Photovoltaic systems, methods for installing photovoltaic systems, and kits for installing photovoltaic systems

• US 8,677,702 B2
• Filed: 09/23/2011
• Issued: 03/25/2014
• Est. Priority Date: 09/28/2010
• Status: Expired due to Fees

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Jenkins, Robert L.
• Primary Examiner(s): Chapman, Jeanette E
• Application Number:
  US13/243,726
• Publication Number:
  US 20120137600A1
• Time in Patent Office: 914 Days
• Field of Search: 521/733, 136/244, 136/245, 136/246, 136/247, 136/248, 136/249, 136/250, 136/251, 126/621, 126/622, 428/143
• US Class Current: 52/173.3
• CPC Class Codes: E04D 13/0481 Drainage guiding provisions, e.g. deflectors or stimulation by inclined surfaces
• CPC Class Codes: F24S 2025/021 Sealing means between support elements and mounting surface
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• 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: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49355 Solar energy device making

Abstract

The present invention relates particularly to photovoltaic systems for use in photovoltaically generating electrical energy. One aspect of the invention is a photovoltaic roofing system including a plurality of photovoltaic elements contiguously disposed on a roof deck arranged in at least two horizontal rows, defining a photovoltaic area; a plurality of roofing elements disposed adjacent the contiguously-disposed photovoltaic elements, along their side edges; side flashing disposed along the side edges of the contiguously-disposed photovoltaic elements, the side flashing having a flange facing away from the photovoltaic area at least partially disposed between a roofing element and the roof deck, and a structure at least partially disposed on the surface of the photovoltaic element or at least partially disposed between a photovoltaic element and the roof deck.

Claims

1. A photovoltaic roofing system disposed on a roof deck having an upper end and a lower end, the photovoltaic roofing system comprising:

a plurality of photovoltaic elements contiguously disposed on the roof deck arranged in at least two horizontal rows such that no panel is disposed between substantially the entire area of the photovoltaic elements and the roof deck, the contiguously-disposed photovoltaic elements together having a top edge facing the upper end of the roof deck, a bottom edge facing the lower end of the roof deck, and two side edges, the one or more photovoltaic elements defining a photovoltaic area;

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

side flashing disposed along the side edges of the contiguously-disposed photovoltaic elements, the side flashing having a flange facing away from the photovoltaic area at least partially disposed between a roofing element and the roof deck, and a structure at least partially disposed on the surface of the photovoltaic element or at least partially disposed between a photovoltaic element and the roof deck but not extending under substantially the entire photovoltaic element.

2. The photovoltaic roofing system according to claim 1, wherein an adhesive on the bottom surface of the photovoltaic element adheres the one or more photovoltaic element to the photovoltaic element-facing flange of the side flashing.

3. The photovoltaic roofing system according to claim 1, wherein the plurality of photovoltaic elements is a linear array of strip-shaped photovoltaic elements, arranged top-to-bottom.

4. The photovoltaic roofing system according to claim 1, wherein at least one horizontal row of photovoltaic elements comprises two or more laterally adjacent photovoltaic elements.

5. The photovoltaic roofing system according to claim 1, wherein the plurality of photovoltaic elements is arranged such that one or both side edges of the photovoltaic area is linear.

6. The photovoltaic roofing system according to claim 1, wherein the photovoltaic elements overlap one another in a top-to-bottom fashion.

7. The photovoltaic roofing system according to claim 1, further comprising flashing disposed at the interfaces between adjacent contiguously disposed photovoltaic elements.

8. The photovoltaic roofing system according to claim 7, wherein the plurality of photovoltaic elements is a linear array of strip-shaped photovoltaic elements, and the photovoltaic roofing system further comprises standing seam flashing, the standing seam flashing having a cross-sectional shape comprising a vertically extending feature, and two flanges, one extending laterally from each side at the bottom of the vertically extending feature, wherein the standing seam flashing is disposed at each interface between contiguously disposed photovoltaic elements, with each flange is disposed between one of the contiguously disposed photovoltaic elements and the roof deck.

9. The photovoltaic roofing system according to claim 1, wherein at least one side flashing comprises a flange facing away from the photovoltaic area at least partially disposed between a roofing element and the roof deck, a flange at least partially disposed between a photovoltaic element and the roof deck, and a covered cavity therebetween.

10. The photovoltaic roofing system according to claim 9, wherein the covered cavity acts as a cover and/or conduit for electrical features protruding from the surface of the one or more photovoltaic elements at their side edges.

11. The photovoltaic roofing system according to claim 1, further comprising a bottom flashing disposed along the bottom edge of the photovoltaic area, disposed at least partially underneath the one or more photovoltaic elements and at least partially on top of a roofing element disposed along the bottom edge of the photovoltaic area.

12. The photovoltaic roofing system according to claim 11, wherein the bottom flashing has a cross-sectional shape comprising a vertically-extending feature and a flange extending from each lateral side at the bottom of the vertically-extending feature, with the flange facing the photovoltaic area being disposed at least partially underneath the one or more photovoltaic elements, and the flange facing away from the photovoltaic area being disposed at least partially on top of a roofing element disposed along the bottom edge of the photovoltaic area.

13. The photovoltaic roofing system according to claim 11, wherein the bottom surface of the at least one photovoltaic element is adhered to the top surface of the bottom flashing.

14. The photovoltaic roofing system according to claim 11, wherein the side flashing and the bottom flashing meet at a corner, where the photovoltaic area-facing flange of the side flashing is at least partially disposed on top of the bottom flashing.

15. The photovoltaic roofing system according to claim 1, further comprising a top flashing disposed along the top edge of the photovoltaic area, the top flashing disposed at least partially under a roofing element disposed along the top edge of the photovoltaic area, and at least partially over the one or more photovoltaic elements.

16. The photovoltaic roofing system according to claim 15, wherein the top flashing includes one or more cavities and/or recesses that act as a cover and/or conduit for electrical features associated with one or more of the photovoltaic elements.

17. The photovoltaic roofing system according to claim 1, wherein no metal sheet is disposed between substantially the entire area of the photovoltaic elements and the roof deck.

18. The photovoltaic roofing system according to claim 1, wherein a panel is disposed between the one or more photovoltaic elements and the roof deck.

19. The photovoltaic roofing system according to claim 1, wherein the roofing elements are bituminous shingles.

20. The photovoltaic roofing system according to claim 1, wherein the side flashings include a recessed insertion area formed in a side of the vertically-extending feature, and one or more roofing elements are at least partially disposed in the recessed insertion area.

21. The photovoltaic roofing system according to claim 1, wherein at least one of the side flashings is provided as one or more continuous pieces of flashing on the side facing the photovoltaic elements, and a plurality of stepped side flashing pieces on the side facing the roofing elements.

22. A method for installing a photovoltaic roofing system according to claim 1 onto a roof comprising a roof deck having an upper end and a lower end, the method comprising

disposing side flashing along the side edges of a photovoltaic area, the side flashing having a flange facing away from the photovoltaic area at least partially disposed between a roofing element and the roof deck, and a structure facing the photovoltaic area;

and

contiguously disposing a plurality of photovoltaic elements in the photovoltaic area in at least two horizontal rows, with the structure of the side flashing facing the photovoltaic area being at least partially disposed on the surface of the photovoltaic element or at least partially disposed between a photovoltaic element and the roof deck but not extending under substantially the entire photovoltaic element, such that no panel is disposed between substantially the entire area of the photovoltaic elements and the roof deck.

23. The method according to claim 22, wherein the roof further comprises roofing elements arrayed on the roof deck, the method further comprising, before performing the disposing steps, removing a plurality of roofing elements disposed within an area surrounding the photovoltaic area.

24. A kit for the installation of a photovoltaic roofing system according to claim 1, the kit comprising

a plurality of photovoltaic elements;

and

a plurality of side flashings, each having a flange configured to face away from the photovoltaic area and be at least partially disposed between a roofing element and a roof deck, and a structure configured to be at least partially disposed on the surface of the photovoltaic element or at least partially disposed between a photovoltaic element and a roof deck.

25. A kit for the installation of a photovoltaic roofing system according to claim 1, the kit being for use with one or more contiguously-disposed photovoltaic elements, the kit comprising:

a plurality of side flashings, each having a flange configured to face away from the photovoltaic area and be at least partially disposed between a roofing element and the roof deck, and a structure configured to be at least partially disposed on the surface of the photovoltaic element or at least partially disposed between a photovoltaic element and the roof deck;

one or more top flashings; and

one or more bottom flashings,

wherein the side flashings, the one or more top flashings and the one or more bottom flashings are sufficient length to enclose a photovoltaic area defined by the contiguously-disposed photovoltaic elements.

26. A photovoltaic roofing system according to claim 1, wherein the photovoltaic elements are disposed directly on the roof deck.

27. A photovoltaic roofing system according to claim 1, wherein the photovoltaic elements are disposed directly on a roofing membrane or an underlayment disposed on the roof deck.