Patent Application
20080083176
Exemplary embodiments will be described with reference to the drawings, wherein like numerals represent like parts, and wherein:
In the following description, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.
A structural roofing panel 10 is provided that spans across roof framing members 12 to form a roofing surface of a commercial or residential building. In embodiments, the roofing panel may be provided with photovoltaic cells for generating solar electrical energy, as well as tubing disposed in the panel for generating thermal energy transferred from the roofing panel 10 by a heat transfer fluid that flows through the tubing. The heat transfer fluid transfers thermal energy from the roofing panel 10 for reuse, and also provides the benefit of cooling the photovoltaic cells, thereby increasing the efficiency of the cells in generating electricity.
As shown in
A first embodiment of a structural roofing panel 10, shown in
The roofing panel 10 provides hot water, electrical power, and structural roofing support to replace the sheeting, felt, and shingles that form conventional roofing, as well as providing thermal and electrical energy. Embodiments of the present invention provide for solar electric, hot water, and roofing in a single roofing panel assembly. This significantly reduces manufacturing costs by integrating those three functions into an integrated roofing module. Use of the embodiments reduces labor by eliminating the need to install sheeting, felt, shingles, and photovoltaic or solar thermal components on top of the roofing panel. Additionally, the embodiments enhance photovoltaic performance by cooling the backside of the photovoltaic array with water because photovoltaic efficiencies rise with lower temperatures.
In the first embodiment, a corrugated deck 20 preferably of aluminum is attached to truss braces 32, also preferably of aluminum. In some embodiments, the corrugated support deck 20 comprises two folded aluminum sheets to form, for example, 4′ wide by 8′ long panels that replace conventional 4′×8′ wood-based roof structural sheets. The corrugations in the support deck 20 provide substantial strength in the long direction, while also providing channels 22 or recesses formed in the upper surface 20a of the deck to securely hold the tubes 24 attached to the upper surface 20a such as by, for example, welding, fastening or adhering. The sides 20e of the deck may be relieved as shown for example, in
Tubing 24, such as comprised of cross linked polyethylene (PEX) or copper is positioned in the channels 22 or ‘valleys’ of the upper surface of the corrugated decking. Although alternate configurations are contemplated, in some embodiments, a length of tubing 24 bent in a serpentine pattern is laid into the channels 22 formed in the upper surface of the corrugated support deck 20. Tubing, via a heat transfer fluid flowing therethrough, extracts heat from the roofing panel 10 surface during solar conditions. The tubing 24 generally has a diameter B of less than about 0.75 inches, however, larger diameter tubing is contemplated.
An upper roofing layer 26, such as, for example in some embodiments, a single ply roofing material is provided with or without photovoltaic cells 28 to cover the deck 20 and tubing 24. In embodiments, the roofing layer 26 may be laminated to the top of the decking 20 and wrapped around the top edge 20c and further adhered to securely fasten the roofing layer 26 along the top edge 20c. Other embodiments supplement the flexible single ply 26 with a photovoltaic cell layer 28 that is laminated to form an upper surface of the roofing layer 26, to provide the roofing panel's source of electrical energy production and in some cases also to provide the panel with a water seal. The photovoltaic array 28 is nominally 4′×8′, but other dimensions based on the specific need as applicable. The roofing layer generally has a thickness C of less than about 0.1 inch, however, thicker roofing layers are applicable.
In a second embodiment, shown in
In some embodiments, the roofing panel 10 may also include a plurality of truss braces 32, each truss brace being affixed to a lower surface of the deck 20. In some embodiments, the truss braces 32 are optionally positioned within of a plurality of truss brace channels 34 formed in a lower surface of the deck 20.
As shown in
In some embodiments, the truss braces 32 are spot welded to the lower surface 20b of the deck, and are fabricated of heavier gauge aluminum. The truss braces 32 may be provided with central braces 32e centrally located within the panel 10, as well as end braces 32f positioned along the sides 20e of the deck. The truss braces 32 stiffen the assembly in the 4′ dimension to withstand wind uplift forces on the panel 10, and reduce the number of field-driven fasteners 14 used to secure the deck 20 to roof trusses 12. The end truss braces 32f also cover the sharp vertical edges of the deck 20 for better handling.
In embodiments a structural roofing panel 10 is provided with a wooden support deck 20′ having a lower support portion 20f. Although different sizes are contemplated, the wooden support deck 20′ generally has a thickness A of less than about 4.0 inches, with an upper portion 20f of the deck having a thickness D of less than about 0.5 inches. In some embodiments, the roofing panel 10 having a wooden deck 20′ may also include a plurality of truss braces 32 affixed to a lower surface of the deck 20.
In embodiments, the panel has a bottom edge 10d that interlocks with a top edge 10c of an adjacent panel. In embodiments, the truss braces 32 are configured to have lower 32a and upper 32b ends that provide an interlocking system.
An exemplary method of installing a structural roofing panel 10 to a plurality of roofing trusses 12 is provided to include inserting S1000 the lower ends 32a of truss braces 32 of a first roofing panel 10 into corresponding upper ends 32b of truss braces 32 of a second roofing panel 10′. The first 10 and second 10′ roofing panels each have a support deck 20 with an upper surface 20a that forms a plurality of tubing channels 22. Tubing 24 for use in conveying a heat transfer fluid therein is positioned within the tubing channels 22, and an upper roofing layer 26 covers the deck 20, tubing 24 and, if necessary, the plate layer 25. The first 10 and second 10′ panels also include a plurality of truss brace channels 34 formed in a lower surface of the deck 20b, and a plurality of truss braces 34, each truss brace 32 being affixed to a lower surface 20a of the deck and being positioned within one of the truss brace channels 34. The truss braces 32 having a lower end 32a that terminates in at least one projection 32c extending from a bottom edge 10d of the deck and an upper end 32b forming an opening 32d for slidingly receiving a lower end 32a of a truss brace of an adjacent panel 10′. The method includes fastening S1100 the upper ends 32a of the truss braces to the trusses 12. With this method, only top edge fasteners 14 are used to affix the roofing panel 10 to the trusses 12.
In embodiments, a method of installing a structural roofing panel 10 to roof trusses 12 is provided where the roofing layer 26 is affixed to the deck 20 only along a top edge 10c of the deck. In embodiments, the roofing layer 26 is a rectangular shape having four sides, and the roofing layer 26 is attached to the deck 20 along only one of the sides of the roofing layer 26. The method includes positioning S2000 a bottom surface 10b of a roofing panel on roof trusses 12, the roofing panel 10 having a deck 20 with an upper surface 20a that forms a plurality of tubing channels 22, tubing 24 positioned within the tubing channels 22, and an upper roofing layer 26 covering the deck 20, plate layer 25, if necessary, and tubing 24. The method also includes moving S2100 the roofing layer about the top edge 20c of the deck to expose the upper surface 20a of the deck, as shown in
A rooftop array 10 is provided including a corrugated metal or wooden deck 20 forming a plurality of channels 22 on its upper surface, tubing 24 positioned within the channels 22 for use in conveying a heat transfer fluid, and a single ply roofing layer 26, including a photovoltaic array 28, covers an upper surface 20a of the deck above the tubing 24. The embodiments may further comprise a plurality of truss braces 32. The rooftop array 10 may also be adapted for connection along its bottom edge 10d to the top edge 10c of another, adjacent array. This may include the use of a lower edge flap along the bottom edge 10d of the array to allow sealing the panel to another panel, or alternatively, to the roofing 12 below.
The roofing module 10 provides structural roofing in addition to electrical and thermal energy for commercial and domestic use and space heating. The roofing panel 10 with truss braces 32 allows the panel 10 to be fastened only along the top edge 10c, reducing installation labor costs. The truss braces 32 interlock adjacent panels 10. The roofing panel with a single ply cover 26 and a lower edge flap also allows sealing to the panel 10 or roofing 12 below it.
The edges of the roofing panel may be fastened with additional strips 36, as shown in
In some embodiments, the panels 10 will be held to the roof 12 at the top edge 10c with lag bolts driven into the trusses through prepared, recessed holes at the top edge 10c of the panel at the truss braces 32. These holes can be formed on an angle to avoid engaging the roof layer 26. These holes can be caulked and further sealed by the overlapping roofing layer 26 at the edges of adjacent panels, or by flashing strips 36 used as a transition to adjacent standard roofing materials (shingles, flashing, etc.). The bottom edge 10d of the panels can be held in place by truss brace 34 interlocking, and fastening the lowest panel to the roof 12.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
| Number | Date | Country | |
|---|---|---|---|
| 60849778 | Oct 2006 | US |
