Photovoltaic roofing elements and photovoltaic roofing systems

• US 8,950,128 B2
• Filed: 11/13/2012
• Issued: 02/10/2015
• Est. Priority Date: 11/14/2011
• Status: Active Grant

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Kalkanoglu, Husnu M., Chihlas, Peter, Livsey, Robert D.
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): BARLOW, ADAM G
• Application Number:
  US13/675,585
• Publication Number:
  US 20130125482A1
• Time in Patent Office: 819 Days
• Field of Search: 521/733, 523/021, 523/023, 126/621, 126/622, 126/623
• US Class Current: 52/173.3
• 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: H02S 20/25 Roof tile elements
• CPC Class Codes: H02S 30/10 Frame structures
• 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

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 element comprising:

a frame structure having an upward-facing surface and a downward-facing surface, 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 having one or more raised sidewalls that at least partially define the area in which the one more photovoltaic elements are held; and

one or more photovoltaic elements held in the exposure zone of the frame structure, each photovoltaic element having a downward-facing surface,

wherein the area in which the one or more photovoltaic elements are held has an upward-facing base surface, and wherein the frame structure further includes one or more raised structures protruding from the base surface, and

wherein the one or more photovoltaic elements rest on the one or more raised structures, such that a gap remains between the downward-facing surface of the photovoltaic element and the upward-facing base surface of the frame structure, and

wherein a first material adheres the photovoltaic element to the upward-facing base surface of the frame structure; and

wherein a second, different material seals the photovoltaic element to one or more of the one or more raised sidewalls of the frame structure.

2. The photovoltaic roofing element according to claim 1, wherein the sidewalls have one or more channels formed therein.

3. The photovoltaic roofing element according to claim 1, wherein the sidewalls extend above the upward-facing base surface of the area in which the one or more photovoltaic elements are held by at least about 2 mm.

4. The photovoltaic roofing element according to claim 1, wherein the one or more raised structures are greater than about 10 mils in height.

5. The photovoltaic roofing element according to claim 1, wherein the raised structures are substantially continuous.

6. The photovoltaic roofing element according to claim 1, wherein the raised structures are discontinuous.

7. The photovoltaic roofing element according to claim 1, wherein the upward-facing base of the frame structure comprises a plurality of slats on which the one or more raised structures are disposed.

8. The photovoltaic roofing element according to claim 1, wherein the frame structure includes a wiring containment structure.

9. The photovoltaic roofing element according to claim 1, wherein the frame structure is rigid.

10. The photovoltaic roofing element according to claim 1, wherein adhesive bonds the photovoltaic element to the frame structure, the adhesive being disposed in the gap between the downward-facing surface of the photovoltaic element and the upward-facing base surface of the frame structure.

11. The photovoltaic roofing element according to claim 1, wherein a sealant or adhesive seals the edge of the photovoltaic element to the frame structure along the one or more raised sidewalls of the frame structure, the adhesive being disposed in the gap between the downward-facing surface of the photovoltaic element and the upward-facing base surface of the frame structure.

12. The photovoltaic roofing element according to claim 1, wherein the one or more raised structures are in the range of about 20 mils to about 100 mils in height.

13. The photovoltaic roofing element according to claim 1, wherein the one or more raised structures include one or more substantially continuous raised ridges along the perimeter of the area in which the one or more photovoltaic elements are held.

14. The photovoltaic roofing element according to claim 13, wherein a sealant or adhesive seals the edge of the photovoltaic element to the frame structure along the one or more raised sidewalls, the adhesive being disposed in a channel or moat between one or more of the substantially continuous raised ridges along the perimeter of the area in which the one or more photovoltaic elements are held and the one or more raised sidewalls.

15. The photovoltaic roofing element according to claim 13, wherein the one or more raised structures further include one or more substantially continuous raised ridges along the interior of the area in which the photovoltaic element is to be disposed.

16. The photovoltaic roofing element according to claim 1, wherein the height of one or more of the one or more sidewalls along the bottom edge is lower than the top surface of the photovoltaic element.

17. The photovoltaic roofing element according to claim 1, wherein one or more of the raised structures is positioned in contact with a sidewall.

18. The photovoltaic roofing element according to claim 1, wherein one or more of the one or more sidewalls extend above the upward-facing base surface by at least about 3 mm.