WO2010039541A1 - Building integrated power generating system, method and components thereof - Google Patents

Building integrated power generating system, method and components thereof Download PDF

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Publication number
WO2010039541A1
WO2010039541A1 PCT/US2009/058059 US2009058059W WO2010039541A1 WO 2010039541 A1 WO2010039541 A1 WO 2010039541A1 US 2009058059 W US2009058059 W US 2009058059W WO 2010039541 A1 WO2010039541 A1 WO 2010039541A1
Authority
WO
WIPO (PCT)
Prior art keywords
curtain wall
unitized curtain
energy conversion
integrated
building
Prior art date
Application number
PCT/US2009/058059
Other languages
French (fr)
Inventor
Joe Brescia
Mark Tofflemire
Original Assignee
Architectural Glass & Aluminum Company, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Architectural Glass & Aluminum Company, Inc. filed Critical Architectural Glass & Aluminum Company, Inc.
Priority to CN2009801460103A priority Critical patent/CN102273060A/en
Priority to EP09818279.3A priority patent/EP2342811A4/en
Publication of WO2010039541A1 publication Critical patent/WO2010039541A1/en

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • H02S20/20Supporting structures directly fixed to an immovable object
    • H02S20/22Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/26Building materials integrated with PV modules, e.g. façade elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88Curtain walls
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88Curtain walls
    • E04B2/885Curtain walls comprising a supporting structure for flush mounted glazing panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88Curtain walls
    • E04B2/96Curtain walls comprising panels attached to the structure through mullions or transoms
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/88Curtain walls
    • E04B2/96Curtain walls comprising panels attached to the structure through mullions or transoms
    • E04B2/967Details of the cross-section of the mullions or transoms
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02Details
    • H01L31/02016Circuit arrangements of general character for the devices
    • H01L31/02019Circuit arrangements of general character for the devices for devices characterised by at least one potential jump barrier or surface barrier
    • H01L31/02021Circuit arrangements of general character for the devices for devices characterised by at least one potential jump barrier or surface barrier for solar cells
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30Electrical components
    • H02S40/32Electrical components comprising DC/AC inverter means associated with the PV module itself, e.g. AC modules
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30Electrical components
    • H02S40/34Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • Y02A30/60Planning or developing urban green infrastructure
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S136/00Batteries: thermoelectric and photoelectric
    • Y10S136/291Applications
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49616Structural member making
    • Y10T29/49623Static structure, e.g., a building component
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49616Structural member making
    • Y10T29/49623Static structure, e.g., a building component
    • Y10T29/49629Panel

Definitions

  • Unitized Curtain Wall Module Adapted for Integrated Photovoltaic Conversion Module; serial no. 12/564,732 (attorney docket number 2009-6); Unitized Building Integrated Photovoltaic Conversion Module; serial no. 12/564,740 (attorney docket number 2009-7);
  • Unitized Building Integrated Photovoltaic Conversion Module Adapted With Electrical Isolation and Grounding; serial no. 12/564,748 (attorney docket number 2009-8); Unitized Building Integrated Photovoltaic Conversion Module
  • serial no. 12/564,761 (attorney docket number 2009-9); Integrated Electrical Conduit for Solar PV System; serial no. 12/564,768 (attorney docket number 2009-10);
  • the present invention relates to power generating systems integrated within building facade or exterior shell structures, and more specifically to building integrated photovoltaic or BIPV systems.
  • PV photovoltaic
  • Conventional roof-top based systems are limited in photovoltaic capability because, among other reasons, the modules which make up these conventional systems are connected in series which effectively lowers the productivity of the entire system to that of the least productive of the modules.
  • Conventional roof-top based systems also depend upon racking systems which do not afford a practical method to integrate photovoltaic elements into a vertical building face in an attractive and safe manner. Shading by building elements, equipment, and other constraints severely limit the area available for PV deployment.
  • PV devices in a larger area of a building structure, and in a more visually appealing fashion.
  • a building in New York City incorporated PV elements in vertical facade assemblies that were actually physically separate from the main structure, and configured as artistic elements.
  • the project was in fact a failure due to the inability of the system designer to overcome regulatory restrictions on the incorporation of electrical elements into this type of structure.
  • the panels are still attached to the side of the building, they have not been utilized to generate useful PV power.
  • Unitized curtain wall systems are those which can be preassembled and glazed as units (i.e., the glass or other surface material installed) off site and progressively installed section by section on a building.
  • Unitized systems are suitable for mid to large projects, i.e. high-rise buildings (four stories or more), those with significant repetition of their components, and/or projects in locations that have higher seismic design requirements.
  • Frame units for unitized curtain walls are typically configured as one module (glazing or glass unit) wide by one story in height. These pre-glazed frames are typically placed on bunks consisting of about 6 units each and hoisted by a tower crane to their respective floors where they are installed, often by utilizing a small mobile hoist from the floor above.
  • the unitized curtain wall systems also typically include a pressure equalized rain screen, which counteracts the forces that cause water infiltration, such as surface tension, capillary action, gravity, kinetic energy, and pressure differential.
  • Unitized curtain wall systems are in wide spread use and gaining commercial popularity across for the country because of their ease of integration, reasonable cost, schedule-friendly capabilities and aesthetic beauty and high performance.
  • Photovoltaic modular panels have been integrated into curtain wall glass for building integrated photovoltaics, as seen in U.S. Publication Serial No. 2008/0163918 incorporated by reference herein. Nonetheless the design described is optimized only for amorphous type solar cells, and is not conducive to ease of construction because it is not configured for efficient inter-modular connection. Nor does such design compensate for shading, a problem that severely impairs the performance of conventional series-connected solar panels particularly in articulated applications like building enclosures. As is well known, in conventional PV approaches shading degrades the performance and power output (or yield) of the shaded module or unit. When shading falls on one or more of the conventional series- connected solar panels, the series connected modules degrade in overall performance to that of the lowest yield in the string.
  • WO 2006/123335 incorporated by reference herein suffers from similar deficiencies, in that inter-module connections (in particular those between each individual solar module and those adjacent left and right) are depicted in great detail. However, this system is connected in series, without individual module management.
  • the array construction method lacks inter-module conduits or passages suitable for routing wiring.
  • the modules are connected to each other only in a lateral (left and right) fashion; there is no teaching of vertical connection. For this reason any vertical connections must be accommodated through additional structures, such as tracks, tubes or strips that are not integrated into the curtain wall framing members.
  • US Patent Nos. 6,646,196 incorporated by reference herein shows a similar set up, and suffers similar deficiencies.
  • An object of the present invention is to reduce and/or overcome the aforementioned limitations of the prior art.
  • a first aspect of the invention concerns a building integrated power generating system
  • Another aspect of the invention concerns a building integrated power generating system that is UL/regulatory compliant
  • a further aspect concerns integrating control management units into such power generating system; Yet another aspect concerns a building integrated power generating system that is implemented in both vision and spandrel areas of a building facade;
  • unitized curtain wall units that are adapted for photovoltaic energy conversion modules
  • Still other aspects cover electrical isolation, electrical conduits and grounding features of such unitized curtain wall units and associated building integrated power generating systems;
  • Another aspect of the invention covers integrated wireways/raceways used with the unitized curtain wall units
  • FIG. 1 is an illustration of a preferred embodiment of a photovoltaic power generating system implemented within an exterior shell or facade of a building structure;
  • FIG. 2 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 2, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
  • FIG. 3 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 3, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
  • FIG. 4 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 4, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
  • FIG. 5 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 5, to illustrate further details and the spatial relationship of components of the preferred solar power generating system
  • FIG. 6 is a block diagram of the main electrical components employed in the preferred solar power generating system
  • FIG. 7 is a flowchart depicting a preferred process used to assemble embodiments of the solar power generating system
  • FIGs. 8 A and 8B show another perspective of the curtain wall units along the direction shown in FIG. 1 designated with a bubble and the numeric notation 8, to illustrate further details and the spatial relationship of components of the preferred solar power generating system.
  • the present invention preferably incorporates mono and/or poly silicon crystalline cells used for converting solar energy into electrical energy, such as those offered by Suntech Power Holdings Co. Ltd. (Suntech) directly into standardized curtain wall products, such as those offered by Architectural Glass and Aluminum Co, Inc (AGA) of Alameda California.
  • the AGA curtain wall products are well-known durable exterior facades. The end result is a solar power generation system that also, much in the same manner as conventional curtain wall, functionally and aesthetically encloses a building.
  • the cost of implementing such green capability is greatly reduced.
  • the cost of operating such buildings also goes down dramatically as a result of net energy savings by reducing the need for lighting using Daylighting Techniques and by controlling the solar heat gain and envelope U-value to reduce the energy needed for heating, ventilation and air-conditioning systems (HVAC).
  • HVAC heating, ventilation and air-conditioning systems
  • the invention also has applicability, however, to retrof ⁇ tting/re-cladding existing buildings to include solar capability, particularly when such structures include mechanical screening surrounding their rooftop.
  • the invention can be used in such instances to both beautify and increase the functionality of such otherwise unaesthetic and nonfunctional architectural features.
  • Unitized curtain walls are an extremely popular form of building facade used throughout the world.
  • unitized curtain walls are substantially (and usually entirely) preassembled off site in units and, after transport to the project site, hung or fastened onto on the building's structural slab edges.
  • the unitized curtain wall does not typically function as a structural support element for the building. The final installation of these pre-assembled units into the integrated whole results in a "unitized" curtain wall system.
  • Off-site pre-assembly of the units is far preferable to onsite because operations can be done far more efficiently - at a dedicated facility by skilled personnel - with much lower cost and with higher speed and throughput. Off-site assembly also leads to higher quality work with better seals, stronger bonds, and fewer errors, and further enables assembly bench testing prior to transportation and installation.
  • stick built curtain wall frames are not manufactured in a controlled factory environment, before they can be UL certified, they must be field inspected, one by one, for approval. Such one by one field inspection is less preferable than the present invention, because the one by one approach consumes longer time and runs the risk that inspection, even after the expense of transport and assembly on site, will fail to result in certification.
  • Prior building integrated PV curtain walls such as that mentioned in New York City above, suffered these very failures.
  • curtain wall unitized panels are typically prefabricated as standardized 4'-8' width x 1O'-15' height units made up of different cladding materials (stone, painted aluminum, glass, opaque-glass, etc.) depending on the desired aesthetic/look the Architect is trying to achieve. A common form factor is five feet wide by thirteen and a half feet tall. The shop pre-assembly of the different materials into a unit, among other things, allows for:
  • a unitized curtain wall unit is typically made up of the following major parts/components:
  • Framing Members these capture and support the different cladding or glazing materials desired and frame them into a unit which is manageable and conveniently sized for final installation.
  • the framing is typically rectangular (although other shapes could be used) with vertical framing elements and horizontal framing elements.
  • Framing members may be comprised of any materials known in the art, including, aluminum, steel, fiberglass or other composite materials.
  • each unitized curtain wall unit also includes one or more intermediate horizontal members. These intermediate horizontal members are typically used to hold or mount and provide support to pieces of glazing or cladding.
  • the glazing below might be transparent or vision glass, while that above might be PV material.
  • these framing members are pre-assembled in the factory . The pre-assembled frame thus forms the skeleton of the unit which will, after completion of the pre-assembly as described below, be transported to the building site for installation.
  • Support Structure/Brackets are used to fix/connect each of the curtain wall units to the edge of the building's floor-slab. In addition to providing the structural support for the wall, these brackets provide the ability to take up variation in the building's construction (typically +/- 2 to 4 inches) and exactly align each of the units with one another (typically within +/- 1/8 to 1/4 of an inch) to achieve the continuity required and the aesthetic alignment desired.
  • the support structures/brackets are composed of two mating components. One of these is pre-assembled into the unitized frame at the factory. The other mating component of the support structure/brackets is typically fastened to the building's floor-slab onsite. In this manner, the installation on site can be achieved with convenient attachment of the mating components.
  • Sealant / Gaskets physically connect and isolate the cladding or glazing materials to the framing members.
  • the sealant/gaskets effectively affix the cladding materials to the framing members, providing a waterproof seal.
  • the sealant/gasket material is typically semi-flexible to accommodate minor movement of the frame relative to the cladding material. This isolation of movement is particularly important for PV, glass, or stone as they can break due to their brittle nature, but also important with other thin, opaque materials due to their tendency to buckle producing an undesirable aesthetic.
  • sealants and gaskets also serve to electrically insulate PV from framing in many applications.
  • the sealant and gaskets are pre-assembled to the frames and glazing as part of the pre-assembly.
  • Glazing or Cladding the material which forms the aesthetic and structural exterior of the final unitized curtain wall. Different cladding materials (stone, painted aluminum, glass, opaque-glass, etc.) may be utilized depending on the desired aesthetic/look.
  • the glazing or cladding is attached to the unitized curtain wall frame members during pre-assembly.
  • Vision Material the transparent glazed area of the unit located in the zone(s) through which occupants view out or through which daylight is to be admitted to the building interior. This zone is typically the entire width of the curtain wall unit/panel x 18"- 40" above the floor to the underside of the ceiling. The vision material is also pre-assembled into the unit in the factory.
  • spandrel In a building with more than one floor the term spandrel is also used to indicate the space between the top of the window in one story and the sill of the window in the story above. The term is typically employed when there is a sculpted panel or other decorative element in this space, or when the space between the windows is filled with opaque or translucent glass, in this case called spandrel glass. Further, many opaque or translucent materials can be used, including any of a number of form factors of energy conversion devices.
  • the glazing or cladding for the spandrel area is attached to the unitized curtain wall frame members during pre-assembly.
  • Fabrication Labor typically includes all the labor involved in making or cutting/shaping each of the constituent framing and support parts of the curtain wall unit and then pre-assembling all the parts into the pre-assembled units designed for installation at the particular project. Since the curtain wall units are assembled typically in a dedicated facility, consistency and quality can be better controlled and optimized.
  • Installation Labor typically includes the labor involved in attaching the support brackets/structures to the building, laying out, hoisting, and hanging the curtain wall units on the building, mating and aligning all the units and taking up tolerances, completing the necessary electrical connections, adding final seals, insulation and any interior finish trim that needs to be coordinated with finish material (like ceilings or sheetrock) that are typically provided by others. Because the on-site assembly method of the unitized curtain wall units is effectively identical and because all of the units have a common method for mating and attachment, the skill sets of the assemblers can be standardized and more easily controlled as well.
  • Unitized PV curtain walls typically includes the labor involved in attaching the support brackets/structures to the building, laying out, hoisting, and hanging the curtain wall units on the building, mating and aligning all the units and taking up tolerances, completing the necessary electrical connections, adding final seals, insulation and any interior finish trim that needs to be coordinated with finish material (like ceilings or sheetrock) that are typically provided by others. Because the on-site assembly method
  • the present invention aims to enable unitized curtain wall systems to deliver energy production capability - more specifically photovoltaic functionality similar to a rooftop PV installation. That is, a system that primarily functions to generate electricity from solar power once the entire set of parts are assembled, and also performs the same aesthetic cladding function as prior art curtain wall systems. The difference here, of course, is that the power generation must be as compatible as possible with the requirements of a PV curtain wall unit, including resistance and compliance with various regulations concerning heat/conductive/insulation properties, air/water infiltration, wind load resistance and seismic considerations.
  • a photovoltaic (PV) curtain wall unit includes the following (in addition to some or all of the standard components noted earlier): Photovoltaic Panels: for a wall-system application, these are preferably glazable PV panels - and so can be thought of as a direct material replacement for the opaque glazed spandrel and/or vision material in the curtain wall unit - although there are some differences between these materials that are accommodated / designed for as shown in the present embodiments. Other types of panels/energy conversion devices can of course be used, and in this respect the invention is effectively panel-device agnostic. Varying cell density, photovoltaic materials, opacity, and aesthetic look can be adjusted as needed to meet the desired appearance, aesthetics and requirements.
  • Inverters/ module management units/ controls typically convert and optimize electricity generated by PV panels into grid compliant power.
  • the inverters/module management units/controls are provided locally and individually, at each curtain wall unit, to allow the PV wall system to more efficiently generate electricity from solar power.
  • local controls account for self or site shading of each individual wall unit/panel and eliminate or reduce the otherwise typical impact from shading in which one shaded unit/module degrades the performance of the entire string of modules in the affected series.
  • Shading can result from shadows cast by trees, other buildings, dust accumulation, and even birds, planes, and window cleaners. These conditions occur frequently on vertical curtain wall environments, and it is therefore important that the integrated PV curtain wall system include necessary controls and methods to mitigate and/or avoid this deleterious impact.
  • these inverter/control elements should be easily accessible for maintenance and yet preferably be hidden from view of the occupants of the space as well as from viewers of the building exterior for both safety and aesthetic purposes.
  • it preferable that of the above components should be rated UL or equivalent, and outdoor rated to accommodate for building construction conditions.
  • Wiring is preferably accommodated to carry power (and preferably control signals, where necessary) all the way from the PV panels to the grid without adding additional architectural complexity. Ideally, the wiring will be effectively invisible in the installation condition.
  • means are provided from each PV panel, through the curtain wall unit, to transport the generated electricity in a safe and controlled way through the entire wall array and ultimately to the interior of the building.
  • the wiring in a curtain wall system should preferably be done efficiently (i.e., preferably few wires for a long array run helps limit the size of the code required raceway (or other required wiring passage)), in an aesthetically pleasing manner (which, in a curtain wall system typically means hidden from view) while being protected from damage and accessible for maintenance.
  • each PV curtain wall unit of the present invention can be sold, delivered and installed as a complete unit.
  • Each PV curtain wall unit is preferably preassembled off site and transported to the building as a prefabricated module, allowing this new application to not only be simply, quickly hung on the building, but also, as panels, wiring, inverters and controls have also been prefabricated into a series of connected code-rated raceways attached to or formed by the unit framing, each unit can be simply, quickly and efficiently connected, coupled or plugged as needed into its neighboring units.
  • each unit is preferably linked to a common grounding mechanism using methods well known in the art.
  • one main purpose of the invention is to provide a photovoltaic power from a unitized curtain wall system.
  • the units assembled according to the teaching of the invention will preferably be connected or linked in a manner that accumulates the electricity generated by each unit in the manner described above.
  • the electricity so accumulated is connected to the building's primary electrical system and grid tied as appropriate, using methods known in the art. It is possible that the electricity in the system may be harnessed to run existing mechanical systems within the building envelope such as shading devices, window treatments, or blinds.
  • This implementation thus allows a solar energy system to be installed as part of a building facade with the same ease and minimal additional labor cost. Specific Details of Preferred Embodiment In a conventional rooftop system, PV panels, wiring, controls, rack/support, etc.
  • the PV curtain wall units are preferably each 'plug and play' - each unit mates into and is electrically coupled to its adjacent unit to form the solar array.
  • the solar array is electrically connected into the balance of the building electrical system.
  • the inventions better achieve the functionality of a conventional rooftop system, but do so on the vertical sides of the building. Because a typical high rise building has 7-12 times greater wall than rooftop space, the present invention allows far greater harvest of solar energy.
  • the invention is used preferably in cladding at least a substantial vertical portion of a building structure 100 as seen in a partial elevation drawing in FIG. 1.
  • the degree to which PV and non-PV curtain wall units are included and interconnected within a cladding can be tailored as needed for any particular site requirements and system goals. Please note that the elements shown in the figure are not intended to denote specific sizes or ratios, as it expected that the invention will take many different forms, sizes, and form factors in different types of installations.
  • embodiments can be used on virtually any other type or variety of structures, including residential structures, parking structures, other non-habitable structures, hospitals, airport terminals, train station terminals, sea port terminals, government buildings and even within transportation systems such as elevated rails, bridges, and other structures offering suitable solar exposure.
  • the cladding could be extended to other interior areas of a structure as well, such as may be found in an atrium, a courtyard, etc.
  • a preferred unitized curtain wall structure covering a building facade includes a number of separate curtain wall elements 105 preferably constituted of aluminum, although it will be understood that other suitable materials may be used, such as steel, fiberglass, or other composite materials.
  • the curtain wall structure is shown as a combination of vision areas and spandrel areas, but it will appreciated that these could be separate components or utilized in varying combinations.
  • the curtain wall units 105 can be configured as desired to extend across multiple stories in a continuous strip of spandrel and vision areas. While the elements 105 are shown as separate components it will be appreciated that larger "units" in the form of multiple curtain wall elements could be assembled off- site in some instances.
  • the curtain wall elements 105 are further adapted to preferably include a photovoltaic (PV) module 120 and/or other energy conversion device.
  • PV photovoltaic
  • Such devices could include capability for converting other forms of electromagnetic energy, potential energy, kinetic energy, thermal energy and/or chemical energy including photochemical energy.
  • thermionic, piezoelectric and/or mechanical devices could be integrated for harnessing heat/wind/rain energy).
  • Other examples will be apparent to those skilled in the art, and it is expected that other conversion devices will be adapted for use with the present invention. Because of their physical structure the curtain wall elements 105 can be easily adapted (mechanically/physically) to house/integrate different types of such conversion devices (which tend to be smaller than such elements) using the principles set out herein.
  • the conversion devices can be spatially arranged as part of the curtain wall elements in any convenient fashion appropriate for the particular installation. Furthermore as shown in FIG. 1, it is possible that some elements 105 may include conversion devices, while others may not, again depending on system requirements and goals.
  • well-known solar thermal energy collectors/plates could be embedded instead or in addition within the curtain wall elements for heating a conductible fluid, air or some other medium for transporting heat energy.
  • Other well-known solar thermal support elements such as mirrors, lenses and other concentrators (not shown) could be used of course to increase the heat concentration, and conventional heat storage devices (not shown) can be incorporated to store heat energy.
  • the PV module used in the preferred embodiment can be any one of a variety of virtually any commercially available PV module, including preferably a crystalline solar cell/module offered by Suntech Power.
  • the PV module can include any number of conveniently and conventionally interconnected individual solar cell devices, such as described in the aforementioned prior art references.
  • the photovoltaic technology utilized by the PV module may be based on any suitable photovoltaic conversion technology, including for example, thin film, dye tinted, fullerene based, polycrystalline, or monocrystalline.
  • the specifics of the solar cell/module (or other energy conversion device) are not material to the present invention; however regardless of their specific photovoltaic conversion technology the PV modules must be suitable to physically integrate them within the unitized curtain wall units.
  • PV module “agnostic,” which further enhances the commercial potential for the invention.
  • Conventional vision material or, in this case, glass panels 115 are also shown in FIG. 1. As described, these glass panels can be configured to have more than one panel along the vertical axis of the unit. In this configuration, the glass panels will be separated by intermediate horizontal framing members.
  • the PV module 120 is shown in FIG. 1 in the vision area of the building structure 100, it can alternatively be integrated into spandrel areas or as part of a spandrel based module 110, or in any number of combinations of such areas based on system requirements and design aesthetics.
  • a linked solar array or assembly of PV curtain wall elements 105, 105', 105" etc. is thus shown mated together, cladding or enclosing a structure, preferably extending both horizontally and vertically across multiple floors.
  • the elements 105 are preferably sized to be compatible with conventional building elements to further increase their integration potential. This arrangement is also useful for increasing the overall solar energy potential coverage for up to nearly 100% of the wall area of a structure. In contrast, typical rooftop systems only allow for a limited percentage of an overall surface area.
  • FIG. 2 shows a cutaway section of the building structure 100 along the vertical axis/direction shown in FIG. 1 designated with a bubble and the numeric notation 2.
  • the structure of the curtain wall units (such as 105, 105' and 105" which are otherwise identical) is further elaborated, including the relationship of the BIPV module 110 to the other components.
  • the typical components of curtain wall framing members on a BIPV curtain wall unit 105" are largely the same in concept as conventional curtain wall framing members.
  • the PV module 110 (located in a spandrel area as depicted in FIG. 1) is preferably mounted within an extra deep glazing pocket 125 shown generally with cross hatching for emphasis.
  • the extra deep glazing pocket 125 is preferably part of a topmost horizontal framing member 150 in the spandrel area.
  • This framing member 150 is also distinct from conventional designs in that it preferably allows extra space in the glazing pocket 125 for an edge mounted junction box for the PV module 110 and the PV Leads 140 that come out of the PV module.
  • the framing members of the preferred embodiment are unique in that they form both vertical and horizontal conduits/channels for inter-module connectivity, including preferably, power lines, control signal lines, and reporting lines.
  • PV module 110 may be transported using wiring or wireless technology, thus obviating the need for the separate control signal and reporting lines.
  • the curtain wall units 105 are engineered using conventional techniques so that they are adequately resistant to water, pressure and other physical influences that might be attendant to a particular locale. Those skilled in the art will appreciate that the specific physical implementation can be varied from site to site in accordance with local building code, geological and weather based parameters.
  • Framing member 150 further preferably includes an opening allowing the PV leads 140 (or other flexible conduit/piping for transporting fluids/gasses) to be routed to a management module or control circuit 135 preferably situated in a power/control raceway 130. Again, to the extent other types of materials are transported, the opening can be varied accordingly.
  • Power/control raceway 130 is preferably attached to the solar array after installation of the curtain wall units on the building using any of the techniques known in the art. Nonetheless it can be preassembled as well in some instances.
  • the management module 135 is preferably a unit designed for individual and group control of PV modules such as sold by TIGO Energy under the name EnergyTM Module Maximizer-EP (MM-EP) and/or modules as described in US Patent Publication Nos. 20080097655 and 20090120485 incorporated by reference herein.
  • the management module can be used to selectively monitor, troubleshoot, activate or de-activate portions of a building's solar array system, including on a side by side, floor by floor, or individual basis such as might be needed for accommodating window cleaning or maintenance as examples.
  • the management module is part of a control circuit that preferably optimizes power output of each module that it is connected to, and delivers module-level data for operational management and performance monitoring and/or control.
  • the TIGO unit in particular uses dynamic module balancing which manages the energy harvest and sends information for reporting and control.
  • the modules can be connected in a variety of known methods, depending on system needs.
  • management modules 135 are UL rated to UL 1741, they can be used in preferred embodiments of the invention in which an entire solar array for a building is effectively compliant as constructed with UL (and other safety organization, such as Canadian Standards Association (CSA), InterTec North America (ETL), Tuv Rheinlan (TUV)) requirements because it consists of elements which are each previously certified.
  • CSA Canadian Standards Association
  • ETL InterTec North America
  • TUV Tuv Rheinlan
  • the other advantage of the preferred TIGO management module is the improved safety of the solar array during operation.
  • the high voltage wiring in the preferred embodiment can be shut off, thus preventing accumulation of voltage and limiting voltage exposure to the open-circuit voltage (Voc) of a single module 110, generally no more than a normally non lethal level of approximately 60V.
  • this function can be activated with a safety button or via a remote management console or a network such as the Internet (not shown) for maximum flexibility.
  • This function can also be tied into the buildings existing safety system so it can be automatically activated in the case of an emergency. Consequently the system can be installed, maintained or approached by personnel (including fire or other emergency personnel) without exposure to voltage levels which, in some topologies of conventional arrays typically exceed 400 volts during peak operation.
  • each PV module 110 can be controlled individually by the management modules, it is possible to link and interconnect longer runs of PV modules that span more than one face of the building. While the present description presents the TIGO unit as an example it should be understood that the invention is not limited to any particular control module. While the management modules 135 are shown within the power/control raceway 130, it is expected that future generations of integration modules will continue to shrink in size and therefore can be placed in a variety of locations. For example it will be apparent that they can be located in other areas of the curtain wall element 105", including directly on the PV module 1 10 or directly within the framing members, the wiring channels, or potentially embedded in PV Modules 110. However, it should be noted that there is a benefit in most cases to locating the management modules within the power/control raceways because in this way, the signal lines are better isolated and easily routed between pairs of adjacent management modules.
  • the opening for the PV module leads 140 preferably includes a grommet 145 on the inboard vertical surface of the horizontal framing member 150. This allows for the PV module leads (or other conduits, tubes, etc.) 140 to exit the framing member 150 and enter the power/control raceway 130 in a safe and secure fashion, and in a manner that resists aging, corrosion, and damage from movement that may be cause by earthquakes, wind, etc. Skilled artisans will appreciate that the additional space shown within framing member 150 that is not used in the embodiment shown in FIG. 2, could be used in some applications to route electrical wiring or alternative form factors of management module 135.
  • tubing, conduits, etc. could be routed within this part of the framing members and used to transport heat energy in the form of a conductible fluid, gas, air, etc. to other areas of the building structure.
  • one preferred aspect of the present invention is to ensure UL and/or CSA/TUV/ETL compliance.
  • the preferred embodiment further serve such aim by including the capacity to handle regulatory rated cabling, and with mountings (i.e., appropriate hole sizing, grommets and other tethering/tieing mechanism) and cable runs/shielding that allow for appropriate separation of different types of signal cables, such as high and low power lines, that are also designed to satisfy applicable regulations.
  • mountings i.e., appropriate hole sizing, grommets and other tethering/tieing mechanism
  • cable runs/shielding that allow for appropriate separation of different types of signal cables, such as high and low power lines, that are also designed to satisfy applicable regulations.
  • Power/control raceway 130 is also preferably designed to be UL-compliant, reducing duration of work on site, construction costs certification expense and commission expenditures. To this end the raceway may be comprised of materials well- known in the art.
  • the rest of the curtain wall unit 105" is shown with conventional vision material elements 115, and various gaskets - for example, wedge gasket 165, and bed gasket 170, to help in securing and isolating the PV module 110 from the curtain wall unit 105 '.
  • gaskets for example, wedge gasket 165, and bed gasket 170, to help in securing and isolating the PV module 110 from the curtain wall unit 105 '.
  • gaskets are also shown but not annotated specifically in the deep glazing pocket region 125.
  • the gaskets are preferably comprised of materials that are UL rated for this purpose and may vary from installation to installation.
  • FIG. 3 shows a plan view of a curtain wall along the horizontal axis/direction shown in FIG. 1 with the annotation/label having a circle with the number three (3). This perspective is shown between two adjacent curtain wall units 105' and 105."
  • the PV modules 110 are preferably insulated and isolated by a set of gaskets 165, 170 as noted before in FIG. 2.
  • the use of such gaskets accommodates normal material expansions/contractions, and allows for flexibility and movement of the panels, such as needed for wind, seismic and other disturbances.
  • gaskets are illustrated as the isolating mechanism in the preferred embodiment (including for electrical isolation), it will be noted that other materials could be used, including structural silicones or VHB tape, such as that sold by 3M (Minnesota Mining and Manufacturing) without parting from the scope of the invention.
  • FIG. 3 The main feature of FIG. 3 is a vertical framing member 155, the top of which is shown in this plan view.
  • This framing member like the horizontal framing member 150 noted earlier, is preferably formed from the spaces created in the mating or coupling of the individual curtain wall units 105, and preferably without requiring additional separate structures or materials. As with its counterpart this member has additional space that can be used to accommodate other types of conduits as needed by particular energy conversion devices.
  • This clip effectively behaves as a vertical conduit to accept, manage and integrate the power and signal cables from PV modules 110, allowing them to be interconnected in a vertical orientation as well.
  • the PV modules 120 in a vision area can be coupled directly to PV modules 110 in a spandrel area, or even to other modules in a spandrel area below vision area 120, and so on.
  • the use of both vertical and horizontal wire accepting frame members allows for PV modules to be connected in a checkerboard fashion, both in the vertical and horizontal direction, to form a larger array across the face of the building structure and even across separate faces of the building structure.
  • the shape and form of the clip 160 is illustrated in the preferred embodiment as a solid rectangular box structure in FIG. 3, but any number of variants could be used to accommodate the power/signal cables. Additional conduits could also be incorporated (including on the opposite curtain wall element 105') as desired for any application. While the conduits are shown in a closed configuration (which permits easy threading/routing of the cables) it will be apparent that other structures could be used. For example the wiring may also be prefabricated or built into the curtain wall unit 105, (for example along the edge of the vertical framing member).
  • Such wiring would preferably connect with an electrical coupler to PV module leads 140.
  • a corresponding electrical coupler could be used to connect to the leads from a second PV module, or, alternatively, to leads extending to a management module 135. Any number of similar variants are possible, and the invention is not limited in this respect.
  • FIG. 4 is a plan view again along the horizontal direction shown in FIG. 1 with the bubble label containing the number 4. This figure is a cut-away and illustrates more of the details of the power/control raceway 130 used in preferred embodiments of the present invention(s).
  • the power/control raceway 130 is another feature unique to the present invention. Though similar in function to existing technology, the power/control raceway 130 is unique in that it may also be used for multiple purposes: as a conduit to carry the management module-management module cabling 165 (or other tubing/conduits), to contain management module 135, and to serve as an interior architectural trim piece. While not shown in FIG. 4, the power/control raceway also preferably includes a grommeted hole and access for a connector on the underside (bottom) as seen in FIG. 2 for receiving the leads 140 from the PV modules. Again the location of the connector is not critical, and the cabling/coupling is expected to be accomplished in any number of different ways.
  • the power/control raceway 130 is preferably formed separately in a predetermined length and then integrated as an assembly on part of the backside of a curtain wall unit 105 after unit installation on the structure. This enables each curtain wall unit 105 to effectively act as a unitized building block for constructing a solar array when integrated with the power/control raceway 130 as part of a building facade without additional supporting elements.
  • the power/control raceway can be implemented in a similar manner in the vertical direction.
  • the power/control raceway 130 is in the preferred embodiment is to be rated for Underwrites Laboratories (UL) or similar organization compliance and is made of aluminum or some other cost effective materials.
  • UL Underwrites Laboratories
  • the management modules 135 are located in the power/control raceway 130 and manage/control/ communicate with the individual PV modules. These management modules preferably optimize power output per each PV module and exchange operational management and performance monitoring data, allowing remote manipulation/management of the array.
  • the PV module leads 140 are coupled between the PV modules and the management modules to transmit generated power and communicate other status information to and from the modules. It will be understood that the particular coupling, wiring, etc., is expected to vary between different types PV modules or energy conversion devices.
  • Management module to module cabling 165 carries the accumulated power to a management unit 680 (See FIG. 6).
  • the management unit is preferably a TIGO Energy TM Maximizer Management Unit (MMU) that manages the whole assembly by processing the individual and aggregated information from the PV modules.
  • MMU TIGO Energy TM Maximizer Management Unit
  • the management unit is capable of managing an entire set of management modules 635 for a building and/or an array.
  • the management unit communicates between the management modules 635 and an Inverter 690 which is a modified typical component of any solar power generation system. Inverter 690 inverts DC to AC as known in the art.
  • the management unit (680) preferably controls the management modules in real time and sends data to a remote server 695 in order to allow on or offsite monitoring of light, temperature, electricity production and other parameters and provides the resulting information as needed.
  • the monitoring system architecture will be a function of the particular energy generation mechanism selected, and it is expected that other variants of the above will be used with different energy conversion systems.
  • this also shows a bonding jumper 175, which is used to connect the individual curtain wall elements to each other, and, eventually, to a ground potential such as the steel frame, or other conventional common grounding element in the building electrical system (not shown). In the preferred embodiment grounding is accomplished by any of the means known in the art. Note that a portion of the vertical framing members 155 can be seen in FIG.
  • FIG. 5 shows a cross section of the building in FIG. 1, along the bubble annotated with the number five (5).
  • the PV module leads 140 preferably extend from the top of a PV module 180; they are routed through grommet 145, and then into the horizontal framing member 150; and then they are routed to the vertical framing member 155, and thus can be transported (up or down) through the vertical wiring management clip 160.
  • FIGUREs 8 A and 8B show another perspective view of the mullions formed by a pair of adjacent curtain wall elements 105.
  • the additional space 190 formed within the mullion is usable as noted earlier for other array elements as needed. All other labeled elements are the same as like numbered items discussed in earlier figures.
  • FIG. 6 An electrical diagram showing the main preferred components of a solar power generation system is shown in FIG. 6.
  • like numbered elements are intended to correspond to their counterparts in prior figures unless otherwise noted.
  • an array of PV modules 610/620 are preferably coupled to each other through the management module 635.
  • the connections between the PV modules and the management modules are preferably done through the PV leads 640 that are routed both vertically and horizontally through framing members 650 and 655 respectively as noted earlier.
  • the management modules 635 are themselves preferably connected through cabling 665, and eventually to a management unit 680 as noted above.
  • the wiring for these connections are preferably done with power/control raceways 630 that are integrated with the curtain wall units 605.
  • management unit 680 is in turn preferably coupled to a DC disconnect 685.
  • DC disconnect may preferably be activated either manually or electronically to isolate power to the output of the individual PV module.
  • the output of this DC disconnect is preferably coupled to an inverter 690 which converts the DC generated voltage into an AC voltage in a well- known manner.
  • the management unit 680 is shown outside of the curtain wall unit 105, but it could be included within that unit without departing from the scope of the present invention.
  • the preferred embodiment includes a monitoring system 692 can be used to evaluate the performance of the individual PV modules 610 through interrogation of their respective management modules 635.
  • the monitoring system includes conventional computing equipment and software for coordinating data exchanges, calculations, etc., with the management unit and management modules as is known in the art.
  • the computing system is a server that is Internet accessible for remote access.
  • the output of the array is preferably connected to the building electrical system, typically in the main distribution area, where it can be used to offset consumption of electrical power or feed power into the utility grid.
  • the array can offer other DC and AC outlets for charging electrical devices, transportation vehicles, etc.
  • the form of the output, including voltage levels, current levels, etc., can be tailored as needed for any particular application.
  • a conventional electrical storage system 691 can be employed in some cases to provide back-up power if desired.
  • the support elements for a particular power generation system will vary according to the energy conversion devices used, and FIG. 6 is merely depicting the typical elements that would be used in a solar to electrical conversion system.
  • FIG. 6 is merely depicting the typical elements that would be used in a solar to electrical conversion system.
  • FIG. 7 is a flowchart illustrating the general steps employed in a preferred PV solar system assembly process.
  • the curtain wall elements 105 are preferably hung on a building structure in a manner effectively identical to that used in conventional curtain wall systems with the differences described above.
  • the PV module leads are then preferably routed both horizontally and vertically as needed through framing members 150 and 155 respectively integrated within the curtain wall units 105. This allows for flexible interconnection of adjacent PV modules in the solar array.
  • the PV module leads 140 are preferably connected to management modules 135 through connectors contained in horizontal framing member 150.
  • the individual management modules are also preferably electrically coupled together using the management-module-to-management module cabling 165 in the power/control raceway 130.
  • the grounding can be achieved during any one or more of the above steps in the manner known in the art.
  • the entire assembly consisting of unitized curtain wall elements interconnected to form a solar array, is also completely safe and preferably UL compliant.
  • the integration module 135 outputs are preferably connected to one or more management unit 680 as described earlier.
  • the electrical power can then be conveniently transferred to the building electrical distribution system, or made available through other outputs for other applications (charging).
  • the above steps do not have to be performed in the sequence noted, and that the actual assembly process will likely include other obvious variants of the above.
  • the invention implements a new type of PV capable curtain wall unit that has been specifically designed and engineered to be a power generator, but accomplishes a dual purpose: to enclose the building aesthetically as part of the outermost exterior shell enveloping the bulk of the building facade. Summing up, in the preferred embodiment, this is achieved by, among other things:
  • Embodiments of the invention can also be used for an existing building or structure which can be retrofitted or re-clad to incorporate other variants of the invention.
  • the PV modules can be integrated into curtain wall units in an array suitable for mounting on mechanical screening or other vertical faces (not shown) typically found on a building or structure.
  • the invention can add value to existing properties by making them more cost-effective, attractive to environmentally conscious tenants, and so on.
  • the present invention can also be used with additional PV enhancement devices, such as solar concentrators, solar trackers (active and passive) and the like (not shown). Particularly in the spandrel areas, where appearance is not as critical, the integration of solar concentrators/trackers within the curtain wall elements could be used to greatly increase the collection of solar flux, by altering a radiation path to make it more incident to the elements, or adjusting the orientation of the elements themselves. While not explicitly shown or described herein, the details of the various software routines, executable code, firmware, etc., required to effectuate the functionality discussed above in the management modules, management units and monitoring systems are not material to the present invention, and may be implemented in any number of ways known to those skilled in the art. Such code, routines, etc. may be stored in any number of forms of machine readable media.

Abstract

A power generating system is integrated within an exterior shell or facade of a building structure. The energy generating devices (which can be photovoltaic), control units and associated power/signal wiring are incorporated and integrated within individual unitized curtain wall units making up the facade. The curtain wall units include a number of components optimized for accommodating an energy conversion device and associated wiring. Electrical power can be more advantageously generated from surface areas of building structures previously untapped for solar energy harvesting.

Description

Building Integrated Power Generating System, Method and
Components Thereof
RELATED APPLICATION DATA
The present application claims the benefit under 35 U.S. C. § 119(e) of the priority date of Provisional Application Serial no. 61/099437 filed September 23, 2008 and Provisional Application Serial no 61/114410 filed November 13, 2008, both which are hereby incorporated by reference. The application is further related to the following applications, all of which are incorporated by reference herein:
Building Integrated Power Generating System; serial no. 12/564,609 (attorney docket number 2009-1);
UL Compliant Building Integrated Photovoltaic Conversion System; serial no. 12/564,627 (attorney docket number 2009-2); Method of Operating Building Integrated Photovoltaic Conversion
System; serial no. 12/564,664 (attorney docket number 2009-3);
Building Integrated Photovoltaic Conversion System Implemented With Integrated Control Management Units; serial no. 12/564,671 (attorney docket number 2009-4); Building Integrated Photovoltaic Conversion System Implemented In
Both Vision and Spandrel Areas; serial no. 12/564,686 (attorney docket number 2009-5);
Unitized Curtain Wall Module Adapted for Integrated Photovoltaic Conversion Module; serial no. 12/564,732 (attorney docket number 2009-6); Unitized Building Integrated Photovoltaic Conversion Module; serial no. 12/564,740 (attorney docket number 2009-7);
Unitized Building Integrated Photovoltaic Conversion Module Adapted With Electrical Isolation and Grounding; serial no. 12/564,748 (attorney docket number 2009-8); Unitized Building Integrated Photovoltaic Conversion Module
Adapted With Electrical Conduits; serial no. 12/564,761 (attorney docket number 2009-9); Integrated Electrical Conduit for Solar PV System; serial no. 12/564,768 (attorney docket number 2009-10);
Electrical Raceway for Building Integrated Solar PV System; serial no. 12/564,774 (attorney docket number 2009-11); Method of Assembling Building Integrated Photovoltaic Conversion
System; serial no. 12/564,783 (attorney docket number 2009-12);
FIELD OF THE INVENTION
The present invention relates to power generating systems integrated within building facade or exterior shell structures, and more specifically to building integrated photovoltaic or BIPV systems.
BACKGROUND
It has been long been considered desirable to integrate photovoltaic (or PV) devices and systems into commercial and residential buildings. To date, however, such systems have been generally limited to conventional roof-top based systems which have limited photovoltaic capability and little aesthetic appeal. Conventional roof-top based systems are limited in photovoltaic capability because, among other reasons, the modules which make up these conventional systems are connected in series which effectively lowers the productivity of the entire system to that of the least productive of the modules. Conventional roof-top based systems also depend upon racking systems which do not afford a practical method to integrate photovoltaic elements into a vertical building face in an attractive and safe manner. Shading by building elements, equipment, and other constraints severely limit the area available for PV deployment.
Clearly it would be desirable to incorporate PV devices in a larger area of a building structure, and in a more visually appealing fashion. In a recent attempt at such an endeavor, a building in New York City incorporated PV elements in vertical facade assemblies that were actually physically separate from the main structure, and configured as artistic elements. The project was in fact a failure due to the inability of the system designer to overcome regulatory restrictions on the incorporation of electrical elements into this type of structure. Thus, while the panels are still attached to the side of the building, they have not been utilized to generate useful PV power.
"Unitized" curtain wall systems are those which can be preassembled and glazed as units (i.e., the glass or other surface material installed) off site and progressively installed section by section on a building. One advantage of the unitized curtain wall approach is that the labor is performed in an off site, controlled, manufacturing environment. Unitized systems are suitable for mid to large projects, i.e. high-rise buildings (four stories or more), those with significant repetition of their components, and/or projects in locations that have higher seismic design requirements. Frame units for unitized curtain walls are typically configured as one module (glazing or glass unit) wide by one story in height. These pre-glazed frames are typically placed on bunks consisting of about 6 units each and hoisted by a tower crane to their respective floors where they are installed, often by utilizing a small mobile hoist from the floor above.
The unitized curtain wall systems also typically include a pressure equalized rain screen, which counteracts the forces that cause water infiltration, such as surface tension, capillary action, gravity, kinetic energy, and pressure differential. Unitized curtain wall systems are in wide spread use and gaining commercial popularity across for the country because of their ease of integration, reasonable cost, schedule-friendly capabilities and aesthetic beauty and high performance.
Photovoltaic modular panels have been integrated into curtain wall glass for building integrated photovoltaics, as seen in U.S. Publication Serial No. 2008/0163918 incorporated by reference herein. Nonetheless the design described is optimized only for amorphous type solar cells, and is not conducive to ease of construction because it is not configured for efficient inter-modular connection. Nor does such design compensate for shading, a problem that severely impairs the performance of conventional series-connected solar panels particularly in articulated applications like building enclosures. As is well known, in conventional PV approaches shading degrades the performance and power output (or yield) of the shaded module or unit. When shading falls on one or more of the conventional series- connected solar panels, the series connected modules degrade in overall performance to that of the lowest yield in the string. Finally the prior art also fails to address the lack of overall Underwriters Laboratory certification or UL approval. UL certification of the framing system is an essential element to enable PV projects to be approved under applicable building and safety regulations, and thus is a key element to enable widespread adoption. Many commercially available modules are UL Approved to UL 1703, but no framing systems related to Building Integrated
Photovoltaics (UL Category QHZQ) are commercially available today
WO 2006/123335 incorporated by reference herein suffers from similar deficiencies, in that inter-module connections (in particular those between each individual solar module and those adjacent left and right) are depicted in great detail. However, this system is connected in series, without individual module management.
In addition, the array construction method lacks inter-module conduits or passages suitable for routing wiring. Moreover, the modules are connected to each other only in a lateral (left and right) fashion; there is no teaching of vertical connection. For this reason any vertical connections must be accommodated through additional structures, such as tracks, tubes or strips that are not integrated into the curtain wall framing members. US Patent Nos. 6,646,196 incorporated by reference herein shows a similar set up, and suffers similar deficiencies. These additional runs add cost and complexity to installation, reduce operational efficiency, raise maintenance costs and complexity, and potentially increase susceptibility to failure.
SUMMARY OF THE INVENTION
An object of the present invention, therefore, is to reduce and/or overcome the aforementioned limitations of the prior art.
A first aspect of the invention concerns a building integrated power generating system;
Another aspect of the invention concerns a building integrated power generating system that is UL/regulatory compliant;
A further aspect concerns integrating control management units into such power generating system; Yet another aspect concerns a building integrated power generating system that is implemented in both vision and spandrel areas of a building facade;
Other aspects include unitized curtain wall units that are adapted for photovoltaic energy conversion modules; Still other aspects cover electrical isolation, electrical conduits and grounding features of such unitized curtain wall units and associated building integrated power generating systems;
Another aspect of the invention covers integrated wireways/raceways used with the unitized curtain wall units;
Further aspects concern methods of assembling/manufacturing such unitized curtain wall units and building integrated photovoltaic conversion systems;
Other aspects include methods of operating the conversion modules, the control modules, and an entire power generating array integrated within a building shell;
Finally, other aspects of the inventions will be apparent to those skilled in the art from the detailed disclosure that follows.
It will be understood from the Detailed Description that the inventions can be implemented in a multitude of different embodiments. Furthermore, it will be readily appreciated by skilled artisans that such different embodiments will likely include only one or more of the aforementioned aspects or objects of the present inventions. Thus, the absence of one or more of such characteristics in any particular embodiment should not be construed as limiting the scope of the present inventions. While described in the context of a power generating array within a building facade, it will be apparent to those skilled in the art that the present teachings could be used in any number of applications.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a preferred embodiment of a photovoltaic power generating system implemented within an exterior shell or facade of a building structure;
FIG. 2 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 2, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
FIG. 3 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 3, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
FIG. 4 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 4, to illustrate further details and the spatial relationship of components of the preferred solar power generating system;
FIG. 5 shows a cutaway section of the building structure along the direction shown in FIG. 1 designated with a bubble and the numeric notation 5, to illustrate further details and the spatial relationship of components of the preferred solar power generating system; FIG. 6 is a block diagram of the main electrical components employed in the preferred solar power generating system;
FIG. 7 is a flowchart depicting a preferred process used to assemble embodiments of the solar power generating system;
FIGs. 8 A and 8B show another perspective of the curtain wall units along the direction shown in FIG. 1 designated with a bubble and the numeric notation 8, to illustrate further details and the spatial relationship of components of the preferred solar power generating system.
DETAILED DESCRIPTION The present invention preferably incorporates mono and/or poly silicon crystalline cells used for converting solar energy into electrical energy, such as those offered by Suntech Power Holdings Co. Ltd. (Suntech) directly into standardized curtain wall products, such as those offered by Architectural Glass and Aluminum Co, Inc (AGA) of Alameda California. The AGA curtain wall products are well-known durable exterior facades. The end result is a solar power generation system that also, much in the same manner as conventional curtain wall, functionally and aesthetically encloses a building.
By incorporating solar energy directly in the construction process for a building, the cost of implementing such green capability is greatly reduced. The cost of operating such buildings also goes down dramatically as a result of net energy savings by reducing the need for lighting using Daylighting Techniques and by controlling the solar heat gain and envelope U-value to reduce the energy needed for heating, ventilation and air-conditioning systems (HVAC). The invention also has applicability, however, to retrofϊtting/re-cladding existing buildings to include solar capability, particularly when such structures include mechanical screening surrounding their rooftop. The invention can be used in such instances to both beautify and increase the functionality of such otherwise unaesthetic and nonfunctional architectural features.
Unitized curtain walls
Before delving into the specifics of the present invention, it is useful to describe and understand the characteristics of unitized curtain walls. Unitized curtain walls are an extremely popular form of building facade used throughout the world.
The main defining characteristic of unitized curtain walls are that they are substantially (and usually entirely) preassembled off site in units and, after transport to the project site, hung or fastened onto on the building's structural slab edges. The unitized curtain wall does not typically function as a structural support element for the building. The final installation of these pre-assembled units into the integrated whole results in a "unitized" curtain wall system.
Off-site pre-assembly of the units is far preferable to onsite because operations can be done far more efficiently - at a dedicated facility by skilled personnel - with much lower cost and with higher speed and throughput. Off-site assembly also leads to higher quality work with better seals, stronger bonds, and fewer errors, and further enables assembly bench testing prior to transportation and installation.
In contrast conventional stick built curtain wall systems require that the aluminum or metal frames for the glazing be field-assembled at the jobsite according to the specific architectural requirement. The labor for such solutions is costly, and the quality of such an installation is difficult to control from one unit to the next.
Moreover, because stick built curtain wall frames are not manufactured in a controlled factory environment, before they can be UL certified, they must be field inspected, one by one, for approval. Such one by one field inspection is less preferable than the present invention, because the one by one approach consumes longer time and runs the risk that inspection, even after the expense of transport and assembly on site, will fail to result in certification. Prior building integrated PV curtain walls, such as that mentioned in New York City above, suffered these very failures. Unlike stick built approaches, curtain wall unitized panels are typically prefabricated as standardized 4'-8' width x 1O'-15' height units made up of different cladding materials (stone, painted aluminum, glass, opaque-glass, etc.) depending on the desired aesthetic/look the Architect is trying to achieve. A common form factor is five feet wide by thirteen and a half feet tall. The shop pre-assembly of the different materials into a unit, among other things, allows for:
• better quality control of the finished product (both the units themselves and the overall curtain wall system) and,
• easy (and thus rapid) installation on site, as each unitized panel 'mates' with the one above, with the one below and with the ones to either side of it, thereby adding support, and achieving continuity and integrity for the overall wall once completed.
• Decreased duration on job site, thus leading to improved and more efficient construction schedules • minimized packaging because the unitized pre-assembled units may be transported to the site with less packaging and waste than stick built, thus promoting environmental goals for reducing and recycling of jobsite packaging.
A unitized curtain wall unit is typically made up of the following major parts/components:
• Framing Members: these capture and support the different cladding or glazing materials desired and frame them into a unit which is manageable and conveniently sized for final installation. The framing is typically rectangular (although other shapes could be used) with vertical framing elements and horizontal framing elements. Framing members may be comprised of any materials known in the art, including, aluminum, steel, fiberglass or other composite materials. The vertical framing elements (sometimes called 'mullions'), of each unit 'mates' with the units adjacent, thereby providing support to the adjacent units and achieving continuity of the wall system once completely installed. The primary horizontal framing elements (sometimes called the 'stack joints') at the top and bottom of the unit also mate with the units above and below, similarly providing support to the adjacent unit and the entire wall and achieving continuity of the wall system once completely installed. Preferably, each unitized curtain wall unit also includes one or more intermediate horizontal members. These intermediate horizontal members are typically used to hold or mount and provide support to pieces of glazing or cladding. For example, the glazing below might be transparent or vision glass, while that above might be PV material. In unitized curtain wall, these framing members are pre-assembled in the factory .The pre-assembled frame thus forms the skeleton of the unit which will, after completion of the pre-assembly as described below, be transported to the building site for installation.
• Support Structure/Brackets: are used to fix/connect each of the curtain wall units to the edge of the building's floor-slab. In addition to providing the structural support for the wall, these brackets provide the ability to take up variation in the building's construction (typically +/- 2 to 4 inches) and exactly align each of the units with one another (typically within +/- 1/8 to 1/4 of an inch) to achieve the continuity required and the aesthetic alignment desired. Typically, the support structures/brackets are composed of two mating components. One of these is pre-assembled into the unitized frame at the factory. The other mating component of the support structure/brackets is typically fastened to the building's floor-slab onsite. In this manner, the installation on site can be achieved with convenient attachment of the mating components.
• Sealant / Gaskets: physically connect and isolate the cladding or glazing materials to the framing members. The sealant/gaskets effectively affix the cladding materials to the framing members, providing a waterproof seal. The sealant/gasket material is typically semi-flexible to accommodate minor movement of the frame relative to the cladding material. This isolation of movement is particularly important for PV, glass, or stone as they can break due to their brittle nature, but also important with other thin, opaque materials due to their tendency to buckle producing an undesirable aesthetic. In the building integrated PV application, it is preferable to incorporate UL approved materials designed specifically for this purpose to assure System UL
Compliance. In the building integrated PV application, the sealants and gaskets also serve to electrically insulate PV from framing in many applications. The sealant and gaskets are pre-assembled to the frames and glazing as part of the pre-assembly.
• Glazing or Cladding: the material which forms the aesthetic and structural exterior of the final unitized curtain wall. Different cladding materials (stone, painted aluminum, glass, opaque-glass, etc.) may be utilized depending on the desired aesthetic/look. The glazing or cladding is attached to the unitized curtain wall frame members during pre-assembly.
• Vision Material: the transparent glazed area of the unit located in the zone(s) through which occupants view out or through which daylight is to be admitted to the building interior. This zone is typically the entire width of the curtain wall unit/panel x 18"- 40" above the floor to the underside of the ceiling. The vision material is also pre-assembled into the unit in the factory.
• Spandrel Area: In a building with more than one floor the term spandrel is also used to indicate the space between the top of the window in one story and the sill of the window in the story above. The term is typically employed when there is a sculpted panel or other decorative element in this space, or when the space between the windows is filled with opaque or translucent glass, in this case called spandrel glass. Further, many opaque or translucent materials can be used, including any of a number of form factors of energy conversion devices. The glazing or cladding for the spandrel area is attached to the unitized curtain wall frame members during pre-assembly.
It will be understood by those skilled in the art that this is a simplified description, and not intended to be an exhaustive list. The components may vary from those described. Moreover not every curtain wall unit will require such components, and some units may in fact use other components without deviating from the spirit of the present teachings and techniques.
The labor and assembly process associated with curtain wall units is also divided into separate phases which allows for more optimized costing associated with the various activities and better predictability of scheduling. Fabrication Labor: typically includes all the labor involved in making or cutting/shaping each of the constituent framing and support parts of the curtain wall unit and then pre-assembling all the parts into the pre-assembled units designed for installation at the particular project. Since the curtain wall units are assembled typically in a dedicated facility, consistency and quality can be better controlled and optimized.
Installation Labor: typically includes the labor involved in attaching the support brackets/structures to the building, laying out, hoisting, and hanging the curtain wall units on the building, mating and aligning all the units and taking up tolerances, completing the necessary electrical connections, adding final seals, insulation and any interior finish trim that needs to be coordinated with finish material (like ceilings or sheetrock) that are typically provided by others. Because the on-site assembly method of the unitized curtain wall units is effectively identical and because all of the units have a common method for mating and attachment, the skill sets of the assemblers can be standardized and more easily controlled as well. Unitized PV curtain walls
The present invention aims to enable unitized curtain wall systems to deliver energy production capability - more specifically photovoltaic functionality similar to a rooftop PV installation. That is, a system that primarily functions to generate electricity from solar power once the entire set of parts are assembled, and also performs the same aesthetic cladding function as prior art curtain wall systems. The difference here, of course, is that the power generation must be as compatible as possible with the requirements of a PV curtain wall unit, including resistance and compliance with various regulations concerning heat/conductive/insulation properties, air/water infiltration, wind load resistance and seismic considerations.
To accomplish this, a photovoltaic (PV) curtain wall unit includes the following (in addition to some or all of the standard components noted earlier): Photovoltaic Panels: for a wall-system application, these are preferably glazable PV panels - and so can be thought of as a direct material replacement for the opaque glazed spandrel and/or vision material in the curtain wall unit - although there are some differences between these materials that are accommodated / designed for as shown in the present embodiments. Other types of panels/energy conversion devices can of course be used, and in this respect the invention is effectively panel-device agnostic. Varying cell density, photovoltaic materials, opacity, and aesthetic look can be adjusted as needed to meet the desired appearance, aesthetics and requirements. Inverters/ module management units/ controls: these typically convert and optimize electricity generated by PV panels into grid compliant power. Preferably, the inverters/module management units/controls are provided locally and individually, at each curtain wall unit, to allow the PV wall system to more efficiently generate electricity from solar power. As mentioned, there is frequently greater variability in light exposure from one portion of a vertical building surface to another than there is on a typical rooftop installation. As a result, for BIPV applications, it is preferable that local controls account for self or site shading of each individual wall unit/panel and eliminate or reduce the otherwise typical impact from shading in which one shaded unit/module degrades the performance of the entire string of modules in the affected series. Shading can result from shadows cast by trees, other buildings, dust accumulation, and even birds, planes, and window cleaners. These conditions occur frequently on vertical curtain wall environments, and it is therefore important that the integrated PV curtain wall system include necessary controls and methods to mitigate and/or avoid this deleterious impact. In addition, these inverter/control elements should be easily accessible for maintenance and yet preferably be hidden from view of the occupants of the space as well as from viewers of the building exterior for both safety and aesthetic purposes. Finally, it preferable that of the above components should be rated UL or equivalent, and outdoor rated to accommodate for building construction conditions.
Wiring: wiring is preferably accommodated to carry power (and preferably control signals, where necessary) all the way from the PV panels to the grid without adding additional architectural complexity. Ideally, the wiring will be effectively invisible in the installation condition. In the preferred embodiment means are provided from each PV panel, through the curtain wall unit, to transport the generated electricity in a safe and controlled way through the entire wall array and ultimately to the interior of the building. Similar to the needs of the local inverter/controls, the wiring in a curtain wall system should preferably be done efficiently (i.e., preferably few wires for a long array run helps limit the size of the code required raceway (or other required wiring passage)), in an aesthetically pleasing manner (which, in a curtain wall system typically means hidden from view) while being protected from damage and accessible for maintenance. It will be appreciated that in other power generating applications involving other energy conversion devices, other types of tubing/conduits, etc., can be employed to transport other energy related materials, including heated/cooled fluids, etc. between modules and other parts of a circulation system within a building structure.
Accordingly, unlike previous applications of PV technology on a vertical wall, each PV curtain wall unit of the present invention can be sold, delivered and installed as a complete unit. Each PV curtain wall unit is preferably preassembled off site and transported to the building as a prefabricated module, allowing this new application to not only be simply, quickly hung on the building, but also, as panels, wiring, inverters and controls have also been prefabricated into a series of connected code-rated raceways attached to or formed by the unit framing, each unit can be simply, quickly and efficiently connected, coupled or plugged as needed into its neighboring units.
In an electrical generation system each unit is preferably linked to a common grounding mechanism using methods well known in the art.
As described above, one main purpose of the invention is to provide a photovoltaic power from a unitized curtain wall system. The units assembled according to the teaching of the invention will preferably be connected or linked in a manner that accumulates the electricity generated by each unit in the manner described above. The electricity so accumulated is connected to the building's primary electrical system and grid tied as appropriate, using methods known in the art. It is possible that the electricity in the system may be harnessed to run existing mechanical systems within the building envelope such as shading devices, window treatments, or blinds. This implementation thus allows a solar energy system to be installed as part of a building facade with the same ease and minimal additional labor cost. Specific Details of Preferred Embodiment In a conventional rooftop system, PV panels, wiring, controls, rack/support, etc. are all assembled on site and then plugged into the inverter/storage mechanisms. In the case of a preferred unitized PV curtain wall as described herein the PV curtain wall units are preferably each 'plug and play' - each unit mates into and is electrically coupled to its adjacent unit to form the solar array. In turn, the solar array is electrically connected into the balance of the building electrical system. In this respect therefore, the inventions better achieve the functionality of a conventional rooftop system, but do so on the vertical sides of the building. Because a typical high rise building has 7-12 times greater wall than rooftop space, the present invention allows far greater harvest of solar energy.
In a preferred embodiment the invention is used preferably in cladding at least a substantial vertical portion of a building structure 100 as seen in a partial elevation drawing in FIG. 1. The degree to which PV and non-PV curtain wall units are included and interconnected within a cladding can be tailored as needed for any particular site requirements and system goals. Please note that the elements shown in the figure are not intended to denote specific sizes or ratios, as it expected that the invention will take many different forms, sizes, and form factors in different types of installations. Moreover although the discussion herein is presented primarily in the context of a commercial structure, it is expected that embodiments can be used on virtually any other type or variety of structures, including residential structures, parking structures, other non-habitable structures, hospitals, airport terminals, train station terminals, sea port terminals, government buildings and even within transportation systems such as elevated rails, bridges, and other structures offering suitable solar exposure. Furthermore while shown as part of an exterior of the building, the cladding could be extended to other interior areas of a structure as well, such as may be found in an atrium, a courtyard, etc.
A preferred unitized curtain wall structure covering a building facade includes a number of separate curtain wall elements 105 preferably constituted of aluminum, although it will be understood that other suitable materials may be used, such as steel, fiberglass, or other composite materials. In this instance the curtain wall structure is shown as a combination of vision areas and spandrel areas, but it will appreciated that these could be separate components or utilized in varying combinations. The curtain wall units 105 can be configured as desired to extend across multiple stories in a continuous strip of spandrel and vision areas. While the elements 105 are shown as separate components it will be appreciated that larger "units" in the form of multiple curtain wall elements could be assembled off- site in some instances.
The curtain wall elements 105 are further adapted to preferably include a photovoltaic (PV) module 120 and/or other energy conversion device. Such devices could include capability for converting other forms of electromagnetic energy, potential energy, kinetic energy, thermal energy and/or chemical energy including photochemical energy. For example, thermionic, piezoelectric and/or mechanical devices could be integrated for harnessing heat/wind/rain energy). Other examples will be apparent to those skilled in the art, and it is expected that other conversion devices will be adapted for use with the present invention. Because of their physical structure the curtain wall elements 105 can be easily adapted (mechanically/physically) to house/integrate different types of such conversion devices (which tend to be smaller than such elements) using the principles set out herein. It will be understood that the conversion devices can be spatially arranged as part of the curtain wall elements in any convenient fashion appropriate for the particular installation. Furthermore as shown in FIG. 1, it is possible that some elements 105 may include conversion devices, while others may not, again depending on system requirements and goals.
In addition, in some instances well-known solar thermal energy collectors/plates could be embedded instead or in addition within the curtain wall elements for heating a conductible fluid, air or some other medium for transporting heat energy. Other well-known solar thermal support elements such as mirrors, lenses and other concentrators (not shown) could be used of course to increase the heat concentration, and conventional heat storage devices (not shown) can be incorporated to store heat energy.
The PV module used in the preferred embodiment can be any one of a variety of virtually any commercially available PV module, including preferably a crystalline solar cell/module offered by Suntech Power. The PV module can include any number of conveniently and conventionally interconnected individual solar cell devices, such as described in the aforementioned prior art references. As is known in the art, the photovoltaic technology utilized by the PV module may be based on any suitable photovoltaic conversion technology, including for example, thin film, dye tinted, fullerene based, polycrystalline, or monocrystalline. The specifics of the solar cell/module (or other energy conversion device) are not material to the present invention; however regardless of their specific photovoltaic conversion technology the PV modules must be suitable to physically integrate them within the unitized curtain wall units. Accordingly, a wide variety of existing and contemplated technologies can be accommodated, thus making the invention PV module "agnostic," which further enhances the commercial potential for the invention. Conventional vision material or, in this case, glass panels 115 are also shown in FIG. 1. As described, these glass panels can be configured to have more than one panel along the vertical axis of the unit. In this configuration, the glass panels will be separated by intermediate horizontal framing members. Further, while the PV module 120 is shown in FIG. 1 in the vision area of the building structure 100, it can alternatively be integrated into spandrel areas or as part of a spandrel based module 110, or in any number of combinations of such areas based on system requirements and design aesthetics.
A linked solar array or assembly of PV curtain wall elements 105, 105', 105" etc. is thus shown mated together, cladding or enclosing a structure, preferably extending both horizontally and vertically across multiple floors. The elements 105 are preferably sized to be compatible with conventional building elements to further increase their integration potential. This arrangement is also useful for increasing the overall solar energy potential coverage for up to nearly 100% of the wall area of a structure. In contrast, typical rooftop systems only allow for a limited percentage of an overall surface area.
FIG. 2 shows a cutaway section of the building structure 100 along the vertical axis/direction shown in FIG. 1 designated with a bubble and the numeric notation 2. In this figure the structure of the curtain wall units (such as 105, 105' and 105" which are otherwise identical) is further elaborated, including the relationship of the BIPV module 110 to the other components. In general, the typical components of curtain wall framing members on a BIPV curtain wall unit 105" are largely the same in concept as conventional curtain wall framing members. However there are specific and significant differences that allow PV Panels to be used in place of other conventional infill material as explained below.
Specifically, as seen in FIG. 2, the PV module 110 (located in a spandrel area as depicted in FIG. 1) is preferably mounted within an extra deep glazing pocket 125 shown generally with cross hatching for emphasis. The extra deep glazing pocket 125 is preferably part of a topmost horizontal framing member 150 in the spandrel area. This framing member 150 is also distinct from conventional designs in that it preferably allows extra space in the glazing pocket 125 for an edge mounted junction box for the PV module 110 and the PV Leads 140 that come out of the PV module. The framing members of the preferred embodiment are unique in that they form both vertical and horizontal conduits/channels for inter-module connectivity, including preferably, power lines, control signal lines, and reporting lines. In some applications as noted earlier it may be desirable to transport other fluids, gasses, etc. to and between modules using appropriate channels. Further, in some applications the desired control and reporting information flowing to and from the PV module 110 may be transported using wiring or wireless technology, thus obviating the need for the separate control signal and reporting lines.
The curtain wall units 105 are engineered using conventional techniques so that they are adequately resistant to water, pressure and other physical influences that might be attendant to a particular locale. Those skilled in the art will appreciate that the specific physical implementation can be varied from site to site in accordance with local building code, geological and weather based parameters.
Framing member 150 further preferably includes an opening allowing the PV leads 140 (or other flexible conduit/piping for transporting fluids/gasses) to be routed to a management module or control circuit 135 preferably situated in a power/control raceway 130. Again, to the extent other types of materials are transported, the opening can be varied accordingly.
Power/control raceway 130 is preferably attached to the solar array after installation of the curtain wall units on the building using any of the techniques known in the art. Nonetheless it can be preassembled as well in some instances. The management module 135 is preferably a unit designed for individual and group control of PV modules such as sold by TIGO Energy under the name Energy™ Module Maximizer-EP (MM-EP) and/or modules as described in US Patent Publication Nos. 20080097655 and 20090120485 incorporated by reference herein.
There are many other power topologies accommodated, including but not limited to, Enphase, Solar Edge, Solar Magic, or Enecsys. The management module can be used to selectively monitor, troubleshoot, activate or de-activate portions of a building's solar array system, including on a side by side, floor by floor, or individual basis such as might be needed for accommodating window cleaning or maintenance as examples.
The management module is part of a control circuit that preferably optimizes power output of each module that it is connected to, and delivers module-level data for operational management and performance monitoring and/or control. The TIGO unit in particular uses dynamic module balancing which manages the energy harvest and sends information for reporting and control. The modules can be connected in a variety of known methods, depending on system needs.
The benefits of such module specific control/ transmission/ communication within a building structure is that they allow for greater efficiency in power collection and more effective elimination of prior art losses caused by shading by other external elements (trees, other buildings, dirt, etc.) and inherent mismatches in PV modules. These problems have heretofore greatly limited efficiencies of solar arrays in horizontal, vertical, or inclined configurations, particularly in densely built areas. Furthermore since such management modules 135 are UL rated to UL 1741, they can be used in preferred embodiments of the invention in which an entire solar array for a building is effectively compliant as constructed with UL (and other safety organization, such as Canadian Standards Association (CSA), InterTec North America (ETL), Tuv Rheinlan (TUV)) requirements because it consists of elements which are each previously certified.
The other advantage of the preferred TIGO management module is the improved safety of the solar array during operation. In particular, during an emergency, for example, the high voltage wiring in the preferred embodiment can be shut off, thus preventing accumulation of voltage and limiting voltage exposure to the open-circuit voltage (Voc) of a single module 110, generally no more than a normally non lethal level of approximately 60V. More advantageously this function can be activated with a safety button or via a remote management console or a network such as the Internet (not shown) for maximum flexibility. This function can also be tied into the buildings existing safety system so it can be automatically activated in the case of an emergency. Consequently the system can be installed, maintained or approached by personnel (including fire or other emergency personnel) without exposure to voltage levels which, in some topologies of conventional arrays typically exceed 400 volts during peak operation.
Finally, because each PV module 110 can be controlled individually by the management modules, it is possible to link and interconnect longer runs of PV modules that span more than one face of the building. While the present description presents the TIGO unit as an example it should be understood that the invention is not limited to any particular control module. While the management modules 135 are shown within the power/control raceway 130, it is expected that future generations of integration modules will continue to shrink in size and therefore can be placed in a variety of locations. For example it will be apparent that they can be located in other areas of the curtain wall element 105", including directly on the PV module 1 10 or directly within the framing members, the wiring channels, or potentially embedded in PV Modules 110. However, it should be noted that there is a benefit in most cases to locating the management modules within the power/control raceways because in this way, the signal lines are better isolated and easily routed between pairs of adjacent management modules.
The opening for the PV module leads 140 preferably includes a grommet 145 on the inboard vertical surface of the horizontal framing member 150. This allows for the PV module leads (or other conduits, tubes, etc.) 140 to exit the framing member 150 and enter the power/control raceway 130 in a safe and secure fashion, and in a manner that resists aging, corrosion, and damage from movement that may be cause by earthquakes, wind, etc. Skilled artisans will appreciate that the additional space shown within framing member 150 that is not used in the embodiment shown in FIG. 2, could be used in some applications to route electrical wiring or alternative form factors of management module 135. Again also in other embodiments of the invention (using other forms of conversion devices or solar heat collectors) additional tubing, conduits, etc., could be routed within this part of the framing members and used to transport heat energy in the form of a conductible fluid, gas, air, etc. to other areas of the building structure.
Again, one preferred aspect of the present invention is to ensure UL and/or CSA/TUV/ETL compliance. The curtain wall units 105 and power/control raceways
130 of the preferred embodiment further serve such aim by including the capacity to handle regulatory rated cabling, and with mountings (i.e., appropriate hole sizing, grommets and other tethering/tieing mechanism) and cable runs/shielding that allow for appropriate separation of different types of signal cables, such as high and low power lines, that are also designed to satisfy applicable regulations.
Note as shown in FIG. 1 the floor level in the preferred embodiment is somewhat below the bottom of the horizontal framing member 150, but, this can be altered as desired in any particular installation. Power/control raceway 130 is also preferably designed to be UL-compliant, reducing duration of work on site, construction costs certification expense and commission expenditures. To this end the raceway may be comprised of materials well- known in the art.
The rest of the curtain wall unit 105" is shown with conventional vision material elements 115, and various gaskets - for example, wedge gasket 165, and bed gasket 170, to help in securing and isolating the PV module 110 from the curtain wall unit 105 '. Note that these same types of gaskets are also shown but not annotated specifically in the deep glazing pocket region 125. The gaskets are preferably comprised of materials that are UL rated for this purpose and may vary from installation to installation.
FIG. 3 shows a plan view of a curtain wall along the horizontal axis/direction shown in FIG. 1 with the annotation/label having a circle with the number three (3). This perspective is shown between two adjacent curtain wall units 105' and 105." In particular it can be seen that the PV modules 110 are preferably insulated and isolated by a set of gaskets 165, 170 as noted before in FIG. 2. As is known in the art, the use of such gaskets accommodates normal material expansions/contractions, and allows for flexibility and movement of the panels, such as needed for wind, seismic and other disturbances. While gaskets are illustrated as the isolating mechanism in the preferred embodiment (including for electrical isolation), it will be noted that other materials could be used, including structural silicones or VHB tape, such as that sold by 3M (Minnesota Mining and Manufacturing) without parting from the scope of the invention.
The main feature of FIG. 3 is a vertical framing member 155, the top of which is shown in this plan view. This framing member, like the horizontal framing member 150 noted earlier, is preferably formed from the spaces created in the mating or coupling of the individual curtain wall units 105, and preferably without requiring additional separate structures or materials. As with its counterpart this member has additional space that can be used to accommodate other types of conduits as needed by particular energy conversion devices. An additional structure, namely an integral vertical wiring management clip
160 is also included as part of the curtain wall unit 105". This clip effectively behaves as a vertical conduit to accept, manage and integrate the power and signal cables from PV modules 110, allowing them to be interconnected in a vertical orientation as well. Thus, as seen in FIG. 1, the PV modules 120 in a vision area can be coupled directly to PV modules 110 in a spandrel area, or even to other modules in a spandrel area below vision area 120, and so on. The use of both vertical and horizontal wire accepting frame members allows for PV modules to be connected in a checkerboard fashion, both in the vertical and horizontal direction, to form a larger array across the face of the building structure and even across separate faces of the building structure.
Note that the shape and form of the clip 160 is illustrated in the preferred embodiment as a solid rectangular box structure in FIG. 3, but any number of variants could be used to accommodate the power/signal cables. Additional conduits could also be incorporated (including on the opposite curtain wall element 105') as desired for any application. While the conduits are shown in a closed configuration (which permits easy threading/routing of the cables) it will be apparent that other structures could be used. For example the wiring may also be prefabricated or built into the curtain wall unit 105, (for example along the edge of the vertical framing member).
Such wiring would preferably connect with an electrical coupler to PV module leads 140. At the other end of the framing member a corresponding electrical coupler could be used to connect to the leads from a second PV module, or, alternatively, to leads extending to a management module 135. Any number of similar variants are possible, and the invention is not limited in this respect.
As with the other elements of the curtain wall unit 105" the vertical wiring management clip 160 is preferably constructed in a UL compliant manner to permit installation of the units without additional regulatory approval or accompanying delays. FIG. 4 is a plan view again along the horizontal direction shown in FIG. 1 with the bubble label containing the number 4. This figure is a cut-away and illustrates more of the details of the power/control raceway 130 used in preferred embodiments of the present invention(s).
The power/control raceway 130 is another feature unique to the present invention. Though similar in function to existing technology, the power/control raceway 130 is unique in that it may also be used for multiple purposes: as a conduit to carry the management module-management module cabling 165 (or other tubing/conduits), to contain management module 135, and to serve as an interior architectural trim piece. While not shown in FIG. 4, the power/control raceway also preferably includes a grommeted hole and access for a connector on the underside (bottom) as seen in FIG. 2 for receiving the leads 140 from the PV modules. Again the location of the connector is not critical, and the cabling/coupling is expected to be accomplished in any number of different ways.
Returning to FIG. 4 the power/control raceway 130 is preferably formed separately in a predetermined length and then integrated as an assembly on part of the backside of a curtain wall unit 105 after unit installation on the structure. This enables each curtain wall unit 105 to effectively act as a unitized building block for constructing a solar array when integrated with the power/control raceway 130 as part of a building facade without additional supporting elements. In some embodiments the power/control raceway can be implemented in a similar manner in the vertical direction.
The power/control raceway 130, as with the other curtain wall elements, is in the preferred embodiment is to be rated for Underwrites Laboratories (UL) or similar organization compliance and is made of aluminum or some other cost effective materials.
The management modules 135 are located in the power/control raceway 130 and manage/control/ communicate with the individual PV modules. These management modules preferably optimize power output per each PV module and exchange operational management and performance monitoring data, allowing remote manipulation/management of the array.
The PV module leads 140 are coupled between the PV modules and the management modules to transmit generated power and communicate other status information to and from the modules. It will be understood that the particular coupling, wiring, etc., is expected to vary between different types PV modules or energy conversion devices.
Management module to module cabling 165 carries the accumulated power to a management unit 680 (See FIG. 6). The management unit is preferably a TIGO Energy TM Maximizer Management Unit (MMU) that manages the whole assembly by processing the individual and aggregated information from the PV modules. In a preferred embodiment, the management unit is capable of managing an entire set of management modules 635 for a building and/or an array. The management unit communicates between the management modules 635 and an Inverter 690 which is a modified typical component of any solar power generation system. Inverter 690 inverts DC to AC as known in the art. The management unit (680) preferably controls the management modules in real time and sends data to a remote server 695 in order to allow on or offsite monitoring of light, temperature, electricity production and other parameters and provides the resulting information as needed. Again the monitoring system architecture will be a function of the particular energy generation mechanism selected, and it is expected that other variants of the above will be used with different energy conversion systems. Returning to FIG. 4, this also shows a bonding jumper 175, which is used to connect the individual curtain wall elements to each other, and, eventually, to a ground potential such as the steel frame, or other conventional common grounding element in the building electrical system (not shown). In the preferred embodiment grounding is accomplished by any of the means known in the art. Note that a portion of the vertical framing members 155 can be seen in FIG. 4 as well. The routing of PV module leads 140 into such framing members is also shown in more detail in FIG. 5. FIG. 5 shows a cross section of the building in FIG. 1, along the bubble annotated with the number five (5). As shown in FIG. 5, the PV module leads 140 preferably extend from the top of a PV module 180; they are routed through grommet 145, and then into the horizontal framing member 150; and then they are routed to the vertical framing member 155, and thus can be transported (up or down) through the vertical wiring management clip 160.
FIGUREs 8 A and 8B show another perspective view of the mullions formed by a pair of adjacent curtain wall elements 105. The additional space 190 formed within the mullion is usable as noted earlier for other array elements as needed. All other labeled elements are the same as like numbered items discussed in earlier figures.
An electrical diagram showing the main preferred components of a solar power generation system is shown in FIG. 6. In this figure, like numbered elements are intended to correspond to their counterparts in prior figures unless otherwise noted.
As seen in FIG. 6 an array of PV modules 610/620 are preferably coupled to each other through the management module 635. The connections between the PV modules and the management modules are preferably done through the PV leads 640 that are routed both vertically and horizontally through framing members 650 and 655 respectively as noted earlier. The management modules 635 are themselves preferably connected through cabling 665, and eventually to a management unit 680 as noted above. The wiring for these connections, are preferably done with power/control raceways 630 that are integrated with the curtain wall units 605. In the preferred embodiment, management unit 680 is in turn preferably coupled to a DC disconnect 685. As noted above, DC disconnect may preferably be activated either manually or electronically to isolate power to the output of the individual PV module. The output of this DC disconnect is preferably coupled to an inverter 690 which converts the DC generated voltage into an AC voltage in a well- known manner. Note that the management unit 680 is shown outside of the curtain wall unit 105, but it could be included within that unit without departing from the scope of the present invention. The preferred embodiment includes a monitoring system 692 can be used to evaluate the performance of the individual PV modules 610 through interrogation of their respective management modules 635. The monitoring system includes conventional computing equipment and software for coordinating data exchanges, calculations, etc., with the management unit and management modules as is known in the art. Preferably the computing system is a server that is Internet accessible for remote access.
The output of the array is preferably connected to the building electrical system, typically in the main distribution area, where it can be used to offset consumption of electrical power or feed power into the utility grid. In some instances the array can offer other DC and AC outlets for charging electrical devices, transportation vehicles, etc. The form of the output, including voltage levels, current levels, etc., can be tailored as needed for any particular application. Furthermore if desired a conventional electrical storage system 691 can be employed in some cases to provide back-up power if desired. Again it will be understood that the support elements for a particular power generation system will vary according to the energy conversion devices used, and FIG. 6 is merely depicting the typical elements that would be used in a solar to electrical conversion system. FIG. 7 is a flowchart illustrating the general steps employed in a preferred PV solar system assembly process. At step 710, the curtain wall elements 105 are preferably hung on a building structure in a manner effectively identical to that used in conventional curtain wall systems with the differences described above. At steps 715 and 720 the PV module leads are then preferably routed both horizontally and vertically as needed through framing members 150 and 155 respectively integrated within the curtain wall units 105. This allows for flexible interconnection of adjacent PV modules in the solar array.
During step 725 the PV module leads 140 are preferably connected to management modules 135 through connectors contained in horizontal framing member 150. At step 730 the individual management modules are also preferably electrically coupled together using the management-module-to-management module cabling 165 in the power/control raceway 130.
The grounding can be achieved during any one or more of the above steps in the manner known in the art. At this point the entire assembly, consisting of unitized curtain wall elements interconnected to form a solar array, is also completely safe and preferably UL compliant.
At step 735 the integration module 135 outputs are preferably connected to one or more management unit 680 as described earlier. At step 740, the electrical power can then be conveniently transferred to the building electrical distribution system, or made available through other outputs for other applications (charging). It will be apparent the above steps do not have to be performed in the sequence noted, and that the actual assembly process will likely include other obvious variants of the above. To summarize, it can be seen that the invention implements a new type of PV capable curtain wall unit that has been specifically designed and engineered to be a power generator, but accomplishes a dual purpose: to enclose the building aesthetically as part of the outermost exterior shell enveloping the bulk of the building facade. Summing up, in the preferred embodiment, this is achieved by, among other things:
• extra deep glazing pockets incorporated in curtain wall units
• adapting the framing members to include UL and other compliant conduits, channels and raceways for wiring • housing control and management mechanisms locally, in each unit
• Including control needed to eliminate the deleterious effect of on- site/orientation shaded unit from others
• electrically isolating the PV modules with the use of code compliant sealants and gaskets
• the addition of ports and isolating grommets to facilitate electrical connections and contain control mechanisms in the framing members
• framing members with flexible parts/sleeves to accommodate movement (for example in response to a seismic events) without damage to the electrical wiring
As such, virtually all of the components of conventional curtain wall units are adapted to deliver solar generated power as part of a PV system which is constituted substantially within an exterior aesthetic shell.
UL Compliance/ other third party organizations Unlike prior art systems, preferred embodiments of the invention thus efficiently achieve UL compliance as built because:
• each unit is grounded;
• wiring and associated control devices are housed in a pre-certifϊed raceway (for example, inner cavities of the framing members); and • electrical isolation is provided between the PV panels and their framing/surrounding elements (via the sealants and gaskets - that are manufactured from code-rated materials). Retrofits: Embodiments of the invention can also be used for an existing building or structure which can be retrofitted or re-clad to incorporate other variants of the invention.
Moreover in some instances, the PV modules can be integrated into curtain wall units in an array suitable for mounting on mechanical screening or other vertical faces (not shown) typically found on a building or structure. By utilizing such previously unproductive space, the invention can add value to existing properties by making them more cost-effective, attractive to environmentally conscious tenants, and so on.
As alluded to above the present invention can also be used with additional PV enhancement devices, such as solar concentrators, solar trackers (active and passive) and the like (not shown). Particularly in the spandrel areas, where appearance is not as critical, the integration of solar concentrators/trackers within the curtain wall elements could be used to greatly increase the collection of solar flux, by altering a radiation path to make it more incident to the elements, or adjusting the orientation of the elements themselves. While not explicitly shown or described herein, the details of the various software routines, executable code, firmware, etc., required to effectuate the functionality discussed above in the management modules, management units and monitoring systems are not material to the present invention, and may be implemented in any number of ways known to those skilled in the art. Such code, routines, etc. may be stored in any number of forms of machine readable media.
The above descriptions are intended as merely illustrative embodiments of the proposed inventions. It is understood that the protection afforded the present invention also comprehends and extends to embodiments different from those above, but which fall within the scope of the present claims. What is claimed is:

Claims

1. A building integrated power generating system comprising: a plurality of unitized curtain wall units adapted as part of an exterior shell for at least a portion of a building structure; a plurality of energy conversion devices integrated within said plurality of unitized curtain wall units; wherein said plurality of energy conversion devices are adapted to transform a first type of energy form into an electrical energy form; said plurality of unitized curtain wall units further defining and forming a plurality of integrated electrical conduits adapted to carry electrical wiring for said plurality of unitized curtain wall units; wherein the power generating system is integrally incorporated within said plurality of unitized curtain wall units.
2. The building integrated power generating system of claim 1 wherein a plurality of control units are integrated within said unitized curtain wall units; said control units each optimizing a power output of at least one of said plurality of energy conversion devices.
3. The building integrated power generating system of claim 1 wherein a plurality of control units are integrated within said unitized curtain wall units; each of said control units optimizing a power output of no more than six individual ones of said plurality of photovoltaic energy conversion devices.
4. The building integrated power generating system of claim 3 wherein said plurality of control units mitigate the effect of shading on said photovoltaic energy conversion devices. 5. The building integrated power generating system of claim 1 wherein said energy conversion devices are photovoltaic devices.
6. The building integrated power generating system of claim 1 , wherein at least one of said photovoltaic energy conversion devices are of different physical dimensions and/ or electrical characteristics than at least one of the other photovoltaic energy conversion devices.
7. The building integrated power generating system of claim 1 wherein at least one of said energy conversion devices utilizes a different conversion technology than at least one of the other energy conversion devices.
8. The building integrated power generating system of claim 1 wherein said plurality of unitized curtain wall units define a first set of horizontal framing members and a second set of vertical framing members; said horizontal framing members defining first conduits for electrical wiring; and said vertical framing members defining second conduits for electrical wiring.
9. The building integrated power generating system of claim 1 wherein each of said plurality of unitized curtain wall units include a deep pocket region adapted to receive an electrical connector associated with one of said energy conversion devices.
10. The building integrated power generating system of claim 1 wherein each of said plurality of unitized curtain wall units include an integral conduit adapted to carry electrical wires between adjacently situated control modules for said plurality of energy conversion devices .
11. The building integrated power generating system of claim 10 wherein said integral conduit includes an electrical connector adapted to receive a flexible electrical cable from one of said plurality of energy conversion devices.
12. The building integrated power generating system of claim 1 wherein each of said plurality of integrated vertical and horizontal electrical conduits is adapted to contain control circuitry for said plurality of energy conversion devices.
13. The building integrated power generating system of claim 1 wherein the plurality of unitized curtain wall units meet Underwriter Laboratories (UL) or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate inspection prior to operation.
14. The building integrated power generating system of claim 1 wherein different unitized curtain wall units of said system are used for flat regions than for corner regions of said building.
15. The building integrated power generating system of claim 1 , wherein said unitized curtain wall units are interconnected to each other in a two dimensional grid such that said energy conversion devices cover between 1 and 100 % of a surface area of one vertical side of said building structure. 16. The building integrated power generating system of claim 1, wherein said curtain wall units include vision and spandrel areas; and said at least one of said vision areas include at least one energy conversion device; and and at least one of said spandrel areas includes at least one energy conversion device.
17. The building integrated power generating system of claim 1, wherein a plurality of said energy conversion devices utilize CIGS or other thin film photovoltaic conversion technology.
18. The building integrated power generating system of claim 1 , wherein said plurality of energy conversion devices utilize amorphous, monocrystalline or polycrystalline silicon based conversion technology.
19. The building integrated power generating system of claim 1, wherein said energy conversion devices are photovoltaic devices coupled to one or more flux concentrators. 20. The building integrated power generating system of claim 1, wherein said first form of energy includes at least one of: 1) electromagnetic energy; 2) potential energy; 3) kinetic energy; 4) thermal energy; and/or 5) chemical energy. 21. The building integrated power generating system of claim 1 wherein only a first subset of said unitized curtain wall elements contain energy conversion devices while a second subset of said unitized curtain wall elements do not.
22. A building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell for a building structure; a plurality of photovoltaic energy conversion devices integrated within said plurality of interconnected unitized curtain wall units; wherein at least some of said photovoltaic energy conversion devices can be oriented substantially vertically with respect to said building structure at least during certain periods; said plurality of interconnected unitized curtain wall units further defining and forming a plurality of integrated electrical conduits adapted to carry electrical wiring for said plurality of interconnected unitized curtain wall units; wherein the photovoltaic power generating system is integrally incorporated within said plurality of interconnected unitized curtain wall units. 23. The building integrated photovoltaic power generating system of claim 22, wherein said exterior shell encloses a substantial portion of a vertical surface of said building structure which receives solar radiation.
24. The building integrated photovoltaic power generating system of claim 23, wherein said plurality of interconnected unitized curtain wall units occupy at least 50% of a vertical surface of said building structure which receives solar radiation.
25. The building integrated photovoltaic power generating system of claim 22, wherein said photovoltaic energy conversion devices are arranged in a grid that generates in excess of 20kw at a peak output. 26. The building integrated photovoltaic generating system of claim 22 wherein the system as constituted meets Underwriter Laboratories (UL) or other or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate electrical safety inspection prior to operation. 27. The building integrated photovoltaic generating system of claim 22 wherein an orientation of said photovoltaic energy conversion devices or a flux path can be altered to track and maximize incident solar radiation energy.
28. The building integrated photovoltaic generating system of claim 22 wherein said unitized curtain wall units include: a) both vertical and horizontal framing members adapted to support a module associated with said photovoltaic energy conversion devices; b) support brackets adapted to affix the units to a building floor slab; and c) sealants and/or gaskets adapted to connect and isolate said module.
29. The building integrated photovoltaic generating system of claim 22 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal.
30. A building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell enclosing a majority of a surface area of a building structure exposed to solar radiation; wherein said unitized curtain wall units do not function as structural support elements for said building structure; a plurality of individually controlled single-crystalline based photovoltaic energy conversion devices integrated within said plurality of interconnected unitized curtain wall units; wherein said photovoltaic energy conversion devices are each controlled with individualized integrated control units optimizing a power output of such devices; further wherein said photovoltaic energy conversion devices are oriented substantially vertically with respect to said building structure; said plurality of interconnected unitized curtain wall units further defining and forming a plurality of integrated vertical electrical conduits adapted to carry electrical wiring for said plurality of interconnected unitized curtain wall units along a first axis having a first direction; a horizontal raceway coupled to said plurality of interconnected unitized curtain wall units and adapted to carry said electrical wiring for said plurality of interconnected unitized curtain wall units along a second axis in a second direction that is substantially perpendicular to said first direction; wherein substantially all elements of the photovoltaic power generating system are integrally incorporated within said exterior shell.
31. A building integrated power generating system compliant with a set of product safety certification requirements that are prerequisites to operation of such system at a designated site, the system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell for at least a portion of a building structure; said interconnected unitized curtain wall units including a plurality of energy conversion devices integrated into and isolated with isolators from said exterior shell; wherein said isolators are compliant with the set of product safety certification requirements; wherein each of said plurality of interconnected unitized curtain wall units includes wiring and control circuitry for said energy conversion devices; said plurality of interconnected unitized curtain wall units further defining a plurality of integrated vertical and horizontal electrical conduits adapted to carry wiring for said plurality of interconnected unitized curtain wall units; said plurality of integrated vertical and horizontal electrical conduits also being compliant with said set of product safety certification requirements.
32. The building integrated power generating system of claim 31 wherein all components of the system are compliant with the product safety certification requirements prior to assembly within said plurality of interconnected unitized curtain wall elements. 33. The building integrated power generating system of claim 31 wherein at least a plurality of said energy conversion devices are oriented substantially vertically with respect to said building structure.
34. The building integrated power generating system of claim 31 wherein the product safety certification requirements are those of the Underwriter's Laboratory (UL).
35. The building integrated power generating system of claim 31 wherein the product safety certification requirements are those of the Canadian Standards
Association (CSA).
36. The building integrated power generating system of claim 31 wherein the product safety certification requirements are those of TUV Rheinland.
37. The building integrated power generating system of claim 31 wherein the curtain wall units are UL Approved under Category QHZQ.
38. The building integrated power generating system of claim 31 wherein an integrated wireway attached to said interconnected unitized curtain wall units for carrying power and control lines between said units is also compliant with UL safety certification requirements. 39. The building integrated power generating system of claim 31 wherein an integrated vertical wiring management clip within said curtain wall units is also compliant with UL safety certification requirements.
40. The building integrated power generating system of claim 31 further including a grounding element adapted to ground said interconnected curtain wall units to said building structure.
41. The building integrated power generating system of claim 31 further including a high voltage shut-off switch.
42. The building integrated power generating system of claim 39 wherein said shut-off switch is controlled automatically by a computer. 43. The building integrated power generating system of claim 31 wherein said interconnected curtain wall units include regulatory rated cabling, mountings and shielding for separating different types of signal cables.
44. An Underwriters Laboratories (UL) compliant building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell for a building structure; a plurality of photovoltaic energy conversion devices integrated and isolated from said exterior shell with UL compliant isolators within said plurality of interconnected unitized curtain wall units; said plurality of interconnected unitized curtain wall units further defining a plurality of integrated UL compliant vertical and horizontal electrical conduits adapted to carry electrical cabling for said plurality of photovoltaic energy conversion devices situated in said plurality of interconnected unitized curtain wall units; wherein the UL compliant building integrated photovoltaic power generating system is integrally incorporated within said plurality of interconnected unitized curtain wall units.
45. The UL compliant building integrated photovoltaic power generating system of claim 44, wherein said curtain wall units include vision and spandrel areas; and said at least one of said vision areas include at least one photovoltaic conversion device; and and at least one of said spandrel areas includes at least one photovoltaic conversion device.
46. The UL compliant building integrated photovoltaic power generating system of claim 44, wherein the system does not require a UL inspection prior to operation.
47. The UL compliant building integrated photovoltaic power generating system of claim 44, wherein said photovoltaic devices utilize amorphous, monocrystalline or polycrystalline silicon based conversion technology.
48. The UL compliant building integrated photovoltaic power generating system of claim 44 wherein a plurality of control units are integrated within said interconnected unitized curtain wall units; said control units each optimizing a power output of at least one of said plurality of photovoltaic conversion devices.
49. The UL compliant building integrated photovoltaic power generating system of claim 48 wherein said plurality of control units mitigate the effect of shading on said photovoltaic energy conversion devices.
50. An Underwriters Laboratories (UL) compliant building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell for a building structure; wherein each of said plurality of interconnected unitized curtain wall elements includes a framing element that is electrically grounded; a plurality of photovoltaic energy conversion devices integrated and isolated from said exterior shell with UL compliant isolators embedded in said framing element within said plurality of interconnected unitized curtain wall units; wherein at least some of said photovoltaic energy conversion devices are oriented vertically with respect to said building structure; said plurality of interconnected unitized curtain wall units being arranged as interlocked pairs which define a plurality of mullion spaces; wherein said mullion spaces are UL compliant conduits adapted to carry electrical cabling for said plurality of interconnected unitized curtain wall elements; wherein the UL compliant building integrated photovoltaic power generating system is integrally incorporated entirely within said plurality of interconnected unitized curtain wall units.
51. A method of operating a power generating system integrated within a building facade comprising: electrically coupling a plurality of energy conversion devices within a plurality of interconnected unitized curtain wall units; wherein said plurality of interconnected unitized curtain wall units define an exterior shell for at least a portion of a building structure; further wherein said plurality of energy conversion devices transform a first type of energy form into an electrical energy form; communicating power and control signals for said plurality of energy conversion devices within a plurality of integrated electrical conduits which are also integrated within said exterior shell; wherein the power generating system is integrally incorporated and operates within said plurality of interconnected unitized curtain wall units.
52. The method of claim 51 further including a step: coupling a plurality of control units within said interconnected unitized curtain wall units for optimizing a power output of said plurality of energy conversion devices. 53. The method of claim 51 wherein said plurality of control units optimize a power output of no more than six individual ones of a plurality of energy conversion devices.
54. The method of claim 53 wherein said plurality of control units mitigate the effect of shading on said photovoltaic energy conversion devices. 55. The method of claim 51 wherein said energy conversion devices are photovoltaic devices.
56. The method of claim 55, wherein at least one of said photovoltaic energy conversion devices are of different physical dimensions and/ or electrical characteristics than at least one of the other photovoltaic energy conversion devices.
57. The method of claim 51 further including a step: mounting an electrical connector associated with said energy conversion devices within a pocket region of each of said plurality of interconnected unitized curtain wall units.
58. The method of claim 51 wherein each of said plurality of interconnected unitized curtain wall units include an integral conduit adapted to carry electrical wires between adjacently situated control modules for said plurality of energy conversion devices.
59. The method of claim 58 wherein said integral conduit includes an electrical connector adapted to receive a flexible electrical cable from one of said plurality of energy conversion devices.
60. The method of claim 51 wherein the plurality of interconnected unitized curtain wall units meet Underwriter Laboratories (UL) or other applicable local regulatory requirements associated with the building for building integrated power generation systems and the system does not require a separate inspection prior to operation.
61. The method of claim 51 wherein different unitized curtain wall units of said system are used for flat regions than for corner regions of said building.
62. The method of claim 51 , wherein said energy conversion devices cover between 1 and 100 % of a surface area of one vertical side of said building structure.
63. The method of claim 51 , wherein said curtain wall units include vision and spandrel areas; and said at least one of said vision areas include at least one energy conversion device; and and at least one of said spandrel areas includes at least one energy conversion device. 64. The method of claim 55, further including a step: providing a solar flux concentrator for the photovoltaic devices.
65. The method of claim 51 , wherein said first form of energy includes at least one of: 1) electromagnetic energy; 2) potential energy; 3) kinetic energy; 4) thermal energy; and/or 5) chemical energy.
66. A method of operating a photovoltaic power generating system integrated within a building facade comprising: electrically coupling a plurality of photovoltaic conversion devices within a plurality of interconnected unitized curtain wall units; wherein said plurality of interconnected unitized curtain wall units define an exterior shell for at least a portion of a building structure; further wherein at least some of said photovoltaic energy conversion devices are oriented substantially vertically with respect to said building structure at least during certain periods; communicating power and control signals for said plurality of photovoltaic conversion devices within a plurality of integrated electrical conduits which are also integrated within said exterior shell; wherein the photovoltaic power generating system is integrally incorporated and operates within said plurality of interconnected unitized curtain wall units.
67. The method of claim 66, wherein said exterior shell encloses a substantial portion of a vertical surface of said building structure which receives solar radiation.
68. The method of claim 66, wherein said plurality of interconnected unitized curtain wall units occupy at least 50% of a vertical surface of said building structure which receives solar radiation.
69. The method of claim 66, wherein said photovoltaic energy conversion devices are arranged in a grid that generates in excess of 20kw at a peak output.
70. The method of claim 66 wherein the system as constituted meets Underwriter Laboratories (UL) or other or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate electrical safety inspection prior to operation. 71. The method of claim 66, further including a step: coupling an electrical output of said system to a utility grid. 72. The method of claim 66, further including a step: powering one or more electrical outlets within said building structure with an electrical output of said system. 73. The method of claim 66, further including a step: powering one or more mechanical systems within the building using an electrical output of said system. 74. The method of claim 66, further including a step: automatically disconnecting high voltages within the system in response to an emergency-based signal. 75. The method of claim 66 further including a step: altering an orientation of said photovoltaic energy conversion devices or a flux path to track and maximize incident solar radiation energy. 76. The method of claim 66, further including a step: providing a solar flux concentrator for the photovoltaic devices. 77. The method of claim 66, further including a step: controlling said photovoltaic conversion devices to isolate degradations of output in one such conversion device from other conversion devices in said array.
78. The method of claim 66, wherein power generated by the photovoltaic power generating system comes from a substantial portion of said exterior shell that spans across more than one face of said building structure.
79. The method of claim 66, wherein power generated by the photovoltaic power generating system comes from both vision areas and spandrel areas. A method of operating a photovoltaic power generating system integrated within a building facade comprising: electrically coupling a plurality of photovoltaic conversion devices within a plurality of interconnected unitized curtain wall units to form an interconnected array; wherein said unitized curtain wall units enclose a majority of a surface area of a building structure exposed to solar radiation and do not function as structural support elements for said building structure; further wherein at least some of said photovoltaic energy conversion devices are oriented substantially vertically with respect to said building structure at least during certain periods; communicating power and control signals for said plurality of photovoltaic conversion devices within a plurality of integrated electrical conduits which are also integrated within said exterior shell; wherein a first set of power and control signals is routed in said plurality of interconnected unitized curtain wall units within vertical mullions along a first vertical axis having a first direction; and wherein a second set of power and control signals is routed in said plurality of interconnected unitized curtain wall units within a horizontal wireway along a second axis in a second direction that is substantially perpendicular to said first direction; generating an electrical output from said interconnected array; wherein substantially all elements of the photovoltaic power generating system are integrally incorporated within said exterior shell.
81. A building integrated power generating system comprising: a plurality of unitized curtain wall elements defining at least a portion of an exterior shell for a building structure; a plurality of energy conversion devices integrated within said plurality of unitized curtain wall elements; each of said plurality of energy conversion devices being coupled to an associated power control module which is also integrated within said unitized curtain wall elements; wherein the power generating system is integrally incorporated and within said plurality of unitized curtain wall elements.
82. The system of claim 81 wherein said plurality of energy conversion devices can be selectively activated or de-activated by said corresponding power control modules on an individual basis or a floor by floor basis.
83. The system of claim 82, wherein said plurality of energy conversion devices are photovoltaic devices and can be selectively activated or de-activated based on shading, cleaning and/or scheduled maintenance.
84. The system of claim 81 wherein said power control module receives power and signals from an energy conversion device both by physical connection and wireless connection. 85. The system of claim 81 wherein said power control module is physically attached to and part of a module containing an energy conversion device.
86. The system of claim 81 wherein said power control module is coupled to a management unit adapted to control an entire array of energy conversion devices.
87. The system of claim 81 wherein said power control module is coupled to a management unit adapted to control an entire array of energy conversion devices.
88. The system of claim 87 wherein said management unit is coupled to a remote server adapted to monitor said array.
89. The system of claim 81 wherein said unitized curtain wall elements are interconnected in a continuous grid entirely within said exterior shell. 90. The system of claim 89, wherein said continuous grid extends across an entire floor.
91. A building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining at least a portion of an exterior shell for a building structure; each of said plurality of interconnected unitized curtain wall units having an integrated photovoltaic energy conversion module; a control module coupled to each integrated photovoltaic energy conversion module, which control module is adapted to optimize power of such device within a solar power generating array; said control module also being integrated within said unitized curtain wall unit and including electrical wiring for transmitting a power output from an associated photovoltaic energy conversion module to a separate control unit within said solar power generating array.
92. The system of claim 91 wherein said unitized curtain wall elements are interconnected in a two dimensional continuous grid entirely within said exterior shell.
93. The system of claim 91 wherein said control modules mitigate effects of shading on said integrated photovoltaic energy conversion module.
94. The system of claim 91 wherein said control modules are attached directly to said associated integrated photovoltaic energy conversion module.
95. The system of claim 91 wherein said control modules are mounted within a wireway or raceway integrated within said unitized curtain wall units.
96. The system of claim 91 wherein at least some input/output control signals from said control modules are communicated wirelessly between such control module and said integrated photovoltaic energy module.
97. The system of claim 91 wherein said power output is returned to a utility grid.
98. The system of claim 91 wherein at least a portion of said power output is used to power outlets and/or mechanical systems in the building structure.
99. The system of claim 91 wherein the system is compliant with Underwriters Laboratories (UL) requirements and does not require additional UL certification or inspection prior to operation.
100. A building integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall units defining an exterior shell for a building structure; each of said plurality of interconnected unitized curtain wall units having an integrated photovoltaic energy conversion module; each integrated photovoltaic energy conversion module having an individual power control module, which control module is adapted to optimize power of such device within a solar power generating array; wherein a plurality of interconnected control units are used within the solar power generating array and are integrated entirely within said exterior shell; a management unit also being integrated within said unitized curtain wall unit and adapted to monitor said plurality of control units and optimize a power output of said solar power generating array.
101. A building integrated power generating system comprising: a plurality of unitized curtain wall elements adapted as part of an exterior shell for a building structure in both vision areas and spandrel areas; wherein said unitized curtain wall elements span a vertical space that extends and covers both at least one vision area and one contiguous spandrel area; a plurality of energy conversion modules integrated within said plurality of unitized curtain wall elements including a plurality of first energy conversion modules in said vision areas and a plurality of second energy conversion modules in said spandrel areas; wherein said plurality of energy conversion devices are adapted to transform a first type of energy form into an electrical energy form; wherein the power generating system is integrally incorporated within said plurality of unitized curtain wall elements spanning said vision areas and spandrel areas.
102. The building integrated power generating system of claim 101, wherein said energy conversion modules include photovoltaic modules.
103. The building integrated power generating system of claim 102, wherein said photovoltaic modules are amorphous silicon or polycrystalline based solar cell/modules.
104. The building integrated power generating system of claim 102 wherein said plurality of first energy conversion modules are included in at least 25% of said vision areas.
105. The building integrated power generating system of claim 102 wherein said plurality of second energy conversion modules are included in at least 50% of said spandrel areas. 106. The building integrated power generating system of claim 101 wherein said unitized curtain wall elements span a vertical space that extends and covers a continuous strip of vision areas and contiguous spandrel areas over multiple stories of the building structure.
107. The building integrated power generating system of claim 101 wherein said unitized curtain wall elements are pre-assembled into a width ranging from approximately 4 feet to 8 feet, and a height ranging from approximately ten feet to 15 feet.
108. The building integrated power generating system of claim 101 wherein each of said unitized curtain wall elements includes both vision and spandrel regions. 109. The building integrated power generating system of claim 101 said plurality of first energy conversion modules in said vision areas are of a first type having a first power performance characteristic, and said plurality of second energy conversion modules in said spandrel areas are of a second type having a second power performance characteristic that is different from said first power performance characteristic.
110. The building integrated power generating system of claim 101 said plurality of first energy conversion modules in said vision areas are arranged with a first spatial density, and said plurality of second energy conversion modules in said spandrel areas are arranged with a second spatial density that is different from said first spatial density.
111. The building integrated power generating system of claim 101 wherein a power output per unit area differs in said vision areas and spandrel areas.
112. The building integrated power generating system of claim 101 wherein said plurality of unitized curtain wall elements mate with adjacent vertical and horizontal counterpart unitized wall elements so as to seal said shell from air and water intrusions. 113. The building integrated power generating system of claim 101 wherein the plurality of interconnected unitized curtain wall units meet Underwriter Laboratories (UL) or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate inspection prior to operation. 114. The system of claim 101, wherein said first form of energy includes at least one of: 1) electromagnetic energy; 2) potential energy; 3) kinetic energy; 4) thermal energy; and/or 5) chemical energy.
115. The building integrated power generating system of claim 101 wherein said unitized curtain wall units include: a) both vertical and horizontal framing members adapted to support a module associated with said photovoltaic energy conversion devices; b) support brackets adapted to affix the units to a building floor slab; and c) sealants and/or gaskets adapted to connect and isolate said module.
116. A building integrated photovoltaic power generating system comprising: a plurality of unitized curtain wall elements adapted as part of an exterior shell for a building structure in both vision areas and spandrel areas; wherein at least some of said unitized curtain wall elements span a vertical space that extends and covers both at least one vision area and one spandrel area contiguous to said vision area; a plurality of photovoltaic energy conversion modules integrated within said plurality of unitized curtain wall elements including a plurality of first photovoltaic energy conversion modules in said vision areas and a plurality of second photovoltaic energy conversion modules in said spandrel areas; wherein the photovoltaic power generating system is integrally incorporated within said plurality of unitized curtain wall elements spanning said vision areas and spandrel areas.
117. The building integrated photovoltaic power generating system of claim 116 wherein a plurality of control units integrated within said unitized curtain wall elements mitigate the effect of shading on said photovoltaic energy conversion modules. 118. The building integrated power generating system of claim 117 wherein said control units each optimize a power output of at least one of said plurality of photovoltaic energy conversion modules.
119. A building integrated photovoltaic power generating system comprising: a plurality of unitized curtain wall units adapted as part of an exterior shell for a building structure; said unitized curtain wall units including vertical areas formed of glazing and/or cladding materials; wherein at least one such unitized curtain wall unit includes vertical and horizontal framing members defining a plurality of glazing areas; wherein at least two of said plurality of glazing areas each contain one or more integrated photovoltaic conversion devices; said integrated photovoltaic conversion devices being electrically connected to control units integrated within said unitized curtain wall unit; wherein said unitized curtain wall units form a photovoltaic power generating array.
120. The building integrated power generating system of claim 119 wherein a plurality of control units are integrated within said unitized curtain wall units; said control units each optimizing a power output of at least one of said plurality of photovoltaic energy conversion modules. 121. The building integrated power generating system of claim 119 wherein said plurality of control units mitigate the effect of shading on said photovoltaic energy conversion modules. uilding integrated photovoltaic power generating system comprising: a plurality of interconnected unitized curtain wall elements defining an exterior shell for a building structure in both vision areas and spandrel areas; wherein at least some of said unitized curtain wall elements span a vertical space that extends and covers both at least one vision area and one spandrel area contiguous to said vision area; a plurality of photovoltaic energy conversion modules integrated within said plurality of unitized curtain wall elements including a plurality of first photovoltaic energy conversion modules in said vision areas and a plurality of second photovoltaic energy conversion modules in said spandrel areas; wherein only a first subset of said interconnected unitized curtain wall elements contain photovoltaic energy conversion modules while a second subset of said interconnected unitized curtain wall elements do not; said first subset of interconnected unitized curtain wall elements being further adapted with: a) a pocket region configured for receiving an edge connector for said photovoltaic energy conversion modules; b) a vertical conduit for routing wiring cables for said photovoltaic energy conversion modules; c) one or more isolation gaskets and/or sealant to isolate said photovoltaic energy conversion modules; d) a grounding element for grounding said curtain wall elements to a building structure; wherein the photovoltaic power generating system is integrally incorporated within said plurality of unitized curtain wall elements spanning both said vision areas and spandrel areas.
123. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; said rigid frame member being adapted to mount an energy conversion device within the glazing material; said rigid frame member further including an integrated raceway portion adapted to couple electrical wiring for a control module to be paired with said energy conversion device.
124. The unitized curtain wall unit of claim 123 wherein said rigid frame member is made of aluminum.
125. The unitized curtain wall unit of claim 123 including a pocket portion within said rigid frame member adapted to receive an edge connection and electrical wiring for said energy conversion device.
126. The unitized curtain wall unit of claim 123 wherein said rigid frame member includes a first pair of horizontal framing members and a second pair of vertical framing members; said horizontal framing members defining first conduits for electrical wiring; and said vertical framing members defining second conduits for electrical wiring.
127. The unitized curtain wall unit of claim 123 wherein said integrated raceway portion is adapted to house said control module within said module.
128. The unitized curtain wall unit of claim 123 wherein said rigid frame member is sealed against environmental and weather intrusions including air and water.
129. The unitized curtain wall unit of claim 123 wherein the unit is Underwriter Laboratories (UL) rated.
130. The unitized curtain wall unit of claim 123 wherein the unit is compliant with applicable local regulatory requirements associated with power generation systems.
131. The unitized curtain wall unit of claim 123 wherein said module is adapted for a corner region of said building structure.
132. The unitized curtain wall unit of claim 123 wherein said energy conversion devices are photovoltaic devices.
133. The unitized curtain wall unit of claim 123, wherein said module includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one energy conversion device; and and at least one of said spandrel areas can be configured to include at least one energy conversion device.
134. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; said rigid frame member being adapted to mount a photovoltaic energy conversion module within the glazing material; said rigid frame member having a pocket portion adapted to receive an electrical connection and wiring for said photovoltaic energy conversion module; said rigid frame member further including horizontal framing members defining first conduits for carrying electrical wiring associated with said photovoltaic energy conversion module and vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein said unitized curtain wall unit is configured to be physically interconnected to an adjacent unitized curtain wall unit within the exterior shell. 135. The unitized curtain wall unit of claim 134 wherein said rigid frame member is adapted to house a control module for said photovoltaic energy conversion module. 136. The unitized curtain wall unit of claim 135 wherein the unit includes an integrated wireway and/or raceway adapted to house said control module. 137. The unitized curtain wall unit of claim 135 wherein said control module can be mounted on said glazing material.
138. The unitized curtain wall unit of claim 134 wherein said rigid frame member is adapted to mount different types of photovoltaic energy conversion modules.
139. The unitized curtain wall unit of claim 134, wherein said unit includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one photovoltaic energy conversion module; and and at least one of said spandrel areas can be configured to include at least one photovoltaic energy conversion module. 140. The unitized curtain wall unit of claim 139 further including an additional glass pane in said spandrel areas.
141. The unitized curtain wall unit of claim 134 further including intermediate horizontal members adapted to support the glazing material.
142. The unitized curtain wall unit of claim 134 wherein the unit can be interconnected in a grid of additional unitized curtain wall units to form a power generating system within the building shell.
143. The unitized curtain wall unit of claim 134 further including a grounding element adapted to ground the unit to a building structure or other ground path. 144. The unitized curtain wall unit of claim 134 further including isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members. 145. The unitized curtain wall unit of claim 134 wherein said isolation elements are partially flexible seals and/or gaskets. 146. The unitized curtain wall unit of claim 134 wherein any holes present in said rigid frame members are adapted with grommets to be UL compliant.
147. The unitized curtain wall unit of claim 134 wherein said unit is not configured to provide structural support for the building structure.
148. The unitized curtain wall unit of claim 134 wherein said unit is prefabricated to a width of approximately 4 feet to 8 feet wide and 10 feet to 15 feet long.
149. The unitized curtain wall unit of claim 134 further including support brackets for mounting said unit to the building structure.
150. The unitized curtain wall unit of claim 149 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal.
151. The unitized curtain wall unit of claim 134 wherein said electrical wiring is integrated and preassembled within said unit.
152. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a metallic frame member; said metallic frame member being adapted to mount a photovoltaic energy conversion module within the glazing material; a wireway attached to a back portion of said metallic frame member; wherein said wireway is adapted to carry both signal and power cables for said photovoltaic energy conversion module; said metallic frame member further including: i) a pair of first horizontal framing members defining stack joints adapted as first conduits for carrying electrical wiring; and ii) a pair of vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein wiring can be routed in at least two different pathways and directions within said metallic frame member; iii) a pocket portion adapted to receive an edge connector and wiring for said photovoltaic energy conversion module; iv) one or more wire routing holes for routing said wiring between said photovoltaic energy conversion module and said wireway; v) isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members. wherein said unitized curtain wall unit is configured to be physically interconnected to one or more adjacent unitized curtain wall units within the exterior shell to form a continuous multi-story facade for the building structure.
153. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; an energy conversion device mounted on a panel bounded by said rigid frame member and integrally incorporated within the unitized curtain wall unit; said rigid frame member further including an integrated raceway portion adapted to couple electrical wiring for a control module to be paired with said energy conversion device.
154. The unitized curtain wall unit of claim 153 wherein said rigid frame member is made of aluminum.
155. The unitized curtain wall unit of claim 153 wherein said rigid frame member includes a pocket portion adapted to receive an electrical connector and electrical wiring for said energy conversion device.
156. The unitized curtain wall unit of claim 153 wherein said rigid frame member includes a first pair of horizontal framing members and a second pair of vertical framing members; said horizontal framing members defining first conduits for electrical wiring; and said vertical framing members defining second conduits for electrical wiring.
157. The unitized curtain wall unit of claim 153 wherein said integrated raceway portion is adapted to house said control module within said module. 158. The unitized curtain wall unit of claim 153 wherein said rigid frame member is sealed against environmental and weather intrusions including air and water. 159. The unitized curtain wall unit of claim 153 wherein the unit is Underwriter
Laboratories (UL) rated. 160. The unitized curtain wall unit of claim 153 wherein the unit is compliant with applicable local regulatory requirements associated with power generation systems.
161. The unitized curtain wall unit of claim 153 wherein said module is adapted for a corner region of said building structure.
162. The unitized curtain wall unit of claim 153 wherein said energy conversion devices are photovoltaic devices. 163. The unitized curtain wall unit of claim 153, wherein said module includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one energy conversion device; and and at least one of said spandrel areas can be configured to include at least one energy conversion device.
164. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; said rigid frame member being adapted to mount a photovoltaic energy conversion module within the glazing material; a photovoltaic energy conversion module mounted on a panel bounded by said rigid frame member and integrally incorporated within the unitized curtain wall unit; said rigid frame member having a pocket portion adapted to receive an electrical connection and wiring for said photovoltaic energy conversion module; said rigid frame member further including horizontal framing members defining first conduits for carrying electrical wiring associated with said photovoltaic energy conversion module and vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein said unitized curtain wall unit is configured to be physically interconnected to an adjacent unitized curtain wall unit within the exterior shell. 165. The unitized curtain wall unit of claim 164 wherein said rigid frame member is adapted to house a control module for said photovoltaic energy conversion module.
166. The unitized curtain wall unit of claim 165 wherein the unit includes an integrated wireway and/or raceway adapted to house said control module.
167. The unitized curtain wall unit of claim 165 wherein said control module can be mounted on said glazing material. 168. The unitized curtain wall unit of claim 164 wherein said rigid frame member is adapted to mount different types of photovoltaic energy conversion modules.
169. The unitized curtain wall unit of claim 164, wherein said unit includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one photovoltaic energy conversion module; and and at least one of said spandrel areas can be configured to include at least one photovoltaic energy conversion module.
170. The unitized curtain wall unit of claim 169 further including an additional glass pane in said spandrel areas.
171. The unitized curtain wall unit of claim 164 further including intermediate horizontal members adapted to support the glazing material.
172. The unitized curtain wall unit of claim 164 wherein the unit can be interconnected in a grid of additional unitized curtain wall units to form a power generating system within the building shell.
173. The unitized curtain wall unit of claim 164 further including a grounding element adapted to ground the unit to a building structure or other ground path.
174. The unitized curtain wall unit of claim 164 further including isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members.
175. The unitized curtain wall unit of claim 164 wherein said isolation elements are partially flexible seals and/or gaskets.
176. The unitized curtain wall unit of claim 164 wherein any holes present in said rigid frame members are adapted with grommets to be UL compliant.
177. The unitized curtain wall unit of claim 164 wherein said unit is not configured to provide structural support for the building structure.
178. The unitized curtain wall unit of claim 164 wherein said unit is prefabricated to a width of approximately 4 feet to 8 feet wide and 10 feet to 15 feet long.
179. The unitized curtain wall unit of claim 164 further including support brackets for mounting said unit to the building structure. 180. The unitized curtain wall unit of claim 164 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal. 181. The unitized curtain wall unit of claim 164 wherein said electrical wiring is integrated and preassembled within said unit. 182. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a metallic frame member; a photovoltaic energy conversion module mounted on a panel bounded by said rigid frame member and integrally incorporated within the unitized curtain wall unit; a wireway attached to a back portion of said metallic frame member; wherein said wireway is adapted to carry both signal and power cables for said photovoltaic energy conversion module; said metallic frame member further including: i) a pair of first horizontal framing members defining stack joints adapted as first conduits for carrying electrical wiring; and ii) a pair of vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein wiring can be routed in at least two different pathways and directions within said metallic frame member; iii) a pocket portion adapted to receive an edge connector and wiring for said photovoltaic energy conversion module; iv) one or more wire routing holes for routing said wiring between said photovoltaic energy conversion module and said wireway; v) isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members; wherein said unitized curtain wall unit is configured to be physically interconnected to one or more adjacent unitized curtain wall units within the exterior shell to form a continuous multi-story facade for the building structure.
183. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; said rigid frame member being adapted with a mounting structure capable of mounting an energy conversion device within the glazing material; a grounding element connected to and adapted to ground the rigid frame member to a building structure or other ground path; one or more isolation elements within said mounting structure of the rigid frame member that are adapted to isolate said energy conversion device from said rigid frame members.
184. The unitized curtain wall unit of claim 183 wherein said isolation elements are partially flexible seals and/or gaskets.
185. The unitized curtain wall unit of claim 183 wherein said isolation elements include structural silicones and/or VHB tape.
186. The unitized curtain wall unit of claim 183 wherein said isolation elements are sufficiently flexible to accommodate expected minor movements of said rigid frame relative to said glazing materials.
187. The unitized curtain wall unit of claim 184 wherein said gaskets include Underwriter Laboratories (UL) rated wedge gaskets and bed gaskets preassembled into said rigid frame.
188. The unitized curtain wall unit of claim 183 further including an integrated raceway portion connected to said rigid frame member which is adapted to couple electrical wiring for a control module to be paired with said energy conversion device.
189. The unitized curtain wall unit of claim 183 including a pocket portion within said rigid frame member adapted to receive an edge connection and electrical wiring for said energy conversion device.
190. The unitized curtain wall unit of claim 183 wherein said rigid frame member includes a first pair of horizontal framing members and a second pair of vertical framing members; said horizontal framing members defining first conduits for electrical wiring; and said vertical framing members defining second conduits for electrical wiring.
191. The unitized curtain wall unit of claim 183 wherein said rigid frame member is sealed against environmental/weather intrusions including air and water.
192. The unitized curtain wall unit of claim 183 wherein the unit is Underwriter Laboratories (UL) rated. 193. The unitized curtain wall unit of claim 183 wherein the unit is compliant with applicable local regulatory requirements associated with power generation systems. 194. The unitized curtain wall unit of claim 183, wherein said unit includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one energy conversion device; and and at least one of said spandrel areas can be configured to include at least one energy conversion device.
195. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a rigid frame member; said rigid frame member being adapted with a mounting structure to mount a photovoltaic energy conversion module within the glazing material; said rigid frame member having a pocket portion adapted to receive an electrical connection and wiring for said photovoltaic energy conversion module; a grounding element connected to and adapted to ground the rigid frame member to a building structure or other ground path; one or more isolation elements within said mounting structure of the rigid frame member that are adapted to isolate said photovoltaic energy conversion module from said rigid frame members.
196. The unitized curtain wall unit of claim 195 wherein said isolation elements are partially flexible seals and/or gaskets.
197. The unitized curtain wall unit of claim 195 wherein said isolation elements include structural silicones and/or VHB tape. 198. The unitized curtain wall unit of claim 195 wherein said isolation elements are sufficiently flexible to accommodate expected minor movements of said rigid frame relative to said glazing materials.
199. The unitized curtain wall unit of claim 195 wherein said gaskets include Underwriter Laboratories (UL) rated wedge gaskets and bed gaskets preassembled into said rigid frame.
200. The unitized curtain wall unit of claim 195 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal.
201. The unitized curtain wall unit of claim 195 wherein said electrical wiring is integrated and preassembled within said unit. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a metallic frame member; said metallic frame member being adapted to mount a photovoltaic energy conversion module within the glazing material; a wireway attached to a back portion of said metallic frame member; wherein said wireway is adapted to carry both signal and power cables for said photovoltaic energy conversion module; said metallic frame member further including: i) a pair of first horizontal framing members defining stack joints adapted as first conduits for carrying electrical wiring; and ii) a pair of vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein wiring can be routed in at least two different pathways and directions within said metallic frame member; iii) a pocket portion adapted to receive an edge connector and wiring for said photovoltaic energy conversion module; iv) one or more wire routing holes for routing said wiring between said photovoltaic energy conversion module and said wireway; v) one or more semi-flexible gasket isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members; wherein said semi-flexible gasket isolation elements further accommodate minor movement disturbances caused by wind, heat and/or seismic forces; vi) a grounding element adapted to ground said framing unit to the building structure or another electrical ground path; wherein said unitized curtain wall unit is configured to be physically interconnected to one or more adjacent unitized curtain wall units within the exterior shell to form an electrically isolated power generating system integrated within a facade for the building structure.
203. A unitized curtain wall unit adapted for use in an exterior shell of a building structure and comprising: a rigid frame having a glazing material adapted to mount an energy conversion device within the unitized curtain wall unit; a first vertical frame member of said rigid frame adapted to define a vertical mullion within the exterior shell when mated with a second vertical frame member of an adjacent second unitized curtain wall unit; said vertical mullion being adapted with an integrated conduit and a clip to carry electrical cabling and/or tubing for said energy conversion device in a vertical direction within the exterior shell; wherein said vertical mullion is configured so that an electrical or other transport connection can be completed to a second energy conversion device or a control module located above or below the glazing material within the exterior shell.
204. The unitized curtain wall unit of claim 203 wherein said energy conversion devices are photovoltaic devices and said electrical cabling carries both power and control signals. 205. The unitized curtain wall unit of claim 203 wherein said tubing carries a fluid and/or a gas. 206. The unitized curtain wall unit of claim 203 wherein said rigid frame includes a horizontal stack joint adapted to mate with an adjacent unitized curtain wall unit situated above or below in the building shell. 207. The unitized curtain wall unit of claim 203 wherein horizontal stack joint is adapted to carry said electrical cabling and/or tubing for said energy conversion device in a horizontal direction within the exterior shell. 208. The unitized curtain wall unit of claim 203 wherein said vertical mullion carries electrical cabling within a first portion of a mullion cavity and other tubing or conduits for transporting materials within a separate second portion of said mullion cavity isolated from said first portion.
209. The unitized curtain wall unit of claim 203 wherein grommets and/or other flexible bushings are used within holes or ports in said vertical mullion for routing said electrical cabling or tubing.
210. The unitized curtain wall unit of claim 204 wherein said vertical mullion is comprised of Underwriter Laboratories (UL) rated materials.
211. The unitized curtain wall unit of claim 203 wherein said electrical cable and an electrical connector is pre-assembled into said vertical mullion for connection to a second vertical mullion within said exterior shell.
212. The unitized curtain wall unit of claim 203 further including an integrated raceway portion connected to said rigid frame member which is adapted to couple electrical wiring for a control module to be paired with said energy conversion device.
213. The unitized curtain wall unit of claim 203 including a pocket portion within said rigid frame member adapted to receive an edge connection and electrical wiring for said energy conversion device.
214. The unitized curtain wall unit of claim 203, wherein said unit includes vision and spandrel areas; and said at least one of said vision areas can be configured to include at least one energy conversion device; and and at least one of said spandrel areas can be configured to include at least one energy conversion device.
215. The unitized curtain wall unit of claim 203 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal.
216. A unitized curtain wall unit adapted for use in an exterior shell of a building structure and comprising: a rigid frame having a glazing material adapted to mount a photovoltaic energy conversion module within the unitized curtain wall unit; a first vertical frame member of said rigid frame adapted to define a vertical mullion within the exterior shell when mated with a second vertical frame member of an adjacent second unitized curtain wall unit; said vertical mullion being adapted with an integrated conduit and a clip to carry electrical cabling for said photovoltaic energy conversion module in a vertical direction within the exterior shell; wherein said vertical mullion is configured so that an electrical connection can be completed to a second photovoltaic energy conversion module and/or a control module located above or below the glazing material within the exterior shell.
217. The unitized curtain wall unit of claim 216 further including a photovoltaic energy conversion module integrated and mounted in said glazing material.
218. The unitized curtain wall unit of claim 216, wherein said photovoltaic energy conversion modules utilize amorphous, monocrystalline or polycrystalline silicon based cells.
219. The unitized curtain wall unit of claim 216, further including one or more flux concentrators attached to said rigid frame.
220. The unitized curtain wall unit of claim 216 wherein a plurality of first photovoltaic energy conversion devices are arranged with a first spatial density in vision areas of said unit, and a plurality of second photovoltaic energy conversion devices are arranged with a second spatial density in spandrel areas of said unit; and further wherein said second spatial density is different from said first spatial density. 221. The unitized curtain wall unit of claim 216 wherein said electrical cabling can also be routed in intermediate horizontal members situated between vision and spandrel areas within the unit. A unitized curtain wall unit adapted for use in an exterior shell of a building structure and comprising: a rigid frame having a glazing material adapted to mount a photovoltaic energy conversion module within the unitized curtain wall unit; a first vertical frame member of said rigid frame adapted to define a vertical mullion within the exterior shell when mated with a second vertical frame member of an adjacent second unitized curtain wall unit; said vertical mullion being adapted with an integrated conduit and a clip to carry electrical cabling for said photovoltaic energy conversion module in a vertical direction within the exterior shell; wherein said vertical mullion is configured so that an electrical connection can be completed to a second photovoltaic energy conversion module and/or a control module located above or below the glazing material within the exterior shell; a second horizontal frame member adapted to define a horizontal stack joint within the exterior shell when mated with a second horizontal frame member of an adjacent third unitized curtain wall unit; wherein said horizontal stack joint is configured so that an electrical connection can also be completed to a third photovoltaic energy conversion module and/or a control module located adjacent the unit within the exterior shell; wherein said unitized curtain wall unit is configured to be physically interconnected to one or more adjacent unitized curtain wall units within the exterior shell to form an electrically isolated power generating system integrated within a facade for the building structure. A unitized curtain wall unit with glazing material adapted for use in a vertical portion of an exterior shell of a building structure and comprising: a metallic frame member; said metallic frame member being adapted to mount a photovoltaic energy conversion module within the glazing material; a wireway attached to a back portion of said metallic frame member; wherein said wireway is adapted to carry both signal and power cables for said photovoltaic energy conversion module; said metallic frame member further including: i) a pair of first horizontal framing members defining stack joints adapted as first conduits for carrying electrical wiring; and ii) a pair of vertical framing members defining mullions adapted as second conduits for said electrical wiring; wherein wiring can be routed in at least two different pathways and directions within said metallic frame member; iii) a pocket portion adapted to receive an edge connector and wiring for said photovoltaic energy conversion module; iv) one or more wire routing holes for routing said wiring between said photovoltaic energy conversion module and said wireway; v) one or more semi-flexible gasket isolation elements adapted to isolate said photovoltaic energy conversion module from said rigid frame members; wherein said semi-flexible gasket isolation elements further accommodate minor movement disturbances caused by wind, heat and/or seismic forces; vi) a grounding element adapted to ground said framing unit to the building structure or another electrical ground path; wherein said unitized curtain wall unit is configured to be physically interconnected to one or more adjacent unitized curtain wall units within the exterior shell to form an electrically isolated power generating system integrated within a facade for the building structure.
224. An electrical routing structure for a power generating system integrated within unitized curtain wall modules mounted within an exterior shell of a building structure and comprising: a plurality of energy conversion modules configured in an array and integrated within rigid frames associated with the unitized curtain wall units; a plurality of contiguous vertical frame members of said rigid frames defining a plurality of vertical mullions within the exterior shell; wherein said plurality of vertical mullions are defined solely by adjacent ones of the unitized curtain wall units and without reference to other building structures; a plurality of contiguous horizontal frame members of said rigid frames defining a plurality of horizontal mullions within the exterior shell; wherein said plurality of horizontal mullions are defined solely by adjacent ones of the unitized curtain wall units and without reference to other building structures; said plurality of vertical and horizontal mullions being adapted as an integrated electrical conduit to carry electrical cabling for said plurality of energy conversion modules in a vertical direction and a horizontal direction within the exterior shell so as to transfer a power output of said array.
225. The electrical routing structure of claim 224 wherein said integrated electrical conduit includes one or more clips to contain said electrical cabling. 226. The electrical routing structure of claim 224 wherein said electrical cabling includes both power carrying lines and control signal lines. 227. The electrical routing structure of claim 224 wherein said vertical and horizontal mullions are further adapted to carry tubing and/or piping for transporting other materials to/from said energy conversion modules. 228. The electrical routing structure of claim 224 wherein said unitized curtain wall units span a vertical space that extends and covers a continuous strip of vision areas and contiguous spandrel areas over multiple stories of the building structure.
229. The electrical routing structure of claim 224 wherein said unitized curtain wall units are pre-assembled into a width ranging from approximately 4 feet to 8 feet, and a height ranging from approximately ten feet to 15 feet.
230. The electrical routing structure of claim 224 wherein each of said unitized curtain wall units includes both vision and spandrel regions.
231. The electrical routing structure of claim 224 wherein said integrate electrical conduit meets Underwriter Laboratories (UL) or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate inspection prior to operation.
232. The electrical routing structure of claim 224, wherein said energy conversion modules convert at least one of: 1) electromagnetic energy; 2) potential energy; 3) kinetic energy; 4) thermal energy; and/or 5) chemical energy into electrical energy or heat energy. 233. The electrical routing structure of claim 224 wherein said rigid frame is made of aluminum. 234. The electrical routing structure of claim 224 wherein said rigid frame includes a pocket region adapted to mount an edge connector and/or cabling for said energy conversion modules. 235. The electrical routing structure of claim 224 further including control modules integrated within said unitized curtain wall units for optimizing said power output.
236. The electrical routing structure of claim 224 further including an additional wireway/raceway integrated on a back portion of said unitized curtain wall units for routing said electrical cabling.
237. The electrical routing structure of claim 224 wherein said electrical cabling is pre-assembled within said unitized curtain wall units and includes connectors for inter-curtain wall unit connections.
238. The electrical routing structure of claim 224 further including a high voltage disconnect switch that is also integrated into said unitized curtain wall units for selectively disconnecting said power output in response to a predefined event.
239. An electrical routing structure for a photovoltaic generating system integrated within unitized curtain wall modules mounted within an exterior shell of a building structure and comprising: a plurality of photovoltaic energy conversion modules configured in an array and integrated within rigid frames associated with the unitized curtain wall modules; a plurality of contiguous vertical frame members of said rigid frames defining a plurality of vertical mullions within the exterior shell; wherein said plurality of vertical mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures; a plurality of contiguous horizontal frame members of said rigid frames defining a plurality of horizontal mullions within the exterior shell; wherein said plurality of horizontal mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures; said plurality of vertical and horizontal mullions being adapted with an integrated electrical conduit to carry electrical cabling for said plurality of photovoltaic energy conversion modules in a vertical direction and a horizontal direction within the exterior shell to transfer an output of said array.
240. The electrical routing structure of claim 239 wherein said unitized curtain wall modules include mountings and cable runs/shielding that allow for separation of different types of signal cables, including high voltage and low voltage power lines. 241. The electrical routing structure of claim 239 further including an additional wireway/raceway integrated on a back portion of said unitized curtain wall units for routing said electrical cabling.
242. The electrical routing structure of claim 239 wherein said unitized curtain wall modules are adapted to resist water, pressure and other physical disturbances. A electrical routing structure for a photovoltaic generating system integrated within unitized curtain wall modules mounted within an exterior shell of a building structure and comprising: a plurality of photovoltaic energy conversion modules configured in an array and integrated within metallic frames associated with the unitized curtain wall modules; said unitized curtain wall modules being interconnected and extending across a substantial portion of a vertical surface of said building structure which receives solar radiation; a plurality of contiguous vertical frame members of said metallic frames defining a plurality of vertical mullions within the exterior shell; wherein said plurality of vertical mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures including jambs; a plurality of contiguous horizontal frame members of said metallic frames defining a plurality of horizontal mullions within the exterior shell; wherein said plurality of horizontal mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures; a plurality of intermediate horizontal frame members defining a spandrel area and a vision area for said unitized curtain wall modules; wherein both said spandrel area and said vision area include interconnected photovoltaic energy conversion modules; said plurality of vertical and horizontal mullions being adapted with an integrated electrical conduit to carry electrical cabling for said plurality of photovoltaic energy conversion modules in a vertical direction and a horizontal direction within the exterior shell so as to complete connections to corresponding control modules.
244. An electrical wireway adapted for use in a unitized curtain wall module defining part of an exterior shell of a building structure and comprising: a metal based conduit adapted with an insulated channel to route both high voltage cabling and low voltage signal cabling in a first direction; said metal based conduit including a mount adapted to attach the electrical wireway to the unitized curtain wall module; said metal based conduit further including at least one electrical connector situated on an exterior surface and adapted to receive and connect to an output cable from an energy conversion module; further wherein said metal based conduit is adapted to house an integrated control module for said energy conversion module.
245. The electrical wireway of claim 244, wherein said high voltage cabling, low voltage signal cabling and metal based conduit are all Underwriters Laboratories rated.
246. The electrical wireway of claim 244, wherein said high voltage cabling and low voltage signal cabling are routed from said energy conversion module to an inverter within the building structure both horizontally and vertically across multiple stories using only Underwriters Laboratories rated conduits. 247. The electrical wireway of claim 244, wherein said metal based conduit is integrated and permanently affixed to the unitized curtain wall module during manufacture of such module.
248. The electrical wireway of claim 244, wherein said metal based conduit is separately manufactured and is attached to the unitized curtain wall module during installation of such module within said exterior shell.
249. The electrical wireway of claim 244, wherein said metal based conduit is affixed to a backside of the unitized curtain wall module.
250. The electrical wireway of claim 244, wherein said metal based conduit is made of aluminum. 251. The electrical wireway of claim 244, wherein said metal based conduit includes an additional insulating liner.
252. The electrical wireway of claim 244 wherein said connector includes a grommet adapted to reduce damage to said output cable.
253. The electrical wireway of claim 244, wherein said first direction is horizontal with respect to said exterior shell.
254. The electrical wireway of claim 244, wherein said first direction is vertical with respect to said exterior shell. 255. The electrical wireway of claim 244, wherein said metal based conduit also houses additional tubing/conduits for transporting other materials within said exterior shell.
256. The electrical wireway of claim 244, wherein said metal based conduit routes at least one of said high voltage cabling and low voltage signal cabling through one or more mullions of said unitized curtain wall module within said exterior shell.
257. The electrical wireway of claim 244, wherein said metal based conduit further houses a management unit for controlling a plurality of control modules.
258. An electrical wireway adapted for use in a unitized curtain wall module defining part of an exterior shell of a building structure and comprising: a metal based conduit adapted with an insulated channel to route both high voltage cabling and low voltage signal cabling in a first direction; said metal based conduit including a mount adapted to attach the electrical wireway to the unitized curtain wall module; said metal based conduit further including at least one electrical connector situated on an exterior surface and adapted to receive and connect to an output cable carrying a power output from a photovoltaic energy conversion module; further wherein said metal based conduit is adapted to house an integrated control module for said photovoltaic energy conversion module, which integrated control module is coupled to said power output.
259. The electrical wireway of claim 258, wherein said high voltage cabling, low voltage signal cabling and metal based conduit are all Underwriters
Laboratories rated.
260. The electrical wireway of claim 258, wherein said metal based conduit also houses additional tubing/conduits for transporting other materials within said exterior shell.
261. The electrical wireway of claim 258, wherein said metal based conduit routes at least one of said high voltage cabling and low voltage signal cabling through one or more mullions of said unitized curtain wall module within said exterior shell. 262. The electrical wireway of claim 258 wherein said connector includes a grommet adapted to reduce damage to said output cable.
263. An electrical wireway adapted for use in a unitized curtain wall module defining part of an exterior shell of a building structure and comprising: a metal based conduit rated for Underwriters Laboratories compliance and adapted to route both high voltage cabling and low voltage signal cabling in a first direction along a plurality of unitized curtain wall modules; said metal based conduit including a mount adapted to attach the electrical wireway to the plurality of unitized curtain wall modules; said metal based conduit further including a plurality of electrical connectors situated on an exterior surface and adapted to receive and connect to a plurality of output cables carrying a power output from a plurality of associated photovoltaic energy conversion modules forming a solar power generating array; further wherein said metal based conduit is adapted to house a plurality of integrated control modules, each of which is coupled to an associated photovoltaic energy conversion module; wherein a power output from said solar power generating array is carried within a continuous metal based conduit integrated entirely within said exterior shell.
264. A photovoltaic generating system integrated within unitized curtain wall modules mounted within an exterior shell of a building structure and comprising: a plurality of photovoltaic energy conversion modules configured in an array and integrated within metallic frames associated with the unitized curtain wall modules; a plurality of contiguous vertical frame members of said metallic frames defining a plurality of vertical mullions within the exterior shell; wherein said plurality of vertical mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures including those at jambs; a plurality of contiguous horizontal frame members of said metallic frames defining a plurality of horizontal mullions within the exterior shell; wherein said plurality of horizontal mullions are defined solely by adjacent ones of the unitized curtain wall modules and without reference to other building structures; said plurality of vertical and horizontal mullions being adapted with an integrated electrical conduit to carry electrical cabling for said plurality of photovoltaic energy conversion modules in a vertical direction and a horizontal direction within the exterior shell so as to complete connections to corresponding control modules.
265. A method of assembling a power generating system integrated into a building facade comprising: arranging a plurality of interconnected unitized curtain wall units to define an exterior shell for a building structure; providing a plurality of energy conversion modules integrated within said plurality of interconnected unitized curtain wall units; orienting at least some of said plurality of energy conversion modules vertically within said exterior shell; configuring a plurality of integrated vertical and horizontal electrical conduits within said plurality of interconnected unitized curtain wall units to support electrical cabling for said plurality of energy conversion modules.
266. The method of claim 265, wherein said plurality of interconnected unitized curtain wall units occupy at least 50% of a vertical surface of said building structure which receives solar radiation.
267. The method of claim 265, further including a step: routing said electrical cabling within said exterior shell.
268. The method of claim 267, further including a step: coupling said electrical cabling to control modules also situated within said exterior shell.
269. The method of claim 268, further including a step: coupling a plurality of control modules to each other within said exterior shell. 270. The method of claim 269, further including a step: coupling a plurality of control modules to a management module.
271. The method of claim 270, further including a step: providing a disconnect switch for an output of said energy conversion modules.
272. The method of claim 269, further including a step: coupling said plurality of energy conversion modules to an inverter.
273. The method of claim 265 further including a step: generating power from an array of said energy conversion modules integrated entirely within said exterior shell.
274. The method of claim 265 further including a step: altering an orientation of said energy conversion modules or a flux path to track and maximize incident solar radiation energy.
275. The method of claim 265 further including a step: providing outlets within said building structure for charging electrical devices based on said power generated by said array. 276. The method of claim 265 further including a step: assembling said unitized curtain wall units offsite from said building structure and so as to include: a) both vertical and horizontal framing members adapted to support a photovoltaic energy conversion module; b) support brackets adapted to affix such units to said building floor slab; and c) sealants and/or gaskets adapted to connect and isolate said module.
277. The method of claim 265 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train station terminal and/or a sea port terminal.
278. The method of claim 265 wherein the power generating system as constituted meets Underwriter Laboratories (UL) or other or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate electrical safety inspection prior to operation.
279. A method of assembling a photovoltaic power generating system integrated into a building facade comprising: hanging a plurality of interconnected unitized curtain wall units in a vertical orientation on a building structure slab to define an exterior facade for a building structure; wherein said facade does not provide any structural support for said building structure; wherein said plurality of unitized curtain wall units each includes an associated energy conversion module integrated within a glazing panel of such unitized curtain wall units that is mated to an electrical connector within a frame of such units; mounting an electrical wireway to said unitized curtain wall units capable of housing an electrical cabling for said associated energy conversion module; configuring at least a vertical or horizontal mullion of said unitized curtain wall units to carry said electrical cabling.
280. The method of claim 279, further including a step: routing said electrical cabling within said exterior shell.
281. The method of claim 279 further including a step : generating power from an array of said photovoltaic energy conversion modules integrated entirely within said exterior shell.
282. The method of claim 279 further including a step: assembling said unitized curtain wall units offsite from said building structure and so as to include: a) both vertical and horizontal framing members adapted to support a photovoltaic energy conversion module; b) support brackets adapted to affix such units to said building floor slab; and c) sealants and/or gaskets adapted to connect and isolate said module.
283. The method of claim 279 wherein said building structure is one of a commercial structure, a residential structure, a parking structure, a hospital, an airport terminal, a train terminal and/or a sea port terminal.
284. The method of claim 279 wherein the power generating system as constituted meets Underwriter Laboratories (UL) or other or other applicable local regulatory requirements associated with the building for building integrated power generation systems and does not require a separate electrical safety inspection prior to operation.
PCT/US2009/058059 2008-09-23 2009-09-23 Building integrated power generating system, method and components thereof WO2010039541A1 (en)

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EP09818279.3A EP2342811A4 (en) 2008-09-23 2009-09-23 Building integrated power generating system, method and components thereof

Applications Claiming Priority (28)

Application Number Priority Date Filing Date Title
US9943708P 2008-09-23 2008-09-23
US61/099,437 2008-09-23
US11441008P 2008-11-13 2008-11-13
US61/114,410 2008-11-13
US12/564,627 2009-09-22
US12/564,664 2009-09-22
US12/564,761 US20100071282A1 (en) 2008-09-23 2009-09-22 Unitized Building Integrated Photovoltaic Conversion Module Adapted With Electrical Conduits
US12/564,671 US7847181B2 (en) 2008-09-23 2009-09-22 Building integrated photovoltaic conversion system implemented with integrated control management units
US12/564,732 US20100071274A1 (en) 2008-09-23 2009-09-22 Unitized Curtain Wall Module Adapted for Integrated Photovoltaic Conversion Module
US12/564,671 2009-09-22
US12/564,748 2009-09-22
US12/564,686 US7845127B2 (en) 2008-09-23 2009-09-22 Building integrated photovoltaic conversion system implemented in both vision and spandrel areas
US12/564,609 2009-09-22
US12/564,748 US20100071281A1 (en) 2008-09-23 2009-09-22 Unitized Building Integrated Photovoltaic Conversion Module Adapted With Electrical Isolation and Grounding
US12/564,761 2009-09-22
US12/564,664 US20100071747A1 (en) 2008-09-23 2009-09-22 Method of Operating Building Integrated Photovoltaic Conversion System
US12/564,768 2009-09-22
US12/564,774 US8595995B2 (en) 2008-09-23 2009-09-22 Method of assembling an electrical raceway for building integrated solar PV system
US12/564,740 US7845128B2 (en) 2008-09-23 2009-09-22 Unitized building integrated photovoltaic conversion module
US12/564,768 US8171679B2 (en) 2008-09-23 2009-09-22 Integrated electrical conduit for solar PV system
US12/564,783 2009-09-22
US12/564,740 2009-09-22
US12/564,774 2009-09-22
US12/564,627 US7845126B2 (en) 2008-09-23 2009-09-22 UL compliant building integrated photovoltaic conversion system
US12/564,686 2009-09-22
US12/564,732 2009-09-22
US12/564,783 US20100071310A1 (en) 2008-09-23 2009-09-22 Method of Assembling Building Integrated Photovoltaic Conversion System
US12/564,609 US8381465B2 (en) 2008-09-23 2009-09-22 Building integrated power generating system

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