Lightweight, self-ballasting photovoltaic roofing assembly

US 5,746,839 A
Filed: 04/08/1996
Issued: 05/05/1998
Est. Priority Date: 04/08/1996
Status: Expired

First Claim

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1. A photovoltaic assembly comprising:

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

a spacer secured to the lower surface of the photovoltaic module;

said spacer sized and configured to define;

an open region beneath said lower surface andincluding access openings formed therein for fluidly coupling said open region to said upper surface;

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

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

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Abstract

A photovoltaic roofing assembly comprises a roofing membrane (102), a plurality of photovoltaic modules (104, 106, 108) disposed as a layer on top of the roofing membrane (102), and a plurality of pre-formed spacers, pedestals or supports (112, 114, 116, 118, 120, 122) which are respectively disposed below the plurality of photovoltaic modules (104, 106, 108) and integral therewith, or fixed thereto. Spacers (112, 114, 116, 118, 120, 122) are disposed on top of roofing membrane (102). Membrane (102) is supported on conventional roof framing, and attached thereto by conventional methods. In an alternative embodiment, the roofing assembly may have insulation block (322) below the spacers (314, 314'"'"', 315, 315'"'"'). The geometry of the preformed spacers (112, 114, 116, 118, 120, 122, 314, 314'"'"', 315, 315'"'"') is such that wind tunnel testing has shown its maximum effectiveness in reducing net forces of wind uplift on the overall assembly. Such construction results in a simple, lightweight, self-ballasting, readily assembled roofing assembly which resists the forces of wind uplift using no roofing penetrations.

299 Citations

54 Claims

1. A photovoltaic assembly comprising:
- a photovoltaic module having sides and having upper and lower surfaces; and
  
  a spacer secured to the lower surface of the photovoltaic module;
  
  said spacer sized and configured to define;
  
  an open region beneath said lower surface andincluding access openings formed therein for fluidly coupling said open region to said upper surface;
  
  said access openings extending along at least two sides of said photovoltaic module;
  
  whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to a support surface.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
- - 2. The assembly according to claim 1 wherein said photovoltaic module has at least three sides.
  - 3. The assembly according to claim 2 wherein said spacer comprises multiple spacer elements, at least one said spacer element secured to said lower surface along each of said sides.
  - 4. The assembly according to claim 2 wherein said access openings extend along said at least three sides of said photovoltaic module.
  - 5. The assembly according to claim 1 wherein said at least two sides comprise two opposite sides of said photovoltaic module.
  - 6. The assembly according to claim 1 wherein said access openings extend along about 5% to 50% of the length of at least two said sides.
  - 7. The assembly according to claim 1 wherein said spacer has a lower spacer surface and an upper spacer surface tapered relative to said lower spacer surface, said tapered upper spacer surface supporting said photovoltaic module so said open region is a tapered open region tapering between said access openings along two of said sides.
  - 8. The assembly according to claim 7 wherein said tapered upper spacer surface is at an angle of about 5°
    - -12°
      
      relative to the lower spacer surface so said photovoltaic module is oriented at an angle of about 5°
      
      -30°
      
      relative to the support surface.
  - 9. The assembly according to claim 7 wherein said photovoltaic module has an upper side, said photovoltaic module extending downwardly from said upper side, and further comprising a wind deflection surface having an upper edge near said upper side, said wind deflecting surface extending downwardly and outwardly away from said upper side.
  - 10. The assembly according to claim 9 wherein said upper edge is about the same elevation as the upper side.
  - 11. The assembly according to claim 1 further comprising an insulation member securable to the spacer when said spacer is situated between said photovoltaic module and said insulation member.
  - 12. The assembly according to claim 11 wherein said spacer and insulation member forms a variable-height support structure for said photovoltaic module so that said open region is a tapered open region tapering between said access openings along two of said sides.
  - 13. The assembly according to claim 12 wherein said photovoltaic module has an upper side, said photovoltaic module extending downwardly from said upper side, and wherein said insulation member comprises a wind deflection surface having an upper edge near said upper side, said wind deflection surface extending downwardly and outwardly away from said upper side.
  - 14. The assembly according to claim 13 wherein said spacer comprises a plurality of elongate tapered spacers spaced apart from one another.
  - 15. The assembly according to claim 11 wherein said photovoltaic module, insulation member, and spacer have a combined weight of about two to four pounds per square foot.
  - 16. The assembly according to claim 11 wherein said photovoltaic assembly comprises means for interengaging said photovoltaic module, spacer, and insulation member to create an integral assembly for resisting the forces of wind uplift thus enabling lower installed weight per unit area.
  - 17. The assembly according to claim 1 wherein said photovoltaic assembly comprises means for interlocking one said photovoltaic module to another said photovoltaic module.
  - 18. The assembly according to claim 1 wherein said photovoltaic module and spacer have a combined weight of about two to four pounds per square foot.

19. A photovoltaic assembly, comprising:
- a plurality of spacers configured for disposal on top of a building roof;
  
  a plurality of photovoltaic modules having sides and disposed on top of said spacers to form a photovoltaic array; and
  
  said spacers;
  
  being arranged in a geometry which generally follows the sides of said photovoltaic modules; and
  
  having openings that are between about 5% and 50% of the length of at least two sides of each photovoltaic module;
  
  whereby said geometry enables said photovoltaic assembly to resist forces of wind uplift.
- View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
- - 20. The assembly of claim 19 wherein said spacers have a top surface which is joined to said photovoltaic modules, forming an integral unit.
  - 21. The assembly of claim 19 wherein said spacers are positioned adjacent to one another with said photovoltaic modules spaced apart from one another, whereby water may drain between said photovoltaic modules.
  - 22. The assembly of claim 19 further comprising perimeter ties situated around the array and joined with said array to make an integral array assembly.
  - 23. The assembly of claim 22 wherein said perimeter ties are joined with one another whereby the integral array assembly is tied together and strengthened.
  - 24. The assembly according to claim 22 wherein said perimeter ties comprise a chosen one of concrete pavers and hollow metal flashing units.
  - 25. The assembly of claim 19 wherein said assembly further comprises means for resisting forces of wind uplift sufficiently to eliminate the need for penetrations of a building roof.
  - 26. The assembly of claim 19 wherein said spacers are preformed spacers.
  - 27. The assembly of claim 19 wherein said spacers have a tapered profile for orienting the photovoltaic module in a direction for increased sun exposure.
  - 28. The assembly of claim 27 wherein said spacers have tapered profiles with first outwardly and downwardly tapered portions supporting said photovoltaic modules and defining a tapered air-space and second outwardly and downwardly tapered portions, whereby wind is caused to flow over the spacer and not underneath the photovoltaic module,whereby internal pressures within the tapered air-space created by the spacers offset external pressures which aids the overall assembly in resisting net forces of wind uplift.
  - 29. The assembly of claim 19 wherein said spacers are sized to orient the photovoltaic modules at an angle of about 5°
    - -12° and
      
      create a tapered air space beneath the photovoltaic modules.
  - 30. The assembly according to claim 19 wherein said photovoltaic array has a weight of about two to four pounds per square foot.

31. A photovoltaic roofing assembly, comprising:
- a plurality of insulation blocks disposed as a layer on top of a roofing membrane;
  
  a plurality of spacers configured for disposal on top of said insulation blocks;
  
  a plurality of photovoltaic modules having sides and disposed on top of said spacers to form a photovoltaic array; and
  
  said spacers;
  
  being arranged in a geometry which generally follows the sides of said photovoltaic modules; and
  
  having openings that are between 5% and 50% of the length of at least two sides of each photovoltaic module;
  
  whereby said geometry enables said photovoltaic assembly to resist forces of wind uplift.
- View Dependent Claims (32, 33, 34, 35)
- - 32. The assembly of claim 31 wherein each of said insulation blocks have adjoining sides with a joint disposed between said sides for water drainage.
  - 33. The assembly of claim 31 wherein said insulation blocks have top surfaces which are joined to the spacers which in turn are joined to photovoltaic modules, forming three-part integral units.
  - 34. The assembly of claim 31 wherein said spacers are sized to orient the photovoltaic modules at an angle of about 5°
    - -12° and
      
      create a tapered air space beneath the photovoltaic modules.
  - 35. The assembly according to claim 31 wherein said photovoltaic array has a weight of no more than about four pounds per square foot.

36. A photovoltaic roofing assembly comprising:
- a plurality of photovoltaic assemblies, each said photovoltaic assembly comprising;
  
  a photovoltaic module having upper, lower, and lateral sides and having upper and lower surfaces; and
  
  a variable-height spacer secured to the lower surface of the photovoltaic module so to orient said photovoltaic module at an angle with said lateral sides extending downwardly from said upper side to said lower side, said angle being about 5°
  
  -30°
  
  from horizontal;
  
  said spacer sized and configured to define;
  
  a tapered open region beneath said lower surface; and
  
  access openings along said upper and lower sides fluidly coupling said open region to said upper surface;
  
  whereby wind uplift forces are resisted when said photovoltaic assembly is mounted to a support surface; and
  
  means for interengaging adjacent photovoltaic assemblies into an array of photovoltaic assemblies, said array defining a perimeter.
- View Dependent Claims (37, 38, 39, 40)
- - 37. The assembly according to claim 36 wherein said perimeter assembly comprises a concrete paver.
  - 38. The assembly according to claim 36 wherein said photovoltaic assembly further comprises a wind deflection surface, having an upper edge near the upper side, extending downwardly and outwardly away from said upper side.
  - 39. The assembly according to claim 38 wherein said spacer provides said wind deflection surface.
  - 40. The assembly according to claim 36 wherein said array of photovoltaic assemblies has a weight of no more than about four pounds per square foot.

41. A method of making a photovoltaic roofing assembly, comprising the following steps:
- joining a spacer to a photovoltaic module;
  
  sizing and positioning said spacer to provide an open region beneath said photovoltaic module and openings into said open region on at least two sides of said photovoltaic module to reduce wind uplift forces on the photovoltaic module;
  
  joining an insulation layer to said spacer to create a three-part integral assembly; and
  
  installing in the field said three-part integral assembly as a layer on top of a roofing membrane without forming penetrations through a roof surface;
  
  whereby the completed assembly resists the forces of wind uplift.
- View Dependent Claims (42, 43, 44, 45, 46)
- - 42. The method of claim 41 further comprising the step of sizing said openings to comprise about 5% to 50% of the length of at least two sides of said photovoltaic module.
  - 43. The method of claim 41 further comprising the step of providing said openings on all sides of said photovoltaic module.
  - 44. The method of claim 41 further comprising the step of configuring said spacer to have a tapered surface to which said photovoltaic module is joined, said tapered surface having an angle of about 5°
    - -30°
      
      from horizontal thereby forming said open region as a tapered open region.
  - 45. The method according to claim 41 further comprising the step of providing said integral assemblies with interengagable lateral edges, and said installing step is carried out so that said lateral edges of adjacent integral units are interengaged.
  - 46. The method according to claim 41 further comprising the steps of:
    - installing a plurality of said integral assemblies to form an array of said integral assemblies, said array having a periphery; and
      
      joining perimeter ties to said periphery to stabilize said array.

47. A method of making a photovoltaic roofing assembly, comprising the following steps:
- joining a spacer to a photovoltaic module to create a two-part integral assembly;
  
  sizing and positioning said spacer to provide an open region beneath said photovoltaic module and openings into said open region to reduce wind uplift forces on the photovoltaic module;
  
  configuring said spacer to support said photovoltaic module in a manner to form said open region as a tapered open region;
  
  positioning said openings on at least two sides of said photovoltaic module, said two sides being opposite sides of said photovoltaic module, said tapered open region tapering between said openings on said two opposite sides;
  
  installing in the field said two-part integral assembly as a layer above a roofing membrane;
  
  whereby the completed assembly resists the forces of wind uplift.
- View Dependent Claims (48, 49, 50, 51)
- - 48. The method of claim 47 further comprising the step of joining an insulation layer to said spacer to create a three-part integral assembly.
  - 49. The method of claim 47 wherein said spacer configuring step is carried out so that said tapered surface has an angle of about 5°
    - -30°
      
      .
  - 50. The method of claim 47 wherein said installing step is carried out without forming penetrations through, or adhering the unit to, a roof surface.
  - 51. The method according to claim 47 further comprising the steps of:
    - installing a plurality of said integral assemblies to form an array of said integral assemblies, said array having a periphery; and
      
      joining perimeter members to said periphery to stabilize said array.

52. A photovoltaic assembly comprising:
- an array of interlocking photovoltaic units, said array having a perimeter, each said photovoltaic unit comprising;
  
  a photovoltaic module having an upper surface;
  
  an insulation layer;
  
  a spacer coupling the photovoltaic module and the insulation layer and defining an open region therebetween; and
  
  an access opening fluidly coupling said upper surface of said photovoltaic module and the open region; and
  
  said array having a weight of about two to four pounds per square foot;
  
  whereby the configuration of the photovoltaic assembly resists wind uplift without the need for roof surface penetrating elements.
- View Dependent Claims (53)
- - 53. The photovoltaic assembly according to claim 52 further comprising a perimeter assembly joined to said perimeter of said array.

54. A method for making a photovoltaic roofing assembly comprising the following steps:
- selecting a photovoltaic unit having an outer photovoltaic module, an insulation layer, and a spacer coupling the photovoltaic module and insulation layer to define an open region therebetween, the outer photovoltaic module having an outer surface;
  
  the selecting step comprising the step of selecting a photovoltaic unit weighing no more than about four pounds per square foot;
  
  placing a plurality of said photovoltaic units on a roof surface without securing the units to the roof surface to form an array of said photovoltaic units;
  
  said selecting and placing steps further comprising the step of providing at least one access opening for each said photovoltaic unit fluidly coupling the outer surface of said photovoltaic module and said open region; and
  
  surrounding the array with a perimeter assembly without securing the perimeter assembly to the roof surface.

Specification

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Litigation Campaign Assessment

Current Assignee
Sunpower Corporation (Totalenergies Se)
Original Assignee
PowerLight Corp. (Totalenergies Se)
Inventors
Dinwoodie, Thomas L.
Primary Examiner(s)
Weisstuch, Aaron

Application Number

US08/629,052
Time in Patent Office

757 Days
Field of Search

136/246, 136/251, 136/291, 52/173.3
US Class Current

136/251
CPC Class Codes

F24S 2025/02   Ballasting means

F24S 2025/6007   by using form-fitting conne...

F24S 2080/015   Plastics

F24S 25/11   using shaped bodies, e.g. c...

F24S 25/16   Arrangement of interconnect...

F24S 40/85   Arrangements for protecting...

H02S 20/24   specially adapted for flat ...

Y02B 10/10   Photovoltaic [PV]

Y02B 10/20   Solar thermal

Y02E 10/47   Mountings or tracking

Y02E 10/50   Photovoltaic [PV] energy

Y10S 136/291   Applications

Lightweight, self-ballasting photovoltaic roofing assembly

First Claim

5 Assignments

0 Petitions

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Abstract

299 Citations

54 Claims

Specification

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Lightweight, self-ballasting photovoltaic roofing assembly

First Claim

5 Assignments

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0 Petitions

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Accused Products

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Abstract

299 Citations

54 Claims

Specification

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Use Cases

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Others