Photovoltaic roofing elements and photovoltaic roofing systems

• US 8,601,754 B2
• Filed: 12/14/2011
• Issued: 12/10/2013
• Est. Priority Date: 12/31/2010
• Status: Active Grant

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Jenkins, Robert L., Fisher, Christopher C., Livsey, Robert D.
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): Walraed-Sullivan, Kyle
• Application Number:
  US13/326,081
• Publication Number:
  US 20120186630A1
• Time in Patent Office: 727 Days
• Field of Search: 521/733, 523/021, 523/023, 523/024, 52/60
• US Class Current: 52/173.3
• CPC Class Codes: E04B 1/7069 by ventilating means for ventilating in floors E04B5/48, in ceilings E04B9/02, in building blocks E04C1/392, in building panels E04C2/521, in roofs E04D13/16; ventilating wall coverings E04F13/007
• CPC Class Codes: E04D 1/12 Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface E04D1/28, E04D1/30 take precedence
• CPC Class Codes: E04D 1/2916 the fastening means taking hold directly on adjacent elements of the same row
• CPC Class Codes: E04D 1/30 Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles E04D3/40 takes precedence
• CPC Class Codes: E04D 13/00 Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights ventilation tiles E04D1/30; ventilation slabs E04D3/40; internal channels E04F17/00
• CPC Class Codes: E04D 13/04 Roof drainage; Drainage fittings in flat roofs, balconies or the likegutter tiles E04D1/30; gutter slabs E04D3/40; vessels for collecting rainwater E03B3/03; street gullies E03F5/04
• CPC Class Codes: E04D 13/1415 Junctions to walls extending above the perimeter of the roof trimming strips, edge strips or fascias retaining the roof sheathing E04D13/155
• CPC Class Codes: E04D 13/158 covering the overhang at the eave side, e.g. soffits, or the verge of saddle roofs
• CPC Class Codes: E04D 13/16 Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
• CPC Class Codes: E04D 2001/308 for special purposes not otherwise provided for, e.g. turfing tiles, step tiles
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0481 characterised by the composition of the encapsulation material
• CPC Class Codes: H02S 20/00 Supporting structures for PV modules
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/25 Roof tile elements
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

The present invention relates generally to the photovoltaic generation of electrical energy. The present invention relates more particularly to photovoltaic arrays for use in photovoltaically generating electrical energy. Aspects of the present invention provide a variety of photovoltaic roofing elements and systems that include, for example, interlocking geometries to provide for water handling and integration with conventional roofing materials; and wire management features that can protect wiring and associated electrical components from physical and/or environmental damage.

Claims

1. A photovoltaic roofing system disposed on a roof deck having a top end and a bottom end, the photovoltaic roofing system comprising:

a plurality of photovoltaic roofing elements each comprising

a frame structure having an upward-facing surface and a downward-facing surface having a top end and a bottom end, the frame structure having an attachment zone and an exposure zone, with the exposure zone disposed toward the bottom end of the frame structure, and the attachment zone disposed toward the top end of the frame structure, the frame structure further comprising a wiring containment structure; and

one or more photovoltaic elements held in the exposure zone of the frame structure,

the photovoltaic roofing elements being contiguously disposed on the roof deck, the contiguously-disposed photovoltaic elements together having a top edge facing the top end of the roof deck, a bottom edge facing the bottom end of the roof deck, and two side edges, the photovoltaic roofing elements including sidelap portions that interlock to provide water drainage channels;

a plurality of roofing elements disposed adjacent the contiguously-disposed photovoltaic roofing elements, along their side edges; and

side flashing elements disposed along the side edges of the contiguously-disposed photovoltaic roofing elements, the side flashing elements having a cross-sectional shape comprising a vertically-extending feature and a flange extending away from a lateral side at the downward end of the vertically-extending feature, with the flange facing away from the contiguously-disposed photovoltaic roofing elements and being at least partially disposed between a roofing element and the roof deck, the vertically-extending feature including a matched interlocking geometry that interlocks with a sidelap portion of an adjacent photovoltaic roofing element.

2. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, wiring is disposed in the wiring containment structure.

3. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure comprises one or more holes or notches formed in one or more downward-facing support structures of the frame structure.

4. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure comprises a channel formed on a surface of the frame structure.

5. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure comprises a conduit.

6. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure comprises a clip or an adhesive.

7. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure is on the downward-facing surface of the frame structure.

8. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure is on the upward-facing surface of the frame structure.

9. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the wiring containment structure is adjacent an edge of the frame structure.

10. The photovoltaic roofing system of claim 1, wherein in each photovoltaic roofing element, the frame structure includes sidelap portions disposed at the lateral edges of the frame structure and having geometries adapted to interlock with adjacent photovoltaic roofing elements to provide water drainage channels.

11. The photovoltaic roofing system of claim 10, wherein in each photovoltaic roofing element, the sidelap portion at one lateral edge includes an upward-facing water drainage channel;

and the sidelap portion at the other lateral edge includes a downward-facing flange adapted to fit into the upward-facing water drainage channel of an adjacent photovoltaic roofing element.

12. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the frame structure further comprises a raised lip at the top end of the attachment zone.

13. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the frame structure includes one or more raised sidewalls that at least partially define an area in which the one more photovoltaic elements are held.

14. The photovoltaic roofing system according to claim 13, wherein in each photovoltaic roofing element, the sidewalls have one or more channels formed therein.

15. The photovoltaic roofing system according to claim 13, wherein in each photovoltaic roofing element, the area in which the one or more photovoltaic elements are held has an upward-facing base surface, and wherein the sidewalls extend above the base surface by at least about 2 mm.

16. The photovoltaic roofing system according to claim 13, wherein in each photovoltaic roofing element, an adhesive or sealant seals an edge of a photovoltaic element to a sidewall.

17. The photovoltaic roofing system according to claim 13, wherein in each photovoltaic roofing element, the sidewalls substantially enclose the area in which the one or more photovoltaic elements are held;

and the one or more photovoltaic elements substantially fill the area defined by the sidewalls.

18. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the downward-facing surface of the frame structure includes a ridge disposed toward the bottom end of the frame structure, and wherein the upward-facing surface of the frame structure includes a channel disposed near the bottom end of the attachment zone, and wherein the ridge is configured to interlock with the channel of underlying photovoltaic roofing element.

19. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, at least one lateral side edge of the attachment zone does not include a ridge, such that water in the attachment zone can flow off of the side thereof.

20. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the frame structure comprises one or more downward-facing support structures disposed on the downward-facing surface of the frame structure.

21. The photovoltaic roofing system according to claim 1, wherein the vertically-extending features of the side flashing elements along a first lateral edge of the contiguously-disposed photovoltaic roofing elements include a downward-facing flange, disposed in upward-facing channels of the photovoltaic roofing elements disposed along the first lateral edge;

and wherein the vertically-extending features of the side flashing elements along a second lateral edge of the contiguously-disposed photovoltaic roofing elements include an upward-facing water drainage channel, into which downward-facing flanges of the photovoltaic roofing elements disposed along the second lateral edge are disposed.

22. The photovoltaic roofing system according to claim 1, further comprising one or more top flashing elements disposed along the top edge of the contiguously-disposed photovoltaic roofing elements, the one or more top flashing elements having a bottom end disposed over the top edge of the contiguously-disposed photovoltaic roofing elements;

and a top end disposed under one or more roofing elements disposed along the top edge of the contiguously-disposed photovoltaic roofing elements.

23. The photovoltaic roofing system according to claim 1, wherein one or more side flashing elements is configured such that a conduit is formed underneath the side flashing element and adjacent the frame structure of the photovoltaic roofing element with which it interlocks.

24. The photovoltaic roofing system according to claim 1, further comprising a cant strip disposed under the bottom edge of the contiguously-disposed photovoltaic elements and on top of an underlying course of roofing elements.

25. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the area in which the one or more photovoltaic elements are held includes an upward-facing base surface, and wherein the frame structure includes one or more raised structures extending upward from the base surface, the one or more photovoltaic elements being disposed on the one or more raised structures.

26. The photovoltaic roofing system according to claim 1, wherein in each photovoltaic roofing element, the frame structure is a unitary frame structure having an upward-facing surface and a downward-facing surface having a top end and a bottom end, the frame structure having an attachment zone and an exposure zone, with the exposure zone disposed toward the bottom end of the frame structure, and the attachment zone disposed toward the top end of the frame structure, the attachment zone being defined at its top end by a first raised lip extending upward with respect to the upward-facing surface of the frame structure in the attachment zone, the attachment zone being defined at its bottom end by a second raised lip;

and wherein the one or more photovoltaic elements held in the exposure zone of the frame structure, the area in which the photovoltaic elements are held being defined at its top end by the second raised lip.

27. The photovoltaic roofing system according to claim 26, wherein in each photovoltaic roofing element, the frame structure includes a sidewall defining the bottom end of the area in which the one or more photovoltaic elements are held, and wherein the sidewall is lower than the top surface of the photovoltaic element by an amount in the range of about 0.1 mm to about 5 mm.

28. A photovoltaic roofing system disposed on a roof deck having a top end and a bottom end, the photovoltaic roofing system comprising:

a plurality of photovoltaic roofing elements each comprising

a frame structure having an upward-facing surface and a downward-facing surface having a top end and a bottom end, the frame structure having an attachment zone and an exposure zone, with the exposure zone disposed toward the bottom end of the frame structure, and the attachment zone disposed toward the top end of the frame structure, the frame structure further comprising a wiring containment structure; and

one or more photovoltaic elements held in the exposure zone of the frame structure,

the photovoltaic roofing elements being contiguously disposed on the roof deck, the contiguously-disposed photovoltaic elements together having a top edge facing the top end of the roof deck, a bottom edge facing the bottom end of the roof deck, a first side edge and an opposing second side edge, each photovoltaic roofing element along the first side edge of the contiguously-disposed photovoltaic elements having an upward-facing channel disposed therealong, each each photovoltaic roofing element along the second side edge of the contiguously-disposed photovoltaic elements having a downward-facing flange disposed therealong, each downward-facing flange comprising a portion extending laterally away from the body of the tile, and a downward-pointing flange extending from the laterally-extending portion;

each photovoltaic roofing element including one or more sidelap portions that interlock with one or more sidelap portions of adjacent photovoltaic roofing elements to provide water drainage channels;

a plurality of nonphotovoltaic roofing elements disposed adjacent the contiguously-disposed photovoltaic roofing elements, along the first side edge and the second side edge thereof;

one or more first side flashing elements disposed along the first side edge of the contiguously-disposed photovoltaic roofing elements, the one or more first side flashing elements having a cross-sectional shape in a plane normal to a line extending up the roof comprising a vertically-extending feature and a first flange extending away from a lateral side at the downward end of the vertically-extending feature, with the first flange facing away from the contiguously-disposed photovoltaic roofing elements and being at least partially disposed between a nonphotovoltaic roofing element and the roof deck, the vertically-extending feature comprising a portion extending laterally away from the vertically-extending feature in a direction opposite the first flange, and a downward-pointing second flange extending from the laterally-extending portion, the downward-pointing second flange interlocking with the upward-facing channel of one or more of the photovoltaic roofing elements disposed along the first side edge of the contiguously-disposed photovoltaic roofing elements such that the downward-pointing second flange is disposed in the upward-facing channel; and

one or more second side flashing elements disposed along the second side edge of the contiguously-disposed photovoltaic roofing elements, the one or more second side flashing elements having a cross-sectional shape in a plane normal to a line extending up the roof comprising a vertically-extending feature and a first flange extending away from a lateral side at the downward end of the vertically-extending feature, with the first flange facing away from the contiguously-disposed photovoltaic roofing elements and being at least partially disposed between a nonphotovoltaic roofing element and the roof deck, the vertically-extending feature comprising an upward-facing channel, the upward-facing channel interlocking with the downward-pointing flange of one or more of the photovoltaic roofing elements such that the downward-pointing flange is disposed in the upward-facing channel.

29. The photovoltaic roofing system according to claim 28, wherein each photovoltaic roofing element comprises:

a unitary frame structure having an upward-facing surface and a downward-facing surface having a top end and a bottom end, the frame structure having an attachment zone and an exposure zone, with the exposure zone disposed toward the bottom end of the frame structure, and the attachment zone disposed toward the top end of the frame structure, the attachment zone being defined at its top end by a first raised lip extending upward with respect to the upward-facing surface of the frame structure in the attachment zone, the frame structure including one or more mounting tabs extending from the first raised lip into the attachment zone, the mounting tabs comprising raised nail bosses, the attachment zone being defined at its bottom end by a second raised lip; and

one or more photovoltaic elements held in the exposure zone of the frame structure, the area in which the photovoltaic elements are held being defined at its top end by the second raised lip.

30. The photovoltaic roofing system of claim 29, wherein in each photovoltaic roofing element, the frame structure includes sidelap portions disposed at the lateral edges of the frame structure and having geometries interlocking with adjacent photovoltaic roofing elements to provide water drainage channels.

31. The photovoltaic roofing system of claim 28, wherein each photovoltaic roofing element further includes a leading edge extension extending from the bottom edge of the area in which the photovoltaic elements are held, the leading edge extension not spanning the entire length of the frame structure.

32. The photovoltaic roofing system of claim 28, wherein in each photovoltaic roofing element, the downward-facing surface of the frame structure includes a ridge disposed toward the bottom end of the downward-facing surface of the frame structure, and wherein the upward-facing surface of the frame structure includes a channel disposed near the bottom end of the attachment zone, and wherein the ridge interlocks with the channel of underlying photovoltaic roofing element.

33. The photovoltaic roofing system of claim 28, wherein in each photovoltaic roofing element, at least one lateral side edge of the attachment zone does not include a ridge, such that water in the attachment zone can flow off of the side thereof.

34. The photovoltaic roofing system of claim 28, wherein in each photovoltaic roofing element, the frame structure comprises one or more downward-facing support structures disposed on the downward-facing surface of the frame structure.

35. The photovoltaic roofing system of claim 28, wherein in each photovoltaic roofing element, the frame structure comprises a plurality of slats that hold the one or more photovoltaic elements.

36. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, wiring is disposed in the wiring containment structure.

37. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure comprises one or more holes or notches formed in one or more downward-facing support structures of the frame structure.

38. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure comprises a channel formed on a surface of the frame structure.

39. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure comprises a conduit.

40. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure comprises a clip or an adhesive.

41. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure is on the downward-facing surface of the frame structure.

42. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure is on the upward-facing surface of the frame structure.

43. The photovoltaic roofing system according to claim 28, wherein in each photovoltaic roofing element, the wiring containment structure is adjacent an edge of the frame structure.