiment of the assembly, a top cover is arranged on the open end of profile element, the top cover being held in place by fixing means such as clips, screws, or glue. The interior of the profile element is thus protected from the weather.
In an embodiment of the assembly, the structurally-integrated solar building element assembly is adapted to be attached to a support structure such as roof beams or structural panels by means of the profile element. The SISBEs themselves thus do not require holes, clips or similar to attach them to the support structure.
In an embodiment of the assembly, the profile element
comprises at a male end a cutout in each side wall and a pair of tabs, the outer surface of each tab being flush with the inner surface of the adjacent side wall, and wherein the profile element comprises at a female end a pair of further cutouts formed by cutting away the ends of the projecting portions an adjacent section of each respective side wall.
Thus, the male end of a profile element can be inserted into the female end of the subsequent profile element such that they fit together.
The object of the invention is likewise attained by a kit of parts for assembling a structurally-integrated solar building
element assembly according to any of the above assembly embodiments, the kit of parts comprising:
- at least two structurally-integrated solar building
elements, each structurally-integrated solar building element comprising at least one solar energy converter such as a photovoltaic cell situated upon at least one
structural element;
- at least one profile element having a substantially flat
bottom section and two side walls, the top portion of the profile element comprising two projecting flanges adapted respectively to overlap edge portions of two mutually adjacently disposed structurally-integrated solar building elements, which form can be considered as being
substantially capital-Omega (Ω) shaped, said profile · element being adapted to be attached to a support structure by means of at least one fixation element.
Thus, a kit of parts for assembling the SISBE assembly is provided . In an embodiment of the kit of parts, the substantially flat bottom section and the two side walls of the profile element define a conduit or channel adapted to receive at least one cable connecting solar energy converters of adjacent
structurally-integrated solar building elements. Cabling of the electrical connections of the SISBEs is thus simplified, since the cabling can be disposed inside the profile elements rather than on the backside of the SISBEs, rendering access easier. In a further embodiment, the profile element comprises at least one lateral opening provided in the side wall of the profile element for the passage of said at least one cable.
In an embodiment of the kit of parts, the kit further
comprises insulating material adapted to be positioned inside
the channel, for improving the overall insulation of the assembled assembly.
In an embodiment of the kit of parts, the height of the side walls of the profile element is at least the thicknesses of said at least one structural element or of at least one sub- element thereof.
In an embodiment of the kit of parts, the. kit further
comprises a profile seal adapted to be arranged between the surface of each solar energy converter and each respective projecting portion. Weatherproofing of the assembled assembly is thus ensured. The profile seal may comprise a base portion and at least one of the following features:
· one or more projecting seal portions extending from a top surface (178) of the base portion, e.g. so as to contact the underside of a solar energy converter;
• one or more projecting seal portions extending from a side edge of the base portion, e.g. so as to contact the side wall of the profile element;
• a plurality of crenellations , i.e. ribs or ridges,
extending from a bottom surface of the base portion for sealing to the upper surface of a solar energy converter;
• one or more through holes extending along the major length of the base portion for increasing the flexibility of the base portion.
In an embodiment of the kit of parts, the kit further
comprises a top cover adapted to be arranged on the open end of the profile element, the top cover being arranged to be held in place by fixing means such as clips, screws, or glue.
Water can thus be prevented from entering into the profile element when the assembly is assembled.
In an embodiment of the kit of parts, the structurally- integrated solar building element assembly is adapted to be attached to a support structure such as roof beams or
structural panels by means of the profile element. The SISBEs themselves thus do not require holes, clips or similar to attach them to the support structure.
In an embodiment of the kit of parts, the profile element comprises at a male end a cutout in each side wall and a pair of tabs, the outer surface of each tab being flush with the inner surface of the adjacent side wall, and wherein the profile element comprises at a female end a pair of further cutouts formed by cutting away the ends of the projecting portions an adjacent section of each respective side wall. Thus, the male end of a profile element can be inserted into the female end of the subsequent profile element such that they fit together.
The object of the invention is likewise attained by a
structurally-integrated solar building element (SISBE) comprising at least one solar energy converter situated upon at least one structural element, wherein the at least one structural element is wedge shaped and comprises a thicker edge and a thinner edge, said thicker edge and said thinner edge being opposite- edges . Since one edge is thicker than the opposite edge, when the SISBEs are laid together thick-end-to- thin-end, the thick end of one SISBE will sit proud above the thin end of the adjacent SISBE, rendering mounting and
dismounting of the SISBEs easier.
In an embodiment of the structurally-integrated solar building element, the at least one structural element comprises at least one first sub-element situated closest to the at least one solar energy converter, and at least one second sub- element situated on the side of the least one first sub- element opposite to the at least one solar energy converter. The mechanical and insulating properties of the SISBE can thus be optimised, e.g. by choosing different materials for each of the sub-elements. For instance, one sub-element may give the SISBE structural strength while the other gives it good insulating properties.
In an embodiment of the structurally-integrated solar building element, the at least one first sub-element is conformed so as to give the at least one structural element its wedge shape, the at least one second sub-element being of substantially constant cross-section.
In an embodiment of the structurally-integrated solar building element, the second sub-element projects over the first sub- element at the thinner edge of the at least one structural element and is recessed from the first sub-element at the thicker edge of the structural element. This results in a staggered, stepped structure which contributes to the
structural integrity of an assembly of multiple SISBEs.
In an embodiment of the structurally-integrated solar building element, the at least one solar energy converter projects over the least one structural element at said thicker edge (A) thereby defining a projecting portion, and wherein the at least one solar energy converter is recessed from the at least one structural element at said thinner edge thereby defining a recess area, i.e. an area of exposed structural element upon which no solar energy converter is situated. Thus, when
placing SISBEs adjacent to one another with the thicker edge of one abutting the thinner edge of the other, a recess area is formed in which a structural beam, a seal and so on may be placed.
In an embodiment of the structurally-integrated solar building element, the structural element comprises at least one curved or bevelled (i.e. angled) portion at its thicker end and at least one substantially corresponding oppositely-curved or oppositely-bevelled portion at its thinner end. The curved or bevelled portion is arranged so as to substantially fit together with the oppositely-curved or oppositely-bevelled portion of an adjacent structurally-integrated solar building element. This renders mounting and dismounting of SISBEs easier, since the curved or bevelled edges will not impinge upon each other as the SISBEs are rotated into position. In addition, since such impingement does not take place, less clearance is required at the junction between two SISBEs than in the case of the thicker end and the thinner and being squared off, hence the tolerance is better and less heat can escape through the clearance, improving the insulating
properties of such a SISBE assembly. In a further embodiment, the at least one curved or bevelled portion at the thicker end of the structural element underhangs the solar energy
converter, and the said at least one curved or bevelled portion at the thinner end of the structural element extends beyond the solar energy converter. In a yet further
embodiment, the first sub-element comprises a first bevelled portion, and the second sub-element comprises a second
bevelled portion, wherein a first plane defined by the oblique surface of the first bevelled portion intersects a plane defined by the oblique surface of the solar energy converter at an angle of less than 180°, i.e. the first bevelled portion
has a steeper bevel than the second bevelled portion. In other words, the second bevelled portion is more acute than the first bevelled portion. In an embodiment of the structurally-integrated solar building element, the difference in thickness between the thicker edge and the thinner edge is arranged such that the projecting portion of a first structurally-integrated solar building element is arranged to overhang the recess area of a second structurally-integrated solar building element. In
consequence, a stabilising beam and a seal can then be
positioned within an interspace formed between the projecting portion of the solar energy converter of the first
structurally-integrated solar building element and the
structural element of the second structurally-integrated solar building element, with the seal in contact with the
stabilising beam and in contact with the overhanging portion of the solar energy converter of the first structurally- integrated solar building element. Thus, mechanical stability of an assembled SISBE assembly is assured, along with good sealing between adjacent SISBEs.
In an embodiment of the structurally-integrated solar building element, the solar energy converter is attached to the at least one structural element by at least one of: adhesive bonding; welding; clamping; riveting; screws; bolts.
In an embodiment of the structurally-integrated solar building element, the structural element and/or at least one sub- element thereof comprises at least one of the following materials in a foam and/or fibrous form: polypropylene, PMI (polymethacrylimide) , PUR (polyurethane) , PIR
(polyisocyanurate) , expanded perlite, PEEK
(polyetheretherketone) , a styrene-based (PS) material, foam
glass, glass wool (whether compressed or not), a rock wool- based material (whether compressed or not) . These materials are stable at higher temperatures and provide good insulation properties along with suitable mechanical properties.
The object of the invention is likewise attained by a
structurally-integrated solar building element assembly comprising at least two structurally-integrated solar building elements according to any of the above embodiments thereof disposed mutually adjacently such that the thinner end of a first structurally-integrated solar building element abuts or is adjacent to the thicker end of a second structurally- integrated solar building element. In an object of this structurally-integrated solar building element assembly, the assembly comprises at least two
structurally-integrated solar building elements with
projecting solar energy converters as above. The
structurally-integrated solar building element assembly further comprises a stabilising beam and a seal positioned within an interspace formed between the projecting portion of the solar energy converter of the first structurally- integrated solar building element and the structural element of the second structurally-integrated solar building element, the seal being in contact with the stabilising beam and in contact with the overhanging portion of the solar energy converter of the first structurally-integrated solar building element. Thus structural integrity of the SISBE assembly is assured, while also good weather-proofing is attained. In a further embodiment, the stabilising beam substantially fills the recess area, further assisting in assuring structural integrity and structural strength. In a yet further
embodiment, the SISBE assembly further comprises an additional sealing film placed extending from the limit of the pv active
cells of the solar energy converter (typically about 1cm from the edge of the solar energy converter glass) of the second structurally-integrated solar building element up to the beginning of the structural element of the first structurally- integrated solar building element.
In an object of this structurally-integrated solar building element assembly, the seal has a hardness of 20-90 Shore, particularly 35-70 Shore, further particularly 40-60 Shore, yet further particularly substantially 50 Shore. The seal may be σ shaped, i.e. may comprise a flat portion for contacting at least the stabilising beam, and a tubular portion joined to the flat portion adapted to contact the underside of the projecting portion of the solar energy converter of the first structurally-integrated solar building element and to contact the surface of the solar energy converter of the second structurally-integrated solar building element. Furthermore, the tubular portion of the seal may comprise one or more ribs for contacting the underside of the projecting portion of the solar energy converter of the first structurally-integrated solar building element. Good sealing between the SISBEs is thus achieved.
Advantageously, this structurally-integrated solar building element assembly and the first-mentioned structurally- integrated solar building element assembly may be combined so as to form a structurally-integrated solar building element assembly comprising a plurality of structurally-integrated solar building element assemblies according to the first- mentioned embodiments thereof, arranged such that the
structurally-integrated solar building elements form an at least 2x2 matrix of structurally-integrated solar building elements, each adjacent pair of structurally-integrated solar building elements arranged in a direction parallel to the
profile element (50) forming a structurally-integrated solar building element assembly according to the second-mentioned embodiments thereof. Finally, the object of the invention is likewise attained by a building comprising any combination of the above-mentioned embodiments.
BRIEF DESCRIPTION OF THE FIGURES
The appended figures illustrate purely schematically:
Figure 1: a longitudinal cut through a SISBE on line A-A' of fig. 3;
Figure 2: a cross-section of SISBE on line B-B' of fig. 3;
Figure 3: a SISBE mounted on a support structure;
Figure 4: three SISBES mounted on a support structure;
Figure 5: a 3x3 matrix of SISBES mounted on a support
structure;
Figure 6: a longitudinal cut along D-D' of Figure 5;
Figure 7: a cross-section along E-E' of figure 5;
Figure 8: shows an arrangement of SISBEs with their junction boxes connected by cables;
Figure 9: a wireframe isometric view of a SISBE;
Figure 10: an isometric view from above on a crossing point of four SISBEs when mounted;
Figure 11: the situation of Figure 10 with further mounting parts attached;
Figure 12: The situation of Figure 11 with all mounting parts attached;
Figure 13: an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6;
Figure 14: an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6;
Figure 15: an illustration of a further embodiment of two SISBES in longitudinal cut analogue to figure 6;
Figure 16: a cross-section of a variant of the seal shown in figure 6;
Figure 17: a cross-section of a variant of the profile seal shown in figure 7;
Figure 18: a perspective view of the profile seal of figure 17;
Figure 19: an isometric view of a male end of a profile element; and
Figure 20: an isometric view of a female male end of a profile element.
DETAILED DESCRIPTION OF THE INVENTION
The invention shall now be described with the aid of the figures attached.
Figure 9 shows a Structurally Integrated Solar Building
Element 10 (SISBE) comprising a Solar Energy Converter (SEC) 11 and a Structural Element (SE) 15. The SE is being shown here as made from two sub-parts, but this embodiment shall not be limiting. In the following a longitudinal cut shall mean a plane defined by arrows A-A' and C-C . A cross-section shall be defined by the plane B-B' and C-C. If the thickness of one of the features shown in the figures is addressed, the
elongation along C-C is being meant.
The dimensioning in Figure 9 has been adapted to a standard size of one type of SEC 11, 1100mmxl300mm. The size of the SEC may vary and the respective other dimensions will adjust respectively. The SEC may be a flat, plate shaped photovoltaic panel as known in the art, preferably a thin film solar panel.
Figure 1 shows a longitudinal cut through a SISBE 10. In a first embodiment of the invention a Structurally Integrated Solar Building Element 10 comprises at least one Solar Energy Converter SEC 11 and at least one Structural Element 15; the Structural Element may have an uneven thickness. Preferably the Structural Element 15 has the shape of a stretched wedge, with the thickness of the Structural Element 15 being thicker at one edge (A) compared to the other (A' ) .
-,. In other words, the planes defined by the surface of SEC 11 or defined by the interface between SEC 11 and SE 15 and the surface of Structural Element 15 averted from SEC 11 are tilted. In an alternative embodiment not shown in the figure this thickness difference of the opposite edges (A) and (A' ) may not be necessary if during mounting the free end of SEC 11 (region close to A) will be able to overlap over the not shown neighbouring lower module (region close to A' ) ; this may become more evident starting from Fig. 3.
In Fig. 1 and 2 the Structural Element 15 is shown as being composed of a first substructure 12 and second substructure 13, which represents a further embodiment of the invention. Basically Structural Element 15 may comprise a plurality of sandwiched layers.
As shown in Fig. 1, the edges of SEC 11 and SE 15 do not align, but are recessed from each other. It is important to note that SEC 11 will project over Structural Element 15 at one edge A and will be recessed on the opposite edge A' .
Figure 2 shows a cross-section of SISBE 10. Here again
Structural Element 15 is shown as including two sub-layers 12 and 13. In the context of this disclosure in a basic
embodiment SE 15 could be realized with sub-layer 12 alone. Preferably the dimensions in the direction B-B' of SE 15 (or 12, respectively) and SEC 11 would be the same, in other words
SEC 11 will, preferably, not be recessed from nor project over SE 15 (12) .
Figures 3 and 4 show how individual SISBES can be mounted to form a larger surface. Due to the combination of SE 15 with SEC 11 only a limited support area needs to be provided. This may be beams (17, 17', 17", 17'") positioned below and along edges B. These beams could be wood, steel, concrete or any other supporting material. In Fig. 3 and 4 a closed surface is being shown as support surface. In another embodiment said closed surface is not necessarily an overall carrying surface, but could be e.g. moisture barrier (foil) and/or part of the inner wall mounting supported by a beam structure. In an alternative not shown in Fig. 3 and 4 said closed surface could be totally avoided and SISBEs could be directly fixed on said beams: in such case the rear side of the larger surface would directly show the rear SISBEs surface between the beams. In the alternative, also beams arranged orthogonally to beams 17, 17', ... can be used.
Figure 5 shows a 3 x 3 arrangement of readily mounted SISBEs 10, 20, 30, ... already with further fixtures explained in the subsequent figures. Figure 6 shows a longitudinal cut along D-D' (marked as reference 23 in Figure 5) through the overlap area between two SISBEs 30 and 40. The SECs 11, 11', the SE sub-layers 12, 13 and 12', 13' belong to SISBEs 40 and 30 respectively. Due to the wedge-like design of SE 15 a projecting portion 41 of SISBE 40 will overlap recess area 31 of SISBE 30. As can be readily understood from Figure 6, the functionality of sublayer 13, 13' of SE 15 may be omitted to explain the mounting principle. The difference of thicknesses of the adjoining edge portions of references 12 and 12' are calculated such that
they allow for arranging stabilizing beam 22 and a seal 23. Further, between beam 22 and seal 23 an additional sealing film can be placed extending from the lower SEC s 11' upper limit of the pv active cells (about 1 cm away from the SEC s 11' upper limit) up to the beginning of the adjacent SE sublayer 12. As is visible in Figure 5 and 6, stabilizing beam 22 fills a pocket or gap present in recess area 31. The
stabilizing beam advantageously extends across several SISBEs and can be made from any suitable material, light metal, plastic or alike. For cost and weight reasons a hollow profile may be used.
Seal 23 blocks dust, dirt, water, insects from entering the connecting area of SISBEs 30, 40. The seal may be designed according to state of the art techniques with . one or more sealing lips, which may be formed as hollow profile, sealing edges or a combination thereof.
Figure 7 shows a cross-section along E-E' (marked as reference 24 in Figure 5) through the overlap area between two SISBEs 20 and 30. The SECs 11", 11', the SE sub-layers 12", 13" and 12', 13' belong to SISBEs 20 and 30 respectively. Again, as can be readily understood from Figure 7, the functionality of sublayer 13", 13' of SE 15 may be omitted to explain the mounting principle. As has been mentioned above, at the edges meeting in Figure 9, SEC 11", 11' and SE 12, 12' do not protrude or recess. Therefore a specially designed profile 50 can be used to fill the gap between SISBEs 20 and 30. A fixation element 51 like a clamp, a clip, a screw or a nail is being used to fasten profile 50 to the support structure, e. g. beam 17". Profile 50 has a flat bottom section 59 and two side walls 60, 61. The height of the side walls 60, 61 is construed to be at least the thicknesses of SE 15 (or sub-layer 12', 12" - as shown) plus SEC 11', 11". It is important to note that due to the lengthwise wedge-like shape of SE 15 (sub layer 12,
respectively) the side walls 60, 61 preferably have to conform to those dimensions. In case the side walls 60, 61 do not conform the wedge shape, the remaining space between sublayers 13 and 13' could be filled with a dummy material such as plastic, foam or just left with air if sealed properly or according to the incumbent building requirements.
The top portion of profile 50 includes two projecting portions 57, 58 overlapping edge portions of SISBEs 30, 20
respectively. A profile seal 170 may be arranged between SEC 11' and projecting portion 57 and SEC 11" and projecting portion 58 respectively for blocking environmental influences from entering the area between SISBEs 20 and 30. Interspace or channel 62 can accept cables 55 connecting adjacent panels (entering the channel e. g. through lateral opening 56), sensors (temperature, humidity or alike) , insulating material 52. Easy access, e.g. for maintenance, is possible by removing a top cover 54 which is being held in place e. g. by clips 53. Alternatively screws or gluing could be used. Figure 8 shows an arrangement of SISBE' s 10, 20, 30 with their junction boxes 19, 29, 39 connected by cables. Junction boxes connect the photovoltaically active layer stacks with the grid. SISBEs 10, 20, 30 are shown side by side, separated by channels 65, 66. Connectors are being placed in the channels, thus being kept in a protected environment.
Figure 10 is a view from above on a crossing point of four SISBEs when mounted (certain parts omitted, as explained below). In analogy with Figures 6 and 7 we have two SISBEs 70 and 73 mounted side by side with a profile 50' (corresponds to profile 50 in Fig. 6) . Stabilizing beam 22 is being arranged to overlap the edge part of SISBE 70 and 73, whereas seals 23 and 23' are arranged over beam 22. The projecting part of SISBE 71 and 72 over SISBE' s 70, 73 has been omitted to allow this
view (analogy: projecting portion 41 in Figure 6) . The end part of profile 50 arranged between SISBEs 71, 73 shows cutouts allowing beam 22 to be arranged in the overlapping manner described.
Figure 11 shows the situation of Figure 10 with further mounting parts attached. References in Figure 11 have the same meaning as in Figure 10. Again the projecting portion of
SISBEs 71, 72 over SISBEs 70, 73 have been omitted to allow for the view on seals 23, 23' . Top covers 54, 54' have been arranged over profiles 50, 50', in analogy to the situation displayed in Figure 7. It has to be noted that the colours of these covers 54, 54' can be adapted to the look of SISBE's 70- 73, thus resulting in a homogeneous look over the whole covered area. However, those covers could also be coloured differently in order to create a special look or design. For large areas such graphic patterns can be arranged, be them artistic, letter-like, logos or alike.
Figure 12 shows the finalized situation with all mounting parts attached to the crossing point of SISBEs 70, 73, 74, 75. SISBE's 74, 75 now are shown to the full surface extent covering the seal portion 23, 23' , which was still visible in Fig. 11. A small front cover 78 closes the front portion of cover 54. Depending on the embodiment cover 78 may form an integral part of cover 54, too. Areas 76, 77 may receive also front faceplates, if necessary. In terms of colour design for parts 76, 77, 78 the same is valid as stated for parts 54, 54' .
In case of small tolerance adjustments different possible sealing materials may be added, particularly between upper profile 50' and lower profile 50 at their "male-female" like intersection, and also at the intersection region behind front cover 78 and below cover 54 or in all other regions where all other previously mentioned seals end or overlap. Materials for
this purpose include all market available seals as for instance plastics as for instance rubbers (butyl-based) , silicones and/or foams with closed porosity or water and vapour resistant under compression.
Figure 13 illustrates in cross-section parallel to D-D' of figure 5 a further variation of the shape of the structural element 15, facilitating mounting and dismounting of the SISBEs. Figure 13 illustrates a first SISBE placed adjacent to a second, substantially identical SISBE 10' . Beam 22 and seal 23 of figure 6 have been omitted from the drawing for simplicity. Structural element 15 is illustrated here as comprising a first sub element 12 and the second sub element 13, however structural element 15 may be composed of a single element. Contrary to the embodiment illustrated in figure 6, instead of sub-element 12 and 13 having squared ends, the thinner end of structural element 15 comprises a bevelled portion 15bi, and the thicker end of structural element 15 comprises a substantially corresponding oppositely-bevelled portion 152. In the embodiment of figure 13, the bevel angle is constant throughout both sub elements 12, 13. These bevelled portions 15bi, 15b2 are arranged such that, when two SISBEs 10, 10' are placed adjacently as illustrated, the bevelled portion 15' bi at the thinner end of the structural element 15' of one SISBE 10' substantially fits together with the oppositely-bevelled portion 15b2 of the thicker end of the structural element 15 of the adjacent SISBE 10. The sharp end of the bevel may also be squared off or rounded off. In consequence, when mounting or dismounting the SISBEs 10, 10', the bevelled ends of the structural elements 15, 15' do not impinge upon each other as the SISBES are rotated into position. In further consequence thereof, the adjacent SISBES in the direction parallel to D-D' of figure 5 can be fitted
together with higher tolerances due to less clearance being reguired to prevent the ends of the structural elements 15, 15' from impinging upon each other during mounting as is the case with the squared, stepped ends of the sub elements 12, 13 of the structural element 15 as illustrated in figure 6.
Figure 14 illustrates a further variation on the shape of structural element 15, which differs from that of figure 13 in that, instead of both sub elements 12, 13 being bevelled at the same angle, first sub element 12, which is nearest the solar energy converter 11, has a steeper bevel than the second sub element 13. In other words, a plane defined by the
bevelled portion 12bi of first sub element 12 intersects a plane defined by the solar energy converter 11 at an angle greater than the angle of intersect of a plane defined by the bevelled portion 13bi of second sub element 13 with the plane defined by the solar energy converter 11. Put another terms, the plane defined by the bevelled portion 12bi of first sub element 12 intersects the plane defined by the bevelled portion 13bi of second sub element 13 at an angle of less than 180°. Viewed in yet another manner, the acute angle between the bevelled surface of bevelled portion 12bi of first sub element 12 and its adjacent surface is greater than the acute angle between the bevelled surface of bevelled portion 13bi and its adjacent surface. Correspondingly to figure 13, bevelled portion 12' i of one SISBE 10' fits together with oppositely- bevelled portion 12b2 of an adjacent SISBE 10, and likewise bevelled portion 13' bi of one SISBE 10' fits together with oppositely-bevelled portion 13b2 of adjacent SISBE 10. This arrangement presents the same advantages as for figure 13.
Figure 15 illustrates a further variation on the shape of structural element 15, which differs from that of figures 13 and 14 in that, rather than being bevelled, the thinner end of
structural element 15 is concave curved, defining a concave curved portion 15ci. The thicker end of structural element 15 likewise comprises an oppositely-curved portion 15c2, which is convex and substantially fits together with concave curved portion 15'ci of an adjacent SISBE 10'. Although the curved portions 15ci, 15' ci, 15c2 are illustrated in figure 15 as a single curve, the curve may also be discontinuous, e.g. with a different curvature for each of sub elements 12 and 13, or the same curvature with a discontinuity at the junction between sub elements 12 and 13. This arrangement presents the same advantages as for figures 13 and 14.
Figure 16 illustrates in schematic cross-sectional view a seal 23' which is a variation of a seal 23 of figure 6, adapted to seal the gap between the underside of overhanging solar energy converter 11 of one SISBE and the top side of the adjacent solar energy converter 11' of the neighbouring SISBE. Seal 23' comprises a flat portion 161 which joins a tubular portion 162. In the illustrated example, these two portions join tangentially, however this does not have to be the case. In general terms, the shape can be described as that of a lowercase Greek letter Sigma ( σ ) . A plurality of ribs 163 are provided on the exterior of the tubular portion 160 to
substantially opposed to the junction between the flat portion 161 and the tubular portion 162. The flat portion 161, in the assembled position, lies on beam 22 and on the upper surface of the lower solar energy converter 11'. The ribs 163, in the assembled position, contact the underside of the overhanging solar energy converter 11, compressing the tubular portion 162 of the seal 23' . Seal 23' has a hardness of 20-90 Shore, particularly 35-70 Shore, further particularly 40-60 Shore, yet further particularly substantially 50 Shore.
Figure 17 and 18 illustrate a variation of a profile seal 170 of figure 7, intended to be placed between each of the
respective projecting portions 57, 58 of the profile element 50 and the upper surfaces of the respective solar energy converters 11' , 11' ' . Profile seal 170 comprises a base portion 171 provided with a pair of through holes 172. Four projecting portions 173, 174, 175 and 176 project from the base portion 171, side projecting portion 176 extending from a side edge 177 of base portion 171 and destined to be
positioned against the side wall 60, 61 of profile element 50, and the remaining three projecting portions 173, 174, 175 extending from the top surface 178 of the base portion 171, which in use will face the projecting portion 57 or 58 of profile element 50. Projecting portion 175, which is flush with the same side edge 177 as side projecting portion 176 is aligned at a greater angle to top surface 178 than projecting portions 173 and 174. Bottom surface 180 of profile seal 170 is provided with a plurality of ribs or crenellations 179, to provide better sealing against the top surface of the solar energy converter. Cutouts 173a, 174a, 175a are provided at the root of each projecting portion 173, 174, and 175 to provide clearance to allow the projecting portions to bend under pressure applied by the projecting portion 57, 58 of the profile element 50. This arrangement provides good sealing of the profile element 50 to the solar energy converters 11' ,
11' ' . However, the described and illustrated profile is not to be considered as limiting: variations from this form, such as in the shape and number of the projecting portions 173, 174, 175 and 176, through holes 172, and crenellations 179.
Suitable Shore hardness of profile seal 170 is between 20-90, particularly 40-80, further particularly 50-70, even further particularly substantially 60.
Figure 19 illustrates the male end of a profile element 50 adapted to interface with the end of an adjacent profile element. The profile element 50 is partially undercut leaving a pair of cutouts 192 and 193 under each projecting portion 57, 58 respectively. A pair of tabs 190, 191 respectively are provided, the outer surface of each tab 190, 191 being
substantially flush with the inner surface of each side wall 61, 60 respectively of the profile element 50. The cutouts 192, 193 and the tabs 190, 191 may be formed by cutting the profile element 50 appropriately and then bending the material to form the tabs 190, 191. As shown in figure 20, the opposite end, i.e. the female end, of each profile element 50 is provided with further cutouts 201, 202 respectively, formed by cutting away the ends of the projecting portions 58 and 57 respectively, along with an adjacent section of each
respective side wall 60, 61. Thus, a plurality of profile elements 50 can fit together by asserting the male end of one profile element 50 into the female end of an adjacent profile element 50.
MATERIALS
Thin film solar cells as defined above commonly are being deposited on glass substrates. After deposition, quality control and electrical contacting the thin film solar cell needs to be encapsulated in order to avoid degradation of the thin film materials due to environmental influences such as moisture, oxidation, mechanical stress and dirt. Therefore usually a second glass substrate is being used as back
protective layer. With the aid of a lamination layer, e.g. a PVA or PVB foil arranged in between the two glass substrates with their flat sides facing each other this environmental protection can be accomplished. The advantages of glass, such as gasproofness, rigidity, availability are gained by
increased weight and fragility. In an arrangement as disclosed herein even a glass-glass laminate is not sufficient to allow for the required stability. Since the Structural Element SE will provide for sufficient stability as described above, the disadvantages of the second glass laminate may be overcome at the same time. In other words, the second reinforcing glass could be omitted and replaced by a purely protective barrier layer. This could e.g. a laminate of thin plastic foil plus an aluminium foil. These are able to provide for electrical insulation as well as excellent moisture barrier.
The invention advantageously includes a solar module with at least two different material layers (described above as layers 12 and 13) at its backside in order to form a sandwich
structure with elevated thermal insulation and outstanding mechanical properties as toughness and rigidity in order to make it a SISBE that can be used directly as a one-piece solar energy building constructing element. Starting from the back surface of the module said two material layers may each comprise a core material layer and a back surface sandwich material layer. In case the module is not at least partially acting as front surface sandwich material layer a dedicated one has to be introduced into the SISBE between module and core material layer.
Such a sandwich structure applicable to all market available solar modules includes for example a front fibre reinforced thermoplastic or thermoset laminate that can be applied to the backside of a module by different means as for example gluing or by simply heating up the thermoplastic or thermoset
structures of such front side sandwich material layer in order to make it adhere to the back side of a module. Alternatively, the components of the sandwich structure may be simply clamped together, e.g. by clamping elements or by the profile elements (50) upon mounting the structurally-integrated solar building
element to a structure. Further the core material layer of the sandwich may preferably comprise foam-like and/or fibrous- form material and on the back side the sandwich may comprise the same or similar fibre reinforced thermoplastic or resin laminate used for said front side sandwich material layer.
In a further embodiment the front and the back side sandwich material layers used in said sandwich structure may differ from one another.
In still another embodiment the solar module may only have a front glass and therefore the sandwich structure may be directly laminated on the backside of the back glass-free module. It is obvious that in such a configuration the module itself needs to fulfil the already mentioned electrical and chemical insulating parameters.
As already mentioned, in a further embodiment the front side sandwich material layer structure may comprise to a large extent the solar module itself. In this case the foam-like and/or fibrous-form material may be attached in a different way to the solar module as for example by gluing. This may also work if the solar module has only a front glass and not a double glazed structure. In any case the foam and/or fibre may be directly applied by gluing on the back electrode or on the back reflector of a PV module (SEC, as described above) . It is obvious that in such a configuration the solar module itself needs to fulfil the electrical and chemical insulating
requirements, too.
Different materials can be included in the sandwich structure. In the following a few examples are provided; these are meant to be explanatory but not as limiting factor of the scope of the invention and its claims.
As a front side sandwich material layer (reinforcement for SEC, PV module) may be used composite materials as glass fibre
plus polypropylene, epoxy resin, polyester resin, vinylester resin. Also bulk materials as for example polypropylene or aluminium may be applied. The expert will define the necessary thickness based on the standards and regulations required. Also other materials with comparable properties may be used within the context of this invention.
As a core material / sandwich material (i.e. layer 12 and/or 13) different kind of foams and/or fibrous materials based on both organic and/or inorganic materials can be advantageously used, such as: polypropylene, PMI (polymethacrylimide) , PUR (polyurethane) , PIR (polyisocyanurate) , expanded perlite, PEEK (polyetheretherketone) , styrene-based (PS) materials, foam glass, glass wool (whether compressed or not) , rock wool-based materials (whether compressed or not), and alike. These materials are stable at higher temperatures and provide good insulation properties along with suitable mechanical
properties. Further a honeycomb-structured material may be used, reinforced with layer materials as mentioned. In case, high modulus foams can also act as front and/or rear side sandwich material layers depending also on the specific application of the SISBEs. All said materials may be combined with each other to form a multilayer / composite core material / sandwich material. Furthermore, a back side sandwich layer may be used which provides a further reinforcement. Materials as for the front sandwich material layer can be used.
Depending on the climate where the SISBE has to be installed several sandwich layers of insulating and reinforcing material may be used. As has been described above with the aid of the figures, the functionality of layers 12, 13 may again
distributed over several sub-layers.
For cold climate regions it may be necessary to provide for a increased numbers of reinforcement layers to allow for
sufficient stability due to snow and ice load. This however can be accomplished without leaving the basic inventive thought described above.
The layers described above may be integrated to a respective
SISBE unit by gluing, thermal welding, laminating or other methods suitable to durably bond said materials.
Alternatively, these layers may simply be clamped together to form the respective SISBE unit, e.g. by dedicated clamping elements or by the profile elements (50) upon mounting the structurally-integrated solar building element to a structure. The insulating properties of foams described above are well known. A man skilled in the art will, depending on the
requirements, standards and legal prescriptions choose
appropriate materials and thicknesses. By combining different materials with e.g. various thermal coefficient plus one or more reinforcement structures, a man skilled in the art will, without deviating from the inventive mounting concept describe above, create an optimized solution for e.g. industry
requirements (halls, machine shops), private housing, office buildings in tropic or in arctic environments.
The advantages described above can be preserved and even enhanced, if a modular construction system for SISBE is being established. Because mounting elements, such as profile 50, beam 22, Solar Energy Converter SEC 11 can be used
independently of the final thickness and stability design due to their standardized dimensions, the flexibility in terms of requirements does not overinflate costs.
Further advantages can be found in mounting and handling as well as in disassembly and maintenance. Transport systems can be designed to match SISBEs of different thicknesses, tools and handling systems in the manufacturing plant as well as on the construction site may be standardized.
Thicknesses of the various layers may vary. As a coarse rule one can mention that reinforcement layers can be designed advantageously to range from 0.5mm to 2.5mm, whereas the core sandwich and insulating layers may be 50mm to 30cm thick.
The invention describes the use of insulating materials as part of a SISBE. Since PV modules such as SECs exhibit dark colours they will considerably heat up. Increased operating temperatures may be of advantage for certain types of SEC, but not for all. In this case, cooling structures may be
integrated e.g. into the foam layers described above. This may be tube-like structures with circulating cooling fluids or gases (air) or actively cooling elements such as PELTIER elements. Advantageously thermoelements could be integrated close to the backside of the SEC to convert the thermal loads of the SEC into additional electrical energy.
Claims
Structurally-integrated solar building element assembly comprising at least two structurally-integrated solar building elements disposed mutually adjacently and
separated by a gap, each structurally-integrated solar building element comprising at least one solar energy converter (11) situated upon at least one structural element (15), wherein said assembly further comprises a profile element (50) disposed in said gap, said profile element having a substantially flat bottom section (59) and two side walls (60, 61), the top portion of profile element (50) comprising two projecting portions (57, 58)
respectively overlapping edge portions of two mutually adjacently disposed structurally-integrated solar building elements (30, 20) , said profile element being adapted to be attached to a support structure by means of at least one fixation element so as to hold the structurally-integrated solar building element assembly in place on said support structure .
Structurally-integrated solar building element assembly according to claim 1, wherein the substantially flat bottom section (59) and two side walls (60, 61) of the profile element (50) define a channel (62) adapted to receive at least one cable connecting solar energy converters (11) of adjacent structurally-integrated solar building elements (30, 20).
Structurally-integrated solar building element assembly according to claim 2, wherein said profile element (50) comprises at least one lateral opening (56) provided in the side wall (60, 61) of the profile element (50) for the passage of said at least one cable.
Structurally-integrated solar building element assembly according to claim 2 or 3, comprising insulating material (52) inside the channel (62).
Structurally-integrated solar building element assembly according to one of claims 1-4, wherein the height of the side walls (60, 61) is construed to be at least the
thickness of said at least one structural element (15) or of at least one sub-element (12) thereof.
Structurally-integrated solar building element assembly according to any of claims 1-5, further comprising a profile seal (170) arranged between the surface of each solar energy converter (11, 11', 11'') and each respective projecting portion (57, 58) .
Structurally-integrated solar building element assembly according to claim 6, wherein the profile seal (170) comprises a base portion (171) and at least one of the following features:
one or more projecting seal portions (173, 174, 175) extending from a top surface (178) of the base portion (171) ;
one or more projecting seal portions (176) extending from a side edge (177) of the base portion (171);
a plurality of crenellations (179) extending from a bottom surface (180) the base portion (171);
one or more through holes (172) extending along the major length of the base portion (171) .
Structurally-integrated solar building element assembly according to any of claims 1-7, further comprising a top cover (54) arranged on the open end of profile element (50) , the top cover being held in place by fixing means such as clips, screws, or glue.
Structurally-integrated solar building element assembly according to any of claims 1-8, wherein the structurally-
integrated solar building element assembly is adapted to be attached to a support structure (17) by means of the profile element (50) .
10. Structurally-integrated solar building element assembly according to any of claims 1-9, wherein the profile element comprises at a male end a cutout in each side wall (60, 61) and a pair of tabs (190, 191), the outer surface of each tab (190, 191) being substantially flush with the inner surface of the adjacent side wall (60, 61), and wherein the profile element comprises at a female end a pair of further cutouts (201, 202), said cutouts being cutouts of the ends of the projecting portions (57, 58) and of a section of each respective side wall (60, 61) adjacent to the cutout section of the ends of the projecting portions (57, 58). 11. Kit of parts for assembling a structurally-integrated solar building element assembly according to any of claims 1-10, the kit of parts comprising:
- at least two structurally-integrated solar building
elements, each structurally-integrated solar building element comprising at least one solar energy converter
(11) situated upon at least one structural element (15);
- at least one profile element (50) having a substantially flat bottom section (59) and two side walls (60, 61), the top portion of profile (50) comprising two projecting portions (57, 58) adapted respectively to overlap edge portions of two mutually adjacently disposed structurally-integrated solar building elements (30, 20), said profile element being adapted to be attached to a support structure by means of at least one fixation element.
12. Kit of parts according to claim 11, wherein the
substantially flat bottom section (59) and two side walls (60, 61) of the profile element (50) define a channel (62)
adapted to receive at least one cable connecting solar energy converters (11) of adjacent structurally-integrated solar building elements (30, 20) .
Kit of parts according to claim 12, wherein said profile element (50) comprises at least one lateral opening (56) provided in the side wall (60, 61) of the profile element (50) for the passage of said at least one cable.
Kit of parts according to claim 12 or 13, further
comprising insulating material (52) adapted to be
positioned inside the channel (62).
Kit of parts according to one of claims 11-14, wherein the height of the side walls (60, 61) is construed to be at least the thicknesses of said at least one structural element (15) or of at least one sub-element (12) thereof. Kit of parts according to any of claims 11-15, further comprising a profile seal (170) adapted to be arranged between the surface of each solar energy converter (11, 11', 11'') and each respective projecting portion (57, 58).
Kit of parts according to claim 16, wherein the profile seal (170) comprises a base portion (171) and at least one of the following features:
one or more projecting seal portions (173, 174, 175) extending from a top surface (178) of the base portion (171) ;
one or more projecting seal portions (176) extending from a side edge (177) of the base portion (171);
a plurality of crenellations (179) extending from a bottom surface (180) the base portion (171);
one or more through holes (172) extending along the major length of the base portion (171) .
Kit of parts according to any of claims 11-17, further comprising a top cover (54) adapted to be arranged on the open end of profile element (50) , the top cover being arranged to be held in place by fixing means such as clips, screws, or glue.
Kit of parts according to any of claims 11-18, wherein the structurally-integrated solar building element assembly is adapted to be attached to a support structure (17) by means of the profile element (50) .
Kit of parts according to any of claims 11-19, wherein the profile element comprises at a male end a cutout in each side wall (60, 61) and a pair of tabs (190, 191), the outer surface of each tab (190, 191) being flush with the inner surface of the adjacent side wall (60, 61), and wherein the profile element comprises at a female end a pair of further cutouts (201, 202) said cutouts being cutouts of the ends of the projecting portions (57, 58) and of a section of each respective side wall (60, 61) adjacent to the cutout section of the ends of the projecting
portions (57, 58) .
Structurally-integrated solar building element (10) comprising at least one solar energy converter (11)
situated upon at least one structural element (15), wherein the at least one structural element (15) is wedge shaped and comprises a thicker edge (A) and a thinner edge (A' ) , said thicker edge (A) and said thinner edge (A' ) being opposite edges.
Structurally-integrated solar building element (10) according to claim 21 wherein the at least one structural element (15) comprises at least one first sub-element (12) situated closest to the at least one solar energy converter (11), and at least one second sub-element (13) situated on the side of the least one first sub-element (12) opposite to the at least one solar energy converter (11) .
23. Structurally-integrated solar building element (10) according to claim 22, wherein the at least one first sub- element (12) is formed so as to give the at least one structural element (15) its wedge shape, the at least one second sub-element (13) being of substantially constant cross-section .
24. Structurally-integrated solar building element (10)
according to claim 22 or 23, wherein the second sub-element (12) projects over the first sub-element (11) at the thinner edge of the at least one structural element (15) and is recessed from the first sub-element (11) at the thicker edge of the structural element.
25. Structurally-integrated solar building element (10)
according to claim 21-24, wherein the at least one solar energy converter (11) projects over the least one
structural element (15) at said thicker edge (A) thereby defining a projecting portion (41), and wherein the at least one solar energy converter (11) is recessed from the at least one structural element (15) at said thinner edge (A' ) thereby defining a recess area (31) .
26. Structurally-integrated solar building element (10)
according to one of claims 21-25, wherein the structural element comprises at least one curved or bevelled portion at its thicker end and at least one substantially
corresponding oppositely-curved or oppositely-bevelled portion at its thinner end, the curved or bevelled portion being arranged so as to substantially fit together with the oppositely-curved or oppositely-bevelled portion of an adjacent structurally-integrated solar building element (10' ) .
27. Structurally-integrated solar building element (10)
according to one of claims 21-26, wherein said at least one curved or bevelled portion at the thicker end of the structural element underhangs the solar energy converter
(11), and the said at least one curved or bevelled portion at the thinner end of the structural element extends beyond the solar energy converter (11) .
Structurally-integrated solar building element (10)
according to claim 27, wherein the first sub-element (12) comprises a first bevelled portion, and the second sub- element (13) comprises a second bevelled portion, wherein a first plane defined by the oblique surface of the first bevelled portion intersects a plane defined by the oblique surface of the solar energy converter at an angle of less than 180°.
Structurally-integrated solar building element (10) according to claim 25, wherein the difference in thickness between the thicker edge and the thinner edge is arranged such that, when the projecting portion (41) of a first structurally-integrated solar building element (40) is arranged to overhang the recess area (31) of a second structurally-integrated solar building element (30), a stabilising beam (22) and a seal (23, 23' ) can be
positioned within an interspace formed between the
projecting portion (41) of the solar energy converter (11) of the first structurally-integrated solar building element (40) and the structural element (12', 13') of the second structurally-integrated solar building element (30) , with the seal (23, 23') in contact with the stabilising beam (22) and in contact with the overhanging portion (41) of the solar energy converter (11) of the first structurally- integrated solar building element (40) .
Structurally-integrated solar building element (10) according to any of claims 21-29, wherein the solar energy converter (11) is attached to the at least one structural element (12, 13) by at least one of: adhesive bonding;
welding; clamping; riveting; screws; bolts.
31. Structurally-integrated solar building element (10)
according to one of claims 21-28, wherein the structural element (15) and/or at least one sub-element (12, 13) thereof comprises at least one of the following materials in a foam and/or fibrous form: polypropylene, PMI, PUR,
PIR, expanded perlite, PEEK, a styrene-based material, foam glass, glass wool, a rock wool-based material.
32. Structurally-integrated solar building element assembly
comprising at least two structurally-integrated solar building elements according to any of claims 21-31 disposed mutually adjacently such that the thinner end of a first structurally-integrated solar building element (40) abuts or is adjacent to the thicker end of a second structurally- integrated solar building element (30) .
33. Structurally-integrated solar building element assembly
according to claim 32, comprising at least two
structurally-integrated solar building elements according to claims 25, wherein the structurally-integrated solar building element assembly further comprises a stabilising beam (22) and a seal (23, 23') positioned within an
interspace formed between the projecting portion (41) of the solar energy converter (11) of the first structurally- integrated solar building element (40) and the structural element (12', 13') of the second structurally-integrated solar building element (30), the seal (23, 23') being in contact with the stabilising beam (22) and in contact with the overhanging portion (41) of the solar energy converter (11) of the first structurally-integrated solar building element (40) .
34. Structurally-integrated solar building element assembly according to claim 33, wherein the stabilising beam (22) substantially fills the recess area (31) .
35. Structurally-integrated solar building element assembly according to claim 33 or 34, further comprising a sealing
film placed extending from the limit of the pv active cell of the solar energy converter (11') of the second
structurally-integrated solar building element (30) up to the beginning of the structural element (12) of the first structurally-integrated solar building element (40).
Structurally-integrated solar building element assembly according to one of claims 32-35, wherein the seal (23, 23' ) has a hardness of 20-90 Shore, particularly 35-70 Shore, further particularly 40-60 Shore, yet further particularly substantially 50 Shore.
Structurally-integrated solar building element assembly according to one of claims 32-36, wherein the seal (23) comprises a flat portion (161) for contacting at least the stabilising beam (22), and a tubular portion (162) joined to the flat portion (161) adapted to contact the underside of the projecting portion (41) of the solar energy
converter (11) of the first structurally-integrated solar building element (40) and to contact the surface of the solar energy converter (11') of the second structurally- integrated solar building element (30) .
Structurally-integrated solar building element assembly according to claim 37, wherein the tubular portion (162 comprises one or more ribs (163) for contacting the underside of the projecting portion (41) of the solar energy converter (11) of the first structurally-integrated solar building element (40) .
Structurally-integrated solar building element assembly according to any of claims 1-10, wherein each structurally integrated solar building element (10) is a structurally- integrated solar building element (10) according to one of claims 21-31.
Structurally-integrated solar building element assembly according to claim 39, further comprising a plurality of structurally-integrated solar building element assemblies
according to any of claims 1-10, arranged such that the structurally-integrated solar building elements (40, 30) form an at least 2x2 matrix of structurally-integrated solar building elements, each adjacent pair of
structurally-integrated solar building elements arranged in a direction parallel to the profile element (50) forming a structurally-integrated solar building element assembly according to any of claims 32-38.
41. Building comprising at least one structurally-integrated solar building element (10) according to any of claims 21-
31 and/or at least one structurally-integrated solar building element assembly according to any of claims 1-10, 32-38.
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US201161579246P | 2011-12-22 | 2011-12-22 | |
US61/579,246 | 2011-12-22 |
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