Abstract
A solar module includes a plurality of photovoltaic cells and a sandwich structure on which the plurality of photovoltaic cells is structurally supported. The sandwich structure includes top and bottom structural plates and an open-cell inner material located between the top and bottom structural plates.
Claims
1. A structural building element configured as a solar module, the structural building element comprising: a load-bearing first open-cell structure comprising an upper plate having an upper surface and a bottom plate physically connected to the upper plate by a first open-cell element; a plurality of photovoltaic cells fixed to the upper surface of the upper plate of the first open-cell structure; and a transparent cover disposed on the upper surface of the upper plate so as to cover the plurality of photovoltaic cells, the transparent cover comprising a second open-cell structure comprising a lower plate physically connected to a top plate by a second open-cell element, wherein the plurality of photovoltaic cells are disposed between the load-bearing first open-cell structure and the transparent cover.
2. The structural building element of claim 1, wherein the first open-cell element is selected from the group consisting of one or more of a corrugated metal core, a sinusoidal-corrugated plate, and a trapezoidal-corrugated plate.
3. The structural building element of claim 1, wherein the transparent cover comprises a thermally-insulative material.
4. The structural building element of claim 1, wherein the transparent cover has at least one property selected from the group consisting of textured, self-cleaning, anti-reflective, and nano-colored.
5. The structural building element of claim 1, wherein the plurality of photovoltaic cells are disposed in a lamination layer fixed to the upper surface of the upper plate of the first open-cell structure, and wherein a plurality of bypass diodes are disposed in the lamination layer in operative connection with the plurality of photovoltaic cells.
6. The structural building element of claim 1, further comprising a thermal absorber located between the first open-cell structure and the transparent cover.
7. The structural building element of claim 1, further comprising an array of programmable Light Emitting Diodes on the upper surface of the upper plate of the first open-cell structure, wherein the array of programmable Light Emitting Diodes comprises a plurality of sets of RGB diodes.
8. The structural building element of claim 1, wherein the bottom plate of the first open-cell structure defines a bottom surface, and wherein the structural building element further comprises an insulation layer on the bottom surface of the bottom plate.
9. The structural building element of claim 1, wherein the first open-cell structure includes a portion configured for battery storage.
10. The structural building element of claim 1, further comprising a heat transfer fluid conduit disposed in the first open-cell structure.
11. The structural building element of claim 9, further comprising a battery disposed in the portion of the first open-cell structure configured for battery storage, wherein the battery is in thermal contact with the bottom plate of the first open-cell structure.
12. A structural building element configured as a solar module, the structural building element comprising: a load-bearing first open-cell structure comprising an upper plate having an upper surface and a bottom plate physically connected to the upper plate by a first open-cell element; a load-bearing second open-cell structure disposed on the upper plate of the first open-cell structure and comprising a lower plate and a top plate physically connected to the lower plate by a second open-cell structural element; a first thermal absorber element disposed between the upper plate of the first open-cell structure and the lower plate of the second open-cell structure; a second thermal absorber element disposed on the top plate of the second open-cell structure; a plurality of photovoltaic cells fixed to the second thermal absorber element; and a transparent cover covering the plurality of photovoltaic cells, wherein the first open-cell structure and the second open-cell structure are laterally staggered relative to each other in a partially overlapping configuration.
13. The structural building element of claim 12, wherein at least one of the first and second open-cell elements is selected from the group consisting of one or more of a corrugated metal core, a sinusoidal-corrugated plate, and a trapezoidal-corrugated plate.
14. The structural building element of claim 12, wherein the transparent cover comprises a thermally-insulative material.
15. The structural building element of claim 12, wherein the transparent cover has at least one property selected from the group consisting of textured, self-cleaning, anti-reflective, and nano-colored.
16. The structural building element of claim 12, further comprising a plurality of bypass diodes operatively connected to the plurality of photovoltaic cells.
17. The structural building element of claim 12, further comprising a heat transfer fluid conduit disposed in the first open-cell structure.
18. A method of manufacturing a structural building element configured as a solar module, the method comprising: (a) physically connecting a first structural metal plate to a second structural metal plate with a first open-cell structural element so as to form a load-bearing sandwich structure defining a top surface on the first structural metal plate; (b) laminating a plurality of photovoltaic cells onto the top surface of the first structural metal plate; and (c) covering the plurality of photovoltaic cells with a transparent cover, wherein the transparent cover comprising a lower plate physically connected to an upper plate by a second open-cell structural element, so that the plurality of photovoltaic cells are disposed between the first structural metal plate and the transparent cover.
19. The method of claim 18, wherein the first open-cell structural element is selected from the group consisting of one or more of a corrugated metal core, a sinusoidal-corrugated plate, and a trapezoidal-corrugated plate.
20. The method of claim 18, wherein the step (b) of laminating includes the steps of: (b)(1) placing a thermally-absorbing element on the top surface of the first structural metal plate; and (b)(2) laminating the plurality of photovoltaic cells onto the thermally-absorbing element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1A is a perspective view of a building having façade-mounted solar modules, depicted during daytime.
(2) FIG. 1B is a perspective view of a building having façade-mounted solar modules, depicted during night time.
(3) FIG. 1C is a perspective view of a building having roof-mounted solar modules.
(4) FIG. 2A is a side view of a sandwich structure having a sinusoidal-shaped corrugated interior.
(5) FIG. 2B is a perspective view of the sandwich structure having a sinusoidal-shaped corrugated interior.
(6) FIG. 2C is a side view of a sandwich structure having a trapezoid-shaped corrugated interior.
(7) FIG. 2D is a perspective view of the sandwich structure having a trapezoid-shaped corrugated interior.
(8) FIG. 2E is a side view of a sandwich structure having a rectangular-shaped open-cell interior.
(9) FIG. 2F is a perspective view of the sandwich structure having a rectangular-shaped open-cell interior.
(10) FIG. 3A is a side view of a solar module with a metal profile having a trapezoid shape.
(11) FIG. 3B is a side view of a metal profile having a trapezoid shape.
(12) FIG. 3C is a side view of a solar module with a metal profile having a rectangular shape.
(13) FIG. 3D is a side view of a metal profile having a rectangular shape.
(14) FIG. 3E is a side view of a solar module with a metal profile having an “omega” shape.
(15) FIG. 3F is a side view of a metal profile having an “omega” shape.
(16) FIG. 4A is an exploded side view of an upper mounting system for a solar module.
(17) FIG. 4B is a side view of the upper mounting system of FIG. 4A when mounted.
(18) FIG. 4C is an exploded side view of a middle mounting system for a solar module.
(19) FIG. 4D is a side view of the middle mounting system of FIG. 4C when mounted.
(20) FIG. 4E is an exploded side view of a lower mounting system for a solar module.
(21) FIG. 4F is a side view of the lower mounting system of FIG. 4E when mounted.
(22) FIG. 5A is a cross-sectional view of a solar module having a load-bearing sandwich structure.
(23) FIG. 5B is a perspective view of the solar module having a load-bearing sandwich structure.
(24) FIG. 6A is a cross-sectional view of a solar module having a sandwich structure as a cover.
(25) FIG. 6B is a perspective view of the solar module having a sandwich structure as a cover.
(26) FIG. 7A is a cross-sectional view of a solar module with a sandwich structure as a cover and having load-bearing capabilities.
(27) FIG. 7B is a perspective view of the solar module with a sandwich structure as cover and having load-bearing capabilities.
(28) FIG. 8A is a cross-sectional view of a solar module having a sandwich structure and a thermal absorber.
(29) FIG. 8B is a perspective view of the solar module having a sandwich structure and a thermal absorber.
(30) FIG. 9A is a cross-sectional view of a solar module having a staggered sandwich structure.
(31) FIG. 9B is a perspective view of the solar module having a staggered sandwich structure.
(32) FIG. 9C is a perspective view of a roof made of solar modules.
(33) FIG. 10 is a cross-sectional view of a solar module having a copper absorber.
(34) FIG. 11 is a cross-sectional view of a solar module having an aluminium absorber.
(35) FIG. 12 is a perspective view of a piping system.
(36) FIG. 13 is a semi-schematic view of a heating system having a heat exchanger.
(37) FIG. 14 is a semi-schematic view of a heating system having a heat pump.
(38) FIG. 15 is a semi-schematic view of a cooling system.
(39) FIG. 16 is a cross-sectional view of a solar module having a copper absorber and batteries.
(40) FIG. 17 is a cross-sectional view of a solar module having an aluminium absorber and batteries.
(41) FIG. 18 is a cross-sectional view of a solar module having an aluminium absorber, a sandwich structure, and batteries.
DETAILED DESCRIPTION
(42) FIG. 1A shows a perspective view of a building 10 having façade-mounted solar modules 12. During the day, the solar modules 12 generate electrical energy, which may be stored in battery modules (not shown) or fed to the grid. Additionally, the solar modules 12 may produce thermal energy, which may be used directly for domestic heating purposes or stored for later use in the building.
(43) FIG. 1B shows the building 10 of FIG. 1A at night time, having façade-mounted solar modules 12′. The solar modules 12′ may have integrated LEDs, which may form a big screen for displaying images or texts. Further, during the night, the solar modules may be used for night sky cooling of the building 10.
(44) FIG. 1C shows a perspective view of a building 10′ having roof-mounted solar panels 12. The panels are mounted onto the load-bearing structure of the building, in place of roof tiles.
(45) FIGS. 2A and 2B show a sandwich structure 14. The sandwich structure comprises a top plate 16 and a bottom plate 18 made of a material having a structural strength, preferably aluminum. The sandwich structure 14 has a sinusoidal-shaped corrugated interior 20 interconnecting the top plate 16 and the bottom plate 18 in order to form a cell structure, which provides structural strength for the sandwich structure 14. The corrugated interior 20 may be made of aluminium, preferably extruded aluminum.
(46) FIGS. 2C and 2D show a sandwich structure 14′ having a trapezoidal-shaped corrugated interior 20′ similar to the previous embodiment.
(47) FIGS. 2E and 2F show a sandwich structure 14″ having a rectangular-shaped open cell interior 20″ similar to the previous embodiments, and additionally being provided with pipes 22 for circulating cooling or heating fluids, such as water and/or glycol.
(48) FIG. 3A shows a side view of a solar module with a metal profile 24 having a trapezoid shape. The metal profile 24 has flaps that are laminated or welded onto the bottom plate 18 of the sandwich structure, thereby providing a suitable fastening mechanism for the solar module. The metal profile is preferably made of a hard and durable metal. FIG. 3B shows a side view of the metal profile 24 having a trapezoid shape, without the bottom plate of the sandwich structure.
(49) FIG. 3C shows a side view of a solar module with a metal profile 24′ having a rectangular shape, which, as in the previous embodiment, includes flaps attached to a bottom plate 18. FIG. 3D shows a side view of the metal profile 24′ having a rectangular shape, without the bottom plate of the sandwich structure.
(50) FIG. 3E shows a side view of a solar module with a metal profile 24″ having an arcuate or “omega” shape, which, as in the previous embodiment, includes flaps attached to a bottom plate 18. FIG. 3F shows a side view of the metal profile 24″ having an arcuate or “omega” shape, without the bottom plate of the sandwich structure.
(51) FIG. 4A is an exploded side view of an upper mounting system for a solar module. The mount for a complete solar module preferably comprises a total of nine mounting systems, three upper, three middle and three lower. The mounting system 28 comprises a metal profile 24 as described above, which is welded or laminated onto the bottom plate 18 of the sandwich of the solar module. A rail 26 is fastened to the wall of the building, e.g, by one or more screws or bolts. A connecting member 28 is used for interconnecting the metal profile 24 and the rail 26. The connecting member 28 comprises a frame 30, which forms the top part of an outer frame of the module. The connecting member 28 further comprises a holding part 32, which catches the rail 26. The metal profile 24 is fixed to the connecting member 28 via a screw mount 34. FIG. 4B shows a side view of the upper mounting system when mounted on the wall of a building.
(52) FIG. 4C is an exploded side view of a middle mounting system for a solar module. The middle mounting system may advantageously be similar in construction to the above-described upper mounting system. FIG. 4D shows a side view of the middle mounting system when mounted on the wall of a building.
(53) FIG. 4E is an exploded side view of a lower mounting system for a solar module. The lower mounting system may advantageously be similar in construction to the above-described upper and middle mounting systems. In the lower mounting system, however, a frame 30′ forms the lower part of the outer frame of the module. A rail 26′ is fixed to the connecting member 28 via a screw mount 34. FIG. 4F shows a side view of a lower mounting system when mounted on the wall of a building.
(54) FIGS. 5A and 5B show a solar module 12 having a load-bearing sandwich structure 14. The solar module 12 further comprises photovoltaic cells 36, which are laminated onto the sandwich structure 14 by the use of e.g. glue or EVA. The photovoltaic cells 36 are protected by a thin layer or foil 38 of a transparent plastic material.
(55) FIGS. 6A and 6B show a solar module 12 having a transparent cover 40 provided by a sandwich structure. The sandwich structure that forms the cover 40 may be load-bearing, and it may also be used for providing thermal insulation to the solar module 12. Aluminum cannot be used, as it is opaque, and thus glass or plastic are feasible materials. A backing plate 38′ is, in the present embodiment, made of a foil or plate material, such as plastic or metal.
(56) FIGS. 7A and 7B show a solar module 12 with a cover 40 formed as a sandwich structure, and a loadbearing sandwich structure 14 made of, e.g., aluminum located on the opposite side, whereby the photovoltaic cells 36 are located in-between the cover 40 and the load-bearing sandwich structure 14.
(57) FIGS. 8A and 8B show a solar module 12 having a sandwich structure 14 and thermal absorber 42. It should hereby be noted that the thermal absorber 42 is preferably not be a separate part. Thus, it may be omitted. Alternatively, it may be integrated into the sandwich structure 14. The thermal absorber 42 and the sandwich structure 14 may thus form a unitary element. The thermal absorber preferably has a black color in order to efficiently absorb heat energy. A heating (or cooling) fluid such as water or glycol is thereby circulated through the cells of the inner structure of the sandwich structure 14, between the upper plate and the lower plate. The cells of the sandwich structure 14 are connected to a respective inlet and outlet manifold or pipe 22, whereby the fluid heats up (or cools down) a few degrees centigrade by passing though the cells of the sandwich structure 14. The temperature of the circulating fluid may vary depending on the actual application, and temperatures between −5 degrees centigrade and 90 degrees centigrade are feasible. A normal value would be about 25 degrees centigrade. The fluid may also contribute to the cooling of the photovoltaic modules 36. The optional cover 40 of a transparent sandwich material may be used to reduce thermal losses. The pipe 22 is here made circular in cross-section; it may, however, also be square, rectangular or any other appropriate shape.
(58) FIGS. 9A and 9B show a solar module 12 having a staggered sandwich structure 14′ 14″. The staggered sandwich structure comprises an upper sandwich structure 14′ and a lower sandwich structure 14″ which are adhered together in a partially overlapping and partially non-overlapping structure.
(59) FIG. 9C shows a perspective view of a portion of a roof made of the abovementioned solar modules 12 having staggered upper and lower sandwich structures 14′, 14″, respectively. The solar modules 12 may thereby be placed as roof tiles, such that the part of each sandwich structure where the upper sandwich structure 14′ and the lower sandwich structure 14″ are not overlapping themselves, but instead are overlapping a part of a sandwich structure of an adjacent solar module. In this way, the roof may be made fully rain proof, similar to conventional roof tiles. Additionally, the modules 12 may be sealed together forming a fully waterproof surface.
(60) FIG. 10 shows a cross-sectional view of a solar module 12 having metal absorbers 46, 46′ above and below, respectively, and a thermal absorber 42, preferably of a type described above. In this embodiment, the metal absorbers 46, 46′ are copper. Copper absorbers have conventionally been used together with copper pipes 22′ for collecting thermal energy. Copper has a superior thermal conductivity. The photovoltaic cells 36 are encapsulated in EVA.
(61) FIG. 11 shows a cross-sectional view of a solar module 12 in which the metal absorbers 46, 46′ are aluminum. Aluminum also has a very high thermal conductivity and is easier to extrude into a sandwich structure 14. The advantage of this embodiment is that the sandwich structure 14 is a structurally load-bearing element, while it also includes fluid channels 22 for transporting heat-absorbing fluid. The photovoltaic cells 36 are encapsulated in EVA.
(62) FIG. 12 shows a piping system 48 that may advantageously be used with the solar modules 12. Manifolds or pipes 22 feed each of the solar modules with fluid. The fluid flows through each solar module in the cells of the sandwich structure and is then returned for collecting the heat energy thereby obtained.
(63) FIG. 13 shows one type of heating system that may advantageously be used with the solar modules 12. This type of heating system uses a heat exchanger 50. A fluid such as water or glycol is fed through the solar panels 12. The heat exchanger 50 is used for collecting the thermal energy collected by the modules, which corresponds to the temperature difference between the fluid flowing into the heat exchanger 50 and the fluid flowing out of the heat exchanger 50. The heat exchanger 50 is, in turn, connected to a domestic water tank 58 of a building for heating water used for central heating or other domestic purposes. The heating water is conducted from, and returned to the domestic water tank 58 by a hot water conduit circuit 56, as is well known. (The system of FIG. 13 also shows a conventional cold water conduit circuit 54, which is incidental to this disclosure.) As the efficiency of the solar panels is improved, using temperatures of about 25 degrees centigrade compared to domestic water tanks, which normally use temperatures of about 50 degrees centigrade to avoid contamination by microorganism, an additional heater 52 may be required, such that the solar modules 12 provide a pre-heating of the water, and further heating is performed by another heating system (not shown).
(64) FIG. 14 shows a perspective view of another type of heating system, which instead of using an additional heater, uses a heat pump 60 for raising the temperature of the circulating fluid from about 25 degrees centigrade, which is suitable for obtaining solar heat and cool the photovoltaic cells, to about 50 degrees centigrade which is suitable as domestic hot water.
(65) FIG. 15 shows a perspective view of a cooling system, which may be used when no incoming solar radiation exists, for obtaining night sky cooling. In this way, a fluid, such as water or glycol, is circulated through the solar modules 12, releasing heat, such that the temperature of the fluid returning from the solar modules is lower that the fluid flowing into the solar modules. The temperature difference may be collected by a heat exchanger and used in a domestic air conditioning system for providing cooling via air convectors 62.
(66) FIG. 16 is a cross-sectional view of a solar module 12 having an upper copper absorber 46, a lower copper absorber 46′, copper pipes 22′, and batteries 64. The batteries 64 are, in this embodiment, located between the lower copper absorber 46′ (through which the copper pipes 22′ extend) and the rear insulation layer 38′. The batteries 64 have thermal contact with the lower absorber 46′ and thus indirectly to the copper pipes 22′ and the photovoltaic cells 36. The batteries 64 may preferably be releasably attached to the lower absorber 46′, e.g., by being clamped to the lower copper absorber 46′ or in a pocket providing a tight fit and good thermal conductivity between the lower copper absorber 46′ and the batteries 64. The batteries 64 may thus be easily exchanged when needed.
(67) According to the present embodiment, the batteries 64 form an integrated part of the solar module 12 and may be electrically connected to the photovoltaic cells 36 for allowing the photovoltaic cells 36 to charge the batteries 64 during the day. The batteries 64 may be used for various purposes, including various needs of the building, such as for powering heating units, cooling units, ventilation units or other devices such as computers etc. The batteries 64 may further be used, for example, to charge electrical vehicles or light up diodes during the night as described above. The batteries 64 may be, e.g., lithium batteries.
(68) The batteries 64 are cooled during the day by the cooling fluid circulating in the copper pipes 22′ in the same way as the photovoltaic cells 36 are cooled, as described above, and the thermal energy may be collected and used for various purposes, as described above, such as building heating or domestic water heating. During the night, the batteries 64 may be directly cooled by the use of night sky cooling as described above, i.e., the radiant energy from the solar module 12 facing the night sky will yield a cooling effect on the solar module 12.
(69) FIG. 17 is a cross-sectional view of a solar module 12 similar to the previous embodiment, in which the copper tubing is replaced by the aluminum profile 20. Thus, as previously described, the aluminum profile or structure 20 of the present embodiment provides both a structurally load-bearing element, and fluid channels 22 for transporting the absorbed heat via a heat-conducting fluid. The batteries 64 are placed in thermal contact with the aluminum profile 20. Cooling/heating liquid may be circulated through the channels 22.
(70) FIG. 18 is a cross-sectional view of a solar module 12 having an aluminum absorber 20, a lower sandwich structure 14′ and batteries 64. Between the aluminum heat absorber 20 and the batteries 64 a reinforcing lower sandwich structure 14′ made of heat conductive material, such as a suitable metal. In this way, the solar module 12 may be fastened to a load-bearing structure without interfering with the aluminum absorber 20. Combinations of the above mentioned embodiments are of course equally feasible.
REFERENCE NUMERALS USED IN THE FIGURES
(71) TABLE-US-00001 10. Building 12. Solar module 14. Sandwich structure 16. Top plate 18. Bottom plate 20. Inner material 22. Pipe 24. Profile 26. Rail 28. Connecting member 30. Frame 32. Holding part 34. Screw mount 36. Photovoltaic cells 38, 38′. Foil layers 40. Cover 42. Thermal absorber 44. Insulation 46. EVA 48. Pipe system 50. Heat exchanger 52. Heater 54. Domestic hot water 56. Central heating 58. Domestic boiler 60. Heat pump 62. Cooling convector 64. Battery
