Wind uplift-resistant photovoltaic roofing elements and photovoltaic roofing systems

• US 9,166,087 B2
• Filed: 10/01/2013
• Issued: 10/20/2015
• 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: Chihlas, Peter, Jenkins, Robert, Livsey, Robert, Fisher, Chris, Nash, Alex
• Primary Examiner(s): Plummer, Elizabeth A
• Assistant Examiner(s): Walraed-Sullivan, Kyle
• Application Number:
  US14/043,621
• Publication Number:
  US 20140102518A1
• Time in Patent Office: 749 Days
• Field of Search: 521/733, 523/021, 523/023, 523/024, 52/60
• US Class Current: 1/1
• CPC Class Codes: F24S 2020/13 Overlaying arrangements similar to roof tiles
• CPC Class Codes: F24S 2025/6002 by using hooks
• CPC Class Codes: F24S 2025/6007 by using form-fitting connection means, e.g. tongue and groove
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: H01L 31/048 Encapsulation of 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: Y02B 10/20 Solar thermal
• 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; wire management features that can protect wiring and associated electrical components from physical and/or environmental damage; and wind clip and ledge features configured to prevent against wind uplift of the photovoltaic roofing elements when installed.

Claims

1. A photovoltaic roofing element comprising:

a frame structure having a top end and a bottom end, and 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 including a ledge extending away from the top end of the frame structure and one or more wind clips extending from the downward-facing surface of the frame structure in the exposure zone, the ledge and the one or more wind clips being configured such that, when installed in a photovoltaic roofing system, the wind clip of an overlying photovoltaic roofing element engages the ledge of an underlying photovoltaic roofing element; and

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

wherein the exposure zone of the frame structure comprises a plurality of horizontal support structures and a plurality of vertical support structures intersecting with the horizontal support structures, the one or more photovoltaic elements being disposed on the horizontal and vertical support structures, the horizontal and vertical support structures defining the downward-facing surface of the frame structure, and the one or more wind clips extend downwardly from one of the horizontal support structures, the one or more wind clips extending downwardly from the downward-facing surface of the remainder of the frame structure; and

wherein each of the wind clips includes a feature extending substantially horizontally toward the bottom end of the frame structure, the feature being configured such that, when installed in a photovoltaic roofing system, the horizontal feature of an overlying photovoltaic roofing element is disposed under the ledge of an underlying photovoltaic roofing element, the total area of the horizontally-extending features of all wind clips is greater than 20 cm².

2. The photovoltaic roofing element according to claim 1, wherein the frame structure further includes one or more wiring containment structures, disposed along the top end of the frame structure, downward relative to the ledge.

3. The photovoltaic roofing element according to claim 2, wherein the distance between the ledge and the one or more wiring containment structures is at least 1.5 cm.

4. The photovoltaic roofing element according to claim 1, wherein each of the wind clips includes a feature extending substantially vertically downward from the downward-facing surface of the frame structure, the vertically-extending feature having a downward end, the horizontally-extending feature of the wind clip extending from the downward end of the vertically-extending feature.

5. The photovoltaic roofing element according to claim 1, wherein the vertically-extending feature is configured to act as a positive stop, such that, when installed in a photovoltaic roofing system, the vertical feature of an overlying photovoltaic roofing element is disposed substantially against the ledge of an underlying photovoltaic roofing element.

6. The photovoltaic roofing element according to claim 1, wherein the ledge has one or more breaks formed therein.

7. The photovoltaic roofing element according to claim 2, wherein the ledge has one or more breaks formed therein, the breaks being formed in registration with the one or more wiring containment structures.

8. The photovoltaic roofing element according to claim 6, wherein each break is less wide than the one or more wind clips.

9. A photovoltaic roofing system comprising a first course of horizontally-arranged photovoltaic roofing elements and a second course of horizontally-arranged photovoltaic roofing elements overlying the first course, each photovoltaic roofing element being a photovoltaic roofing element according to claim 1, wherein

the second course overlies the first course such that the exposure zones of the photovoltaic roofing elements of the first course are substantially exposed and the attachment zones of the photovoltaic roofing elements of the first course are substantially overlaid, and

the one or more wind clips of each photovoltaic roofing elements of the second course engage the ledge of one or more of the photovoltaic roofing elements of the first course.

10. The photovoltaic roofing system according to claim 9,

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 sidelap portions of the photovoltaic roofing elements interlocking to provide water drainage channels;

the photovoltaic roofing system further comprising

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, the vertically-extending feature having a downward end, 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 adapted to interlock with the sidelap portion of an adjacent photovoltaic roofing element.

11. The photovoltaic roofing system according to claim 10, 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.

12. The photovoltaic roofing system according to claim 10, 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.

13. The photovoltaic roofing system according to claim 10, 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.

14. The photovoltaic roofing element according to claim 1, wherein the horizontally-extending feature of each wind clip has a length in the range of about 1.5 cm to about 8 cm.

15. The photovoltaic roofing element according to claim 14, wherein the horizontally-extending feature of each wind clip has a width in the range of about 1.5 cm to about 6 cm.

16. The photovoltaic roofing element according to claim 1, wherein the horizontally-extending feature of each wind clip has a width in the range of about 1.5 cm to about 6 cm.

17. The photovoltaic roofing element according to claim 1, wherein the horizontally-extending feature of each wind clip has a surface area in the range of about 1.5 cm² to about 10 cm².

18. The photovoltaic roofing element according to claim 1, wherein the total surface area of the horizontally-extending features of all wind clips is greater than 30 cm².

19. The photovoltaic roofing element according to claim 1, wherein the horizontally-extending feature of each wind clip and each ledge includes one or more detent features, locking features, or a combination thereof.

20. The photovoltaic roofing element according to claim 1, wherein the horizontally-extending feature of each wind clip has substantially no other part of the frame structure disposed in an upward direction therefrom.