Solar roofing system

• US 5,590,495 A
• Filed: 07/06/1995
• Issued: 01/07/1997
• Est. Priority Date: 07/06/1995
• Status: Expired due to Term

• Current Assignee: Solar Roofing Systems, Inc. (Applied Solar, Inc.)
• Original Assignee: Bresslergroup Inc.
• Inventors: Coleman, John D., Bressler, Peter W.
• Primary Examiner(s): Weisstuch, Aaron
• Application Number:
  US08/498,734
• Time in Patent Office: 551 Days
• Field of Search: 136/244, 136/246, 136/251, 136/291, 136/293, 52/173.3
• US Class Current: 52/173.3
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 40/22 Light-reflecting or light-concentrating means directly associated with the PV cell or integrated with the PV cell H01L31/054
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/52 PV systems with concentrators
• CPC Class Codes: Y10S 136/291 Applications
• CPC Class Codes: Y10S 136/293 Circuits
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web
• CPC Class Codes: Y10T 156/1087 Continuous longitudinal slitting
• CPC Class Codes: Y10T 156/1095 Opposed laminae are running length webs
• CPC Class Codes: Y10T 156/1097 Lamina is running length web

Abstract

A photovoltaic module that serves as a shingle, tile or other building material that may be placed onto the exterior of a structure. The photovoltaic module generates a voltage when exposed to light and this voltage may be directed onto transmission lines of a power utility and/or into an external battery that may serve as a source of power for the building on which the photovoltaic shingles are laid. The practice of the present invention provides for a variety of mechanical and electrical connectors for securing together the photovoltaic modules and/or for connecting the photovoltaic modules to the exterior structure. Furthermore, the structure of the modules is such that the modules are automatically electrically connected together when laid on the building.

Claims

1. A solar roofing system comprising:

a first longitudinally extending conductive bus;

a second longitudinally extending conductive bus spaced a predetermined distance from and substantially parallel to the first bus;

a plurality of separate photovoltaic modules laid out in a plurality of rows, each row extending between the first and second buses, each module for covering an exterior surface of a structure and having;

a carrier layer constructed from a non-porous building material and including first and second opposing lateral sides and upper and lower surfaces, the upper surface of the carrier layer defining a resting ledge extending inwardly a predetermined distance from the first side;

a photovoltaic layer at least partially laminated to the carrier layer, the photovoltaic layer for generating a DC voltage when exposed to light, the photovoltaic layer including first and second electrical connectors for outputting the DC voltage generated by the photovoltaic layer, the first connector being laminated on and forming a part of the resting ledge, the second connector extending beyond the second side of the carrier layer; and

a translucent layer laminated to the photovoltaic layer, the translucent layer covering all of the photovoltaic layer except for the first connector, a protruding portion of the translucent layer extending beyond the second side of the carrier layer a predetermined distance and being laminated to the second connector such that the protruding portion and the second connector form a protruding ledge;

the protruding ledge of each module being positioned to rest on the resting ledge of an immediately adjacent module such that the second connector on the protruding ledge is in electrical communication with the first connector on the resting ledge, each row having an outermost first connector on an outermost resting ledge and an outermost second connector on an outermost protruding ledge;

the first bus being in electrical communication with each outermost first connector on each outermost resting ledge, the second bus being in electrical communication with each outermost second connector on each outermost protruding ledge such that a DC row voltage appears across the first and second buses; and

a DC/AC converter in electrical communication with the first and second buses, wherein the DC/AC converter converts the DC row voltage into an AC voltage.

2. The roofing system according to claim 1 further comprising a fastener extending through the protruding and resting ledges for securing the protruding ledge of each module to the resting ledge of an immediately adjacent module, the fastener being selected from the group consisting of:

a. a nail having a flat head and a shaft extending therefrom;

b. a nail having a shaft with at least one protrusion extending outward therefrom, a shoulder extending from the shaft and a deformable head extending from the shoulder through an opening in the protruding ledge;

c. a roofing connector having lower, middle and top portions with the lower portion serving as a shaft and having a pointed lowermost region from which upwardly extends a series of stepped edges, the middle portion having an open cavity dimensioned to snugly slip over and abut against the resting ledge of the second module, and the upper portion having a deformable head extending through an opening in the protruding ledge; and

d. a roofing staple having pointed prongs.

3. The roofing system according to claim 1 further comprising a mechanical fastener having a shaft for securing the protruding ledge of each module to the resting ledge of an immediately adjacent module, the mechanical fastener including an electrically insulating member encompassing the shaft and preventing the shaft from directly contacting either module.

4. The roofing system according to claim 1 further including solder in engagement with the first and second connectors to provide the electrical communication therebetween.

5. The roofing system according to claim 1 further comprising a storage battery in electrical communication with the first and second buses.

6. The roofing system according to claim 5 wherein the first and second conductive buses are switchably connected to the storage battery and to the DC/AC converter.

7. The roofing system according to claim 1 further comprising a network in electrical communication with the first and second buses, the network for converting the DC row voltage to an AC voltage for being applied to an input switching stage of a power utility having power transmission lines, the network comprising:

a. a DC/AC converter for receiving the DC row voltage and generating a first AC output voltage having a power factor approaching unity and being suitable for application to the transmission lines of the power utility; and

b. an isolation transformer in electrical communication with the DC/AC converter for receiving the first AC output voltage and developing a second AC output voltage which is routed to the input switching stage of the power utility.

8. The roofing system according to claim 7 further comprising an instrument for measuring and indicating an amount of power directed to the isolation transformer, the instrument being interposed between the DC/AC converter and the isolation transformer.

9. The roofing system according to claim 7 wherein the DC/AC converter includes a feedback input, the system further comprising a transformer interposed between the input switching stage of the power utility and the feedback input of the DC/AC converter, the transformer for receiving indications of voltage, frequency and phase parameters of power conditions present on the transmission lines of the power utility and for providing such indications to the DC/AC converter.

10. The roofing system according to claim 7 further comprising a storage capacitor interposed between the first and second buses.

11. The roofing system according to claim 1 wherein each module further comprises a light diffuser layer arranged over the photovoltaic layer to spread light received thereby.

12. The roofing system according to claim 1 wherein the translucent layer of each module includes a corrosive retarding layer with a corrosive retarding material.