# Patent

## Title
Solar power unit and system

## Abstract

One aspect of the present invention relates to a solar power unit comprising a frame, configured to be integrated into a building structure, for supporting a solar panel, the solar panel for generating a power signal, and a front cover for securing the solar panel to the frame.

## Background
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation patent application of, and claims priority under 35 U.S.C. §120 to, U.S. patent application Ser. No. 13/802,469 filed Mar. 13, 2013, which is a continuation-in-part of U.S. design patent application Ser. No. 29/426,688, filed Jul. 9, 2012, a U.S. nonprovisional patent application of, and claims priority under 35 U.S.C. §119(e) to, U.S. provisional patent application Ser. No. 61/710,709, filed Oct. 6, 2012, and U.S. provisional patent application Ser. No. 61/734,967, filed Dec. 8, 2012, which design and provisional patent applications are incorporated by reference herein.


FIELD OF INVENTION
The present invention relates generally to solar power. More specifically, the present invention relates to an integrated solar power unit and system.
BACKGROUND
With massive energy demands on our cities, existing surfaces of our built environment fail to harvest and utilize potential solar energy. Existing solar arrays on rooftops are far removed from the architecture of our daily lives and require clumsy equipment that is neither integrated nor aesthetically considered. Also, existing products, for example, solar roofing tile, translucent photovoltaic window modules, and façade panels, do not have the components (e.g., battery, inverter, and other electronics) integrated with the product.
Other existing products have the same issues that typical roof-mounted systems have, complicated wiring configurations that connect to electrical equipment located inside the building. These products are also not structural. Typical solar panels that are applied to the façade or roof of the building are mounted on top of structural building materials.
Therefore, there exists a need for an architecturally integrated technology system that collects, stores, and transforms solar energy into usable electricity. The system may also serve as the structural, exterior finish material of the building, and protect the building from environmental forces (rain, wind, UV degradation, etc.).
SUMMARY
The present invention includes many aspects and features. Moreover, while many aspects and features may be described with respect to healthcare, the present invention is not limited to use only in healthcare, as will become apparent from the following summaries and detailed descriptions of aspects, features, and one or more embodiments of the present invention. Indeed, the user interfaces and user interface methodologies are generally as applicable in healthcare as in other industries outside of healthcare.
Accordingly, one aspect of the present invention relates to a solar power unit comprising a frame, configured to be integrated into a building structure, for supporting a solar panel, the solar panel for generating a power signal, and a front cover for securing the solar panel to the frame.
In a feature of this aspect, the frame includes a bottom panel having a first and second bottom panel portion, wherein the second bottom panel portion is angled a certain amount of degrees such that the solar panel is set at an appropriate tilt angel with the solar panel is supported by the frame.
In a feature of this aspect, the solar power unit further comprising a power component, the power component including an inverter for converting the power signal from the solar panel to an AC signal, and a power outlet for providing the AC signal to an electronic device coupled to the power outlet.
In a feature of this aspect, the power outlet is at least one of a Universal Serial Bus (USB) and an electrical outlet.
In a feature of this aspect, the power component further includes a battery for storing the power signal generated by the solar panel and forwarding the power signal to the inverter when the power outlet is coupled to an electronic device.
In a feature of this aspect, the frame further includes a top panel having a first and second top panel portion.
In a feature of this aspect, the building structure is an exterior wall comprising a plurality of building blocks.
In a feature of this aspect, the first top panel portion and the first bottom panel portion are parallel to each other.
In a feature of this aspect, the building blocks are cinder blocks, wherein the frame of the solar power unit is slid over one of plurality of cinder blocks, such that the first top panel portion and the bottom panel portion are engaged with the top and bottom of the one cinder block, respectively.
In a feature of this aspect, the first top panel portion and the first bottom panel portion are bent 90° up and down, respectively.
In a feature of this aspect, the building blocks are cinder blocks; and wherein the solar power unit is attached to one of the plurality of cinder blocks through the first top panel portion and the first bottom panel portion.
In a feature of this aspect, the power component further includes a charge controller for protecting the battery from overcharging.
Another aspect of the present invention relates to a solar power system comprising a plurality of solar power units, each of the plurality of solar power units comprising a frame, configured to be integrated into a building structure, for supporting a solar panel, the solar panel for generating a power signal, and a front cover for securing the solar panel to the frame.
In a feature of this aspect, the frame includes a bottom panel having a first and second bottom panel portion, wherein the second bottom panel portion is angled a certain amount of degrees such that the solar panel is set at an appropriate tilt angel with the solar panel is supported by the frame.
In a feature of this aspect, at least one of the plurality of solar power units further comprises a power component, the power component including an inverter for converting the power signal from the solar panel to an AC signal, and a power outlet for providing the AC signal to an electronic device coupled to the power outlet.
In a feature of this aspect, the power outlet is at least one of a Universal Serial Bus (USB) and an electrical outlet.
In a feature of this aspect, the power component further includes a battery for storing the power signal generated by the solar panel and forwarding the power signal to the inverter when the power outlet is coupled to an electronic device.
In a feature of this aspect, the frames of each of the plurality of solar power units further includes a top panel having a first and second top panel portion.
In a feature of this aspect, the building structure is an exterior wall comprising a plurality of building blocks.
In a feature of this aspect, the first top panel portion and the first bottom panel portion are parallel to each other.
In a feature of this aspect, the building blocks are cinder blocks, wherein the frame of each of the plurality of solar power units is slid over one of the plurality of cinder blocks, such that each of the first top panel portion and the bottom panel portion of the plurality of solar power units are engaged with the top and bottom of the respective cinder blocks, respectively.
In a feature of this aspect, the plurality of solar power units are connected in series with one another.
In a feature of this aspect, the plurality of solar power units are connected in parallel with one another.
In a feature of this aspect, the first top panel portion and the first bottom panel portion of each of the plurality of solar power units are bent 90° up and down, respectively.
In a feature of this aspect, the building blocks are cinder blocks; and wherein each of the solar power units is attached to one of the plurality of cinder blocks through the first top panel portion and the first bottom panel portion.
In a feature of this aspect, the power component further includes a charge controller for protecting the battery from overcharging.
Another aspect of the present invention relates to a solar wall module for installation in a building frame comprising a solar power system including a plurality of solar power units, the solar power units comprising a frame, configured to be integrated into a building structure, for supporting a solar panel, the solar panel for generating a power signal, and a front cover for securing the solar panel to the frame, and a wall assembly for supporting the solar power system.
In a feature of this aspect, the frame of each of the solar power units includes a bottom panel having a first and second bottom panel portion, wherein the second bottom panel portion is angled a certain amount of degrees such that the solar panel is set at an appropriate tilt angel when the solar panel is attached to the frame.
In a feature of this aspect, the wall assembly comprises a power component, the power component, coupled to the solar power system, includes a battery for storing the power signal generated by the solar power system, and an inverter for converting the stored power signal from the battery to an AC signal, and a power outlet, coupled to the power component, for providing the AC signal to an electronic device.
In a feature of this aspect, the power component further includes a charge controller for protecting the battery from overcharging.
In a feature of this aspect, the frames of each of the plurality of solar power units further includes a top panel having a first and second top panel portion.
In a feature of this aspect, the first top panel portion and the first bottom panel portion of each of the plurality of solar power units are bent 90° up and down, respectively.
In a feature of this aspect, each of the solar power units is attached to the wall assembly through the first top panel portion and the first bottom panel portion.
In a feature of this aspect, each of the solar power units are connected in series.
In a feature of this aspect, the wall assembly comprises an outer barrier including furring strips for supporting the solar power system, and sheathing for protecting the inside of the building from the weather elements, and an inner barrier including a cavity for housing the power component, studs for supporting the wall assembly within the building frame, and wall board for providing an interior rigid material which may be painted or covered with a finishing material to blend the wall assembly in with the inside of the building.
Another aspect of the present invention relates to a method for integrating a solar power unit into a building structure, the building structure including a plurality of building blocks, the solar power unit for generating a power signal, the method comprising the steps of attaching the solar power unit to the building block, and installing the building block with the building structure.
In a feature of this aspect, the building structure is an exterior wall; wherein the building blocks of the external wall are cinder blocks.
In a feature of this aspect, the building structure is a new wall and under construction; wherein the building block with the solar power unit attached is placed above and below a plurality of building blocks, each of the building blocks bonded to the other building blocks with a bonding material.
In a feature of this aspect, the bonding material is mortar.
Another aspect of the present invention relates to a method for installing a solar power unit on an existing building structure, the solar power unit, for generating a power signal, comprising a frame for supporting a solar panel, the building structure including a plurality of building blocks, the method comprising attaching the solar power unit to the building block through a first top and bottom panel portion of the frame.
In a feature of this aspect, the solar power unit is attached to the building block using screws.
In a feature of this aspect, the building block is a cinder block.
In addition to the aforementioned aspects and features of the present invention, it should be noted that the present invention further encompasses the various possible combinations and subcombinations of such aspects and features. Thus, for example, any aspect may be combined with an aforementioned feature in accordance with the present invention without requiring any other aspect or feature.



BRIEF DESCRIPTION OF THE DRAWING(S)
A more detailed understanding of the disclosed system and method may be had from the following description, given by way of example and to be understood in conjunction with the accompanying drawing.
FIG. 1 is an example illustration of a disclosed solar power unit;
FIG. 2 is an example illustration of an alternative of the solar power unit shown in FIG. 1;
FIG. 3 is an example illustration of another alternative of the solar power unit shown in FIG. 1;
FIGS. 4 and 5 are example illustrations of exploded views of a frame in accordance with the disclosed solar power unit shown in FIG. 1;
FIG. 6 is an example illustration of the fabrication of the disclosed frame of the disclosed solar power unit;
FIG. 7 is an example illustration of the disclosed solar power unit including a power component;
FIG. 8 is an example illustration of a method for integrating the disclosed solar power unit with a cinder block;
FIG. 9 is an example illustration of the disclosed solar power unit fitted over a cinder block;
FIG. 10 is an example illustration of a cross-sectional view of the solar power unit shown in FIG. 9, including a power component;
FIG. 11 is an example illustration of the alternative implementation of the disclosed solar power unit installed on a pre-existing wall;
FIG. 12 is a cross-sectional view of the alternative solar power unit shown in FIG. 11;
FIG. 13 is an example illustration of a method for integrating the disclosed solar power unit into a wall being built;
FIG. 14 is an example illustration of a method for integrating the disclosed solar power unit within an existing wall;
FIG. 15 is an example illustration of a disclosed solar power system including a plurality of solar power units;
FIG. 16 is an example circuit diagram of the disclosed solar power system shown in FIG. 15 wherein the plurality of solar power units are connected in series;
FIG. 17 is an example circuit diagram of the disclosed solar power system shown in FIG. 15 wherein the plurality of solar power units are connected in parallel;
FIG. 18 is an example illustration of the building of a cinder block wall including the disclosed solar power units;
FIG. 19 is an example illustration of the alternative solar power unit, including a positive and negative leads and lead cavities;
FIG. 20 is an example circuit diagram of the solar power system of FIG. 18, wherein the plurality of solar power units are connected in series;
FIG. 21 is an example circuit diagram of the solar power system of FIG. 18, wherein the plurality of solar power units are connected in parallel;
FIG. 22 is an example illustration of a method for installing the solar power units into a new wall;
FIG. 23 is an example illustration of a cross-sectional view of the disclosed solar power unit shown in FIG. 18;
FIG. 24 is an example illustration of a disclosed solar wall module;
FIG. 25 is an example illustration of a cross-sectional view of the solar wall module shown in FIG. 24;
FIG. 26 is an example illustration of a frame included in the disclosed solar wall module shown in FIG. 24;
FIG. 27 is an example illustration of a plurality of frames shown in FIG. 26 attached together for use in the solar wall module;
FIG. 28 is an example illustration of an exploded view of the disclosed solar wall module shown in FIG. 24;
FIG. 29 is an example illustration of a rear perspective view of the disclosed solar wall module shown in FIG. 24;
FIG. 30 is an example illustration of the power component included in the disclosed solar wall module; and
FIG. 31 is an example illustration of a plurality of solar wall modules installed in a home.



DETAILED DESCRIPTION
As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.
Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.
A disclosed solar power unit may be used in many situations. As a stand alone unit, the solar power unit may be a portable power source used to power an electronic device or charge a battery. The solar power unit may also be integrated into a building structure, for example, a residential deck or exterior wall, a commercial building exterior wall, or public structure, such as a cinderblock wall in a park or public club house, for generating a renewable power source.
FIG. 1 is an example illustration of an implementation of a disclosed solar power unit 100. The solar power unit 100 comprises a solar panel 102, a frame 103 and a front cover 101. The solar panel 102, for example, a photovoltaic panel, converts the sun's solar energy to an electric signal, e.g., a direct current (DC) power signal.
In a preferred implementation, the solar panel 102 is supported in place within the front cover 101, preferably by slots or grooves on the rear of the front cover 101 that prevent the solar panel 102 from moving. Once the solar panel 102 is held within the front cover 101, the front cover 101 is be attached to the frame 103 preferably using screws, but any means of attaching the front cover 101 to the frame 103 can be used. The front cover 101 preferably may be removed and re-attached as required. Example illustrations of the frame 103 and front cover 101 are shown in FIGS. 4 and 5.
Referring to FIG. 5, the front cover 101 includes a panel opening 106 for allowing the solar panel 102 to receive the solar energy from the sun while the solar panel 102 and front cover 101 are attached to the frame 103. In a preferred solar power unit 100, the front cover 101 further includes a front cover output opening 105 for receiving a power output device 104, for example an electrical outlet, USB port, etc.
The frame 103 includes a front panel 131, a left and right side panel 132, a top panel 133 and a bottom panel 134. The front panel 131 includes an access opening 111 to allow a component, for example a charge controller, inverter, or power output device, to be coupled to the output of the solar panel 102, to be disclosed in greater detail below. In a preferred implementation, the front panel 131 further includes at least one power output device opening 136 for providing an opening to insert a power output device, wherein one of the at least one front panel output device openings 136 is lined up with the front cover output opening 105.
The left and right side panels 132 are attached to the left and right edges of the front panel 131. In accordance with the disclosed solar power unit 100, the right and left side panels 132 are shaped such that when attached to the front panel 131, the front panel 131 is positioned at an angle relative to the ground. The angle at which the front panel 131 is situated preferably depends upon the angle best suited to allow the solar panel 102 to receive as much of the sun's solar energy as possible, i.e., receive the most direct sun light for the longest period of time during the day. Those having skill in the art know that differing locations require different angles due to the sun's positioning in the sky over that location. This angle is referred to as the tilt angle.
The top panel 133 is attached to the top edges of the front panel 131 and the right and left panels 132 such that the top panel 133 is parallel to the ground. Preferably, the top panel 133 is a flat piece of material that extends beyond the back edge of the right and left side panels 132. In a preferred implementation of the solar power unit 100, the top panel 133 is perforated, illustrated in FIG. 2, to be disclosed below. Alternatively, the material of the top panel 133 that extends beyond the back edge of the right and left side panels 132 may be bent upwards 90°, for example, such that the solar power unit 100 may be attached to an existing building structure, as illustrated in FIG. 3, to be disclosed in further detail below.
Referring back to FIG. 5, the bottom panel 134 is attached to the bottom edges of the front panel 131 and the left and right panels 132. In accordance with the disclosed solar power unit 100, and it alternatives, the bottom panel 134 is similar to the top panel 133.
An example illustration of how the frame 103 of the disclosed solar power unit 100 may be fabricated is shown in FIG. 6. A flat panel made of any type of material for the frame and front cover may be used. In accordance with the disclosed solar power unit, the material of the frame and front cover is sheet metal, but other materials may be used, for example, plastic. A stencil of the frame and front cover are set on the flat panel and cut out. Once the frame and front cover are cut from the flat panel, the flat frame and flat front covers are cut and folded along the specified lines to form the frame and front cover used in the solar power unit.
As stated above, the power signal generated by the solar panel may be coupled to a power component that utilizes the output power signal. FIG. 7 illustrates an example power component 710 included in the solar power unit 700. As a standalone solar power unit 700, the solar panel (not shown) may be coupled to the power component 710, which includes an inverter 716. The inverter 716 converts the received DC power signal from the solar panel to an AC power signal. In this implementation, a power outlet 704 is coupled to the power component 710. When an electronic device is plugged into the solar power unit 700, the generated AC power signal is used to power the electronic device.
In this implementation of the disclosed solar power unit 700, the power component 710 further includes a charge controller 719 and a battery 711. The charge controller 719, coupled to the solar panel 702 and the battery 711, receives the DC power signal generated by the solar panel 702 and forwards the DC power signal to the battery 711. The battery 711 then stores the DC power received for later use or forwards the signal to the inverter 716 when the power output device 704 is being used. The charge controller 719, as those having skill in the art know, also regulates the charging of the battery 711 to prevent over charging when the power generated by the solar power unit 700 is not being used by a device or other power sink.
The battery 711, coupled to the charge controller 719 and the inverter 716, stores the DC power generated by the solar power panel and forwards the stored DC power signal to the inverter 716. As disclosed above, the inverter 716 then converts the stored DC power signal to an AC power signal when the power output device 704 is being used. Although this implementation of the power component is disclosed as including a battery, charge controller and inverter, if should be noted that the power component may only include a battery or an inverter, with or without the other.
The power component 710 is preferably secured within the frame 703 of a standalone unit 700 by a back panel, not illustrated. Alternatively, the power component 710 may float within the frame 703.
As a standalone unit, the disclosed solar power unit may be used as a power source anywhere. With or without a power outlet, a device or battery may be coupled directly to the solar panel of the solar power unit through the back access opening of the frame and operated accordingly.
In an alternative implementation of the disclosed solar power unit, the solar power unit may be integrated into an existing wall or building structure, or included in a new building structure as it is being built. For example, the solar power unit may be integrated into an existing exterior wall or other building or landscape structure, wherein the wall may be made up of building blocks. The building blocks may be made of any building material used for this purpose, for example, concrete, stone blocks, bricks, etc. For purposes of this disclosure, the building blocks are cinder blocks. As illustrated in FIG. 9, the frame 803 is fabricated to fit over the cinder block 807. Accordingly, the solar power unit 800 may be slid over a cinder block and used in a pre-existing or newly built wall.
FIG. 8 illustrates an example method of integrating the disclosed solar power unit 800 with a cinder block 807. In accordance with this disclosed implementation, the frame 803 and the front cover 801 are designed to fit over a cinder block 807. The top and bottom panels 809, 808 are flat and preferably include perforations. The solar power unit 800 also includes a battery and inverter, not shown. A power output source 804 is coupled to the inverter, receives the AC power signal from the inverter, and provides power to a device coupled to the power output source 804, e.g., an electronic device.
In an implementation, the solar power unit 800 may be installed by sliding the frame 803, including the solar panel 802 and front cover 801, over the cinder block 807 such that the top and bottom panels 809, 808 are covering a portion of the top and bottom of the cinder block 807. In accordance with this implementation, the battery and inverter are situated within the frame 803 such that when the cinder block 807 is slid into the frame 803, the battery and inverter are housed freely between the front panel (not shown) and the front of the cinder block 807. Alternatively, a back panel may be included in the frame 803 such that the top and bottom panels 809, 808 hang over the back panel and the cinder block 807 slides against the back panel.
As disclosed, the top and bottom panels 809, 808 are perforated such that when cinder blocks are placed above and below the integrated solar power unit 800, the bonding material used to build the wall, i.e., mortar, may still bond with the cinder block 807 while within the frame 803. An example illustration of this disclosed implementation is shown in FIG. 10.
This implementation of the solar power unit may also be integrated into an existing wall wherein the frame of the solar power unit is slid into cutouts in the existing building structure, such as an exterior concrete wall. An example illustration of this implementation can be seen in FIG. 14.
Further, the alternative solar power unit illustrated in FIG. 3 may be installed on a preexisting wall as well. In accordance with this implementation, the top and bottom panels are bent to allow the solar power unit to be attached to a building structure. In FIG. 11, the building structure is a pre-existing cinder block wall. Once attached to the wall, the power output source 1104 may be used to power an electronic device.
Referring to FIG. 12, a cross-sectional view of the solar power unit illustrated in FIG. 11, it is preferable that the solar power unit 1100 includes a battery 1111 and inverter 1116, as described above. As illustrated in FIG. 12, the solar power unit 1100 may be attached to the existing wall using screws 1190. Accordingly, the screws 1190 are drilled through the top 1133 and bottom 1134 panels and into the mortar 1127 between each cinder block 1126. Although, screws have been disclosed as the manner for attaching the alternative solar power unit to an existing wall, other means know to those having skill in the art may be used, e.g., an adhesive glue or tape.
In another disclosed implementation, a plurality of solar power units are included in a solar power system, as illustrated in FIG. 15. As illustrated, solar power system 1500 comprises a plurality of solar power units 15101 . . . 1510n. The solar power system 1500 may provide power to the building in which the wall supports or to any devices that may be able to connect thereto. This solar power system 1500 therefore may or may not include a storage device, depending on the purpose of the system 1500. As such, the power being generated by the solar power system 1500 and not used by the building, may then be sold to the electric power company, providing the owner of the building with an additional income stream.
Each solar power unit 1510 in the disclosed implementation may be coupled to one another in series or parallel, depending on the implementation. For example, if the solar power system was being used as a power source to a building, the solar power units 15101 . . . n may be electrically coupled in series. An example circuit diagram of serially connected solar power units 1510 can be seen in FIG. 16.
Referring back to FIG. 15, if the solar power system 1500 was to provide more than a single source of power, the solar power system 1500 may be sectioned off such that the groups of the plurality of solar power units 1510 are electrically coupled in parallel to one another. An example circuit diagram of this implementation can be seen in FIG. 17.
FIG. 18 illustrates an example solar power system 1800 including a plurality of alternative solar power units 18011 . . . n. Each solar power unit 1801 includes a positive lead (+) 1823 and negative lead (−) 1824. An example solar power unit in accordance with this implementation is illustrated in FIG. 19.
As illustrated in FIG. 19, the solar power unit 1800 comprises lead cavities 1833 and 1834 and a positive lead 1823 and negative lead 1824. In accordance with this disclosure, lead cavities 1833 and 1834 are female connectors for additional solar power units 1800 to electrically connect to one another as shown in FIG. 18.
Referring back to FIG. 18, each of a plurality of solar power units 1801n in the solar power system 1800 may be coupled to a solar power unit 1801n above it through its positive lead 1823n or negative lead 1824n, and below the unit through the lead cavities. As disclosed above, depending on how the energy generated by the solar power system may be coupled to one another in series or parallel. Example circuit diagrams of the solar power units 1801 connected in series and parallel in accordance with this disclosed implementation are illustrated in FIGS. 20 and 21, respectively.
In accordance with this implementation, each solar power unit 2210 of the solar power system 2200 may be installed as illustrated in FIG. 22. As illustrated in FIG. 22 and disclosed above, the frame 2203 includes a perforated top and bottom panel 2207, 2208, respectively. Once the lower section of the wall is installed including the solar power unit 22101, mortar or other bonding substance 2240 can be spread over the cinder block 22171. Because the top panel 22071 is perforated, the bonding material is able to adhere to the cinder block 22171.
The solar power unit 22102 is then installed on top of the solar power unit 22101. Again, because the bottom panel of the solar power unit 22102, the bonding substance 2240 is able to bond to the cinderblock 22171. Depending on the how the solar power units 2210 are electrically connected, the lead 22241, 22231 are connected to lead cavity(ies) 22332, 22342 accordingly.
In this implementation, it is a preferred feature to include additional perforations 22532 in the angled portion of a solar power unit's 22102 bottom panel 22082. Similarly, perforations may be added to the portion of the top panel 22101 that is not engaged with the cinder block 22171 of this disclosed implementation. The inclusion of these perforations allow air to flow through the solar power units 2210 to cool the solar power unit 2210 and assist in drying the unit 2210 after wet weather.
FIG. 23 illustrates a cross-sectional view of the disclosed solar power system in a building structure shown in FIG. 18, including a plurality of building blocks 18071, 18072, 18073. As shown in FIG. 23, solar power units 18001, 18002, 18003 are each slid over building blocks 18071, 18072, 18073, and electrically connected to each other at leads 18241 and 18243 through lead cavities 18251 and 18252.
FIG. 18 also illustrates the building of a building structure 1800 including a plurality of building blocks 18071 . . . 1807n, and a plurality of solar power units 18011 . . . 1801n electrically connected to one another to provide power to electrical outlet 1804 included in solar power unit 18011. Once the building structure is complete, a user may then connect an electronic device, requiring a DC power source, to be powered through outlet 1804 of solar power unit 18011, using the power generated by the plurality of solar power units 18011 . . . 1801n.
In accordance with an alternative implementation, a solar wall module is disclosed. FIG. 24 illustrates an example solar wall module 2400 in accordance with this implementation. The solar wall module 2400 comprises a plurality of solar power units 24101 . . . n and wall assembly 2420. As disclosed above, the solar power unit 2410 may include top and bottom panels that are bent 90° up and down, respectively, such that the solar power units can be attached to an existing wall. In accordance with this implementation, each of the plurality of solar panel users are attached to the wall assembly for integrating with a building wall.
An example cross-sectional illustration of the solar wall assembly 2400 is shown in FIG. 25. As illustrated in FIG. 25, the solar power units 2410 are attached to each other and to the wall assembly 2420 using screws 2460. Although screws have been disclosed, it should be noted that any means of supporting the plurality of solar power units on the wall assembly may be used.
An example frame for each of the solar power units 2410 included in the disclosed solar wall assembly is illustrated in FIG. 26. The frame 2415 comprises a top panel 2604, a bottom panel 2602, and a face plate 2603. As disclosed above, the top and bottom panels 2602, 2604 are bent 90° up and down, respectively, to attached the frame 2115 to the wall assembly. It is preferable that the top and bottom panels 2602, 2604 include perforations in the portions of the panels that are not attached to the wall assembly to allow for air to flow through the unit.
The face plate 2603 is attached to the top and bottom panels 2602, 2604 and supports the solar panel. One or more access openings 2605 are included on the face plate 2603 to allow connections to the one or more solar panels.
In accordance with a preferred fabrication of the frame 2415, the bent portion of the top panel 26032 of frame 24152 is attached to the bent portion of the bottom panel 26021 of frame 24151,, and so on. An example illustration of the frames attached in this manner is shown in FIG. 27.
Referring back to FIG. 24, solar panels 24011 . . . n are attached to the frame 24151 . . . n directly using screws, for example, or a front cover (not shown) as disclosed above.
The wall assembly 2420, attached to the plurality of solar power units 24101 . . . n, supports the solar power units in the building structure and acts as a part of a wall for the building structure. An exploded view of the solar wall module 2400 is illustrated in FIG. 28. The wall assembly comprises an outer barrier and an inner barrier. The outer barrier is the portion of the wall assembly that is directly touching the solar power system, and includes a water barrier 2422, furring strip 2421 and sheathing 2423. An air and water barrier 2422 material may serve as a drainage plane for water to escape quickly at the bottom of the panel. This material may also prevent water and outside air from penetrating into the building. Metal flashing 2424 may also be included in the outer barrier to protect against water entering in the walls.
Since the disclosed implementation is a wall module that will be fitting within the framework of a building structure, the wall assembly's 2420 inner barrier includes two studs 2450, preferably spaced apart the same distance as the studs in the other portions of the building structure, for example 24′′. The height of the studs 2450 depends on the size selection of the solar wall module 2400. Structural studs could be made of wood or metal and may serve as the structural layer of the assembly 2420 to enable the solar wall module 2400 to be robust and withstand wind loads.
The inner barrier further includes a rigid insulation core 2426 that may be used as a thermal barrier and to prevent unwanted hot and cold air from penetrating into the building and significantly lowering utility bills. A moisture barrier 2427 may be used to prevent condensation from building up within the insulation 2426. Gypsum board or wall board 2429 may be used to provide an interior rigid material which may be painted or covered with a finishing material like paint, wall-paper, or wood trim, etc.
The solar wall module 2400 further includes a power component 2428. As illustrated in FIGS. 28 and 30, the power component 2428 is preferably enclosed within a cavity in the insulation 2426 and the wall board 2429. The power component 2428 comprises an inverter 3072, a battery 3073 and charge controller 3071. The inverter 3072 may be equipped with a traditional 120 volt outlet and can be accessed and plugged directly into from either the interior, as shown in FIG. 30, or exterior side of the wall, as shown in FIG. 24.
A removable metal panel 2430 may cover the pocket of the wall that holds power components. The panel 2430 may be perforated to allow ventilation to the equipment and accommodates a socket for the outlet.
FIG. 31 illustrates an example of a plurality of solar wall modules 24001 . . . n installed in a building structure, such as a residential home.
The disclosed solar power unit is an improvement over existing Building Integrated Photovoltaic products for several reasons. As disclosed above, the solar power unit may be an all-in-one, plug-n-play system. Also, the disclosed solar power units are structurally integrated and may significantly reduce cost by serving as both the structural layer and exterior, finish layer, of the building.
The disclosed solar power system replaces, or can be used in conjunction with traditional building material and may be integrated with concrete block or brick in the same wall system. The entire wall does not have to entirely be made out of the solar power systems. For example, a customer may have a specific energy load (electric lighting) that they are interested in generating from the Solar Power systems. The number of units that would generate this electric load would be utilized and the rest of the wall may be constructed with another traditional block material.
There are many commercial applications for this product. Not only can the Solar Power Units be utilized for new building construction projects (commercial, residential, industrial, civil, educational, etc.), they can also be utilized for retrofit applications as well, over existing facades and serve as charging walls for electric devices or vehicles.
Since the solar power unit is designed to be a modular unit, it may be utilized for many applications at varying scales. The units may become a part of our daily lives. Walls of cities and towns may replace power plants.
Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.

## Claims

1. A pre-assembled solar power wall module for integration into a building structure, comprising:
a wall assembly configured to serve as a structural component of the building structure, comprising:
an outer barrier having sheathing for protecting the inside of the building structure from weather elements; and
an inner barrier having studs for supporting the wall assembly; and
wall board mounted to the studs for providing an interior rigid material, the wall board accessible from the interior of the building structure,
wherein a cavity is formed in a space between the outer barrier, the studs and the wall board;

a solar power system comprising:
a solar panel, for generating a power signal;
a frame configured to support the solar panel such that the solar panel is set to a tilt angle when the solar panel is supported by the frame, wherein the frame is affixed to the outer barrier; and
a front cover, for securing the solar panel to the frame; and

a power component, coupled to the solar power system and disposed in the cavity, comprising:
a battery for storing the power signal generated by the solar power system; and
an inverter for converting the stored power signal from the battery to an AC signal,
wherein the pre-assembled wall assembly replaces at least a portion of a wall of the building structure.

2. The solar power wall module of claim 1 wherein the power component further comprises a charge controller for protecting the battery from overcharging.

3. The solar power wall module of claim 1, wherein the power component further comprises a power outlet disposed on the wall board, coupled to the power component, for providing the AC signal to an electronic device disposed within the building structure.

4. The solar power wall module of claim 1, wherein the power component further comprises a power outlet disposed on the sheathing, coupled to the power component, for providing the AC signal to an electronic device disposed external to the building structure.

5. The solar power wall module of claim 1, wherein the solar power system comprises at least a second solar panel, so as to form a plurality of solar panels.

6. The solar power wall module of claim 5, wherein the plurality of solar panels is connected to one another in at least one of a series configuration and a parallel configuration.

7. The solar power wall module of claim 1, wherein the inner barrier further comprises an insulation core disposed between the studs.

8. The solar power wall module of claim 1, wherein the outer barrier further comprises furring strips disposed external to the sheathing for supporting the solar power system.

9. The solar power wall module of claim 1, wherein the outer barrier further comprises an air and water barrier disposed external to the sheathing.

10. The solar power wall module of claim 1, further comprising a removable panel disposed on the wall board and covering the cavity.

11. The solar power wall module of claim 10, wherein the removable panel is perforated to allow ventilation for the power component.

12. The solar power wall module of claim 1, wherein the frame is perforated.

13. A building structure, comprising a plurality of walls, wherein at least one wall comprises the solar power wall module of claim 1.

14. The solar power wall module of claim 1, wherein the studs are spaced substantially similar to studs within the building structure.

15. The solar power wall module of claim 14, wherein the studs are separated by 24′′.

16. The solar power wall module of claim 1, wherein the wall board comprises gypsum board.

17. The solar power wall module of claim 1, wherein the outer barrier further comprises a water barrier, and the inner barrier further comprises a thermal barrier.

18. The solar power wall module of claim 1, further comprising an electrical connection to a second solar power wall module.