Structural Insulated Monolithic Photovoltaic Solar-Power Roof and Method of Use Thereof

Abstract

A photovoltaic roof structure is provided. The monolithic roof structure comprises a plurality of composite panels, photovoltaic modules and connectors, wherein the respective composite panels are comprised of an outer skin, an inner skin, and an insulation layer between the outer and inner skins, the photovoltaic modules are incorporated into the outer skin, and the connectors physically and electrically couple the composite panels to one another to form the roof structure.

1 . A composite roof panel, the composite roof panel comprising:
 an outer skin;   an inner skin;   an insulation material positioned between the inner and outer skins; and   photovoltaic cells containing photovoltaic materials integrated onto the outer skin.   
     
     
         2 . The panel of  claim 1 , further comprising outer ribs, wherein the outer ribs are positioned between the skins near distal edges of the skins so as to contain the insulation material positioned between the skins 
     
     
         3 . The panel of  claim 2 , wherein each of the outer ribs is configured in a c-shape and a top of the c-shape engages the outer skin and a bottom of the c-shape engages the inner skin. 
     
     
         4 . The panel of  claim 1 , further comprising inner ribs, wherein the inner ribs are positioned between the skins at regular intervals within the panel. 
     
     
         5 . The panel of  claim 4 , wherein each of the inner ribs is configured in an I-beam shape and a top of the I-beam engages the outer skin and a bottom of the I-beam engages the inner skin. 
     
     
         6 . The panel of  claim 5 , wherein each of the inner ribs further comprises openings therein positioned at regular intervals along the length of the I-beam shape. 
     
     
         7 . The panel of  claim 1 , further comprising a reinforcement layer coupled to a bottom surface of the inner skin. 
     
     
         8 . The panel of  claim 1 , wherein a portion of the inner and outer skins extend beyond an outer rib, such that the portions of the inner and outer skins that extend beyond the outer rib are structured to couple the panel to an adjacent structure. 
     
     
         9 . The panel of  claim 1 , further comprising a honeycomb structure, wherein the honeycomb structure is positioned between the inner and outer skins and prevents the insulation material from penetrating within the honeycomb structure so as to allow light to pass through the outer skin, the honeycomb structure, and the inner skin. 
     
     
         10 . A roof structure of a building, the roof structure comprising:
 a plurality of composite roof panels having an outer skin, an inner skin, and an insulation layer therebetween;   a support; and   photovoltaic modules,   wherein one or more of the plurality of roof panels are coupled together and positioned on and collectively supported by the support, and wherein one or more of the photovoltaic modules are integrated onto the outer skin of each panel.   
     
     
         11 . The roof structure of  claim 10 , wherein the support is a steel support and is configured to support the plurality of composite roof panels thereby. 
     
     
         12 . The roof structure of  claim 11 , further comprising a cradle, wherein the cradle is fixedly coupled to the steel support and is structured to receive and secure the roof panels therein. 
     
     
         13 . The roof structure of  claim 10 , further comprising a support panel configured to be positioned between two adjacent roof panels and having a first end and a second end, the first end being elevated with respect to the second end, wherein one adjacent roof panel couples to the first end and the other adjacent roof panel couples to the second end, such that the first end raises the one adjacent roof panel coupled thereto above the level of the other adjacent roof panel coupled to the second end. 
     
     
         14 . The roof structure of  claim 13 , wherein successive coupling of roof panels to one another with a support panel therebetween situates the roof panels at an angle with respect to the horizontal. 
     
     
         15 . The roof structure of  claim 14 , wherein the roof panels are angled from between 5 and 33 degrees, inclusive, with respect to the horizontal. 
     
     
         16 . The roof structure of  claim 14 , wherein the support panel further comprises a horizontal portion between the first and second ends, the horizontal portion forming a flat area between adjacent roof panels coupled to the support panel. 
     
     
         17 . The roof structure of  claim 10 , further comprising electrical components, wherein the electrical components are incorporated in the panels to electrically couple the photovoltaic modules to the panels, the panels to one another, and the panels to the building, such that the solar energy absorbed by each of the photovoltaic modules is converted to electric energy and transported to the building to power the building. 
     
     
         18 . The roof structure of  claim 10 , further comprising a heat exchange system, wherein the heat exchange system pumps a fluid through a closed loop that passes through one or more panels and a water storage tank, the fluid entering the one or more panels and heating up by dissipating and carrying away heat generated by the photovoltaic modules, the heated fluid thereafter entering the water storage tank and transferring heat to the potable water contained in the water storage tank to heat the potable water, the cooled fluid thereafter exiting the water storage tank and returning to the one or more panels to be reheated. 
     
     
         19 . A method of forming a roof structure of a building comprising:
 forming a plurality of composite roof panels and composite support panels at a location;   transporting the composite roof panels from the location to a building location;   assembling the composite roof panels to one another with a composite support panel therebetween on top of the building at the building location;   electrically coupling the composite roof panels to one another; and   electrically coupling the composite roof panels to the building.   
     
     
         20 . The method of  claim 19 , the forming a plurality of composite roof panels further comprises:
 providing a first skin;   providing a second skin;   placing inner ribs between the first and second skins at regular intervals;   placing outer ribs between the first and second skins at distal ends of the skins;   coupling the first skin to the second skin by adhering the first and second skins to opposing edges of the outer ribs;   injecting or placing insulation between the first and second skins;   integrating photovoltaic modules having solar cells containing photovoltaic material therein onto the first skin; and   electrically coupling the photovoltaic modules to the panel.