Integrated photovoltaic roofing component and panel

• US 20040144043A1
• Filed: 01/23/2003
• Published: 07/29/2004
• Est. Priority Date: 01/23/2003
• Status: Active Grant

• Current Assignee: Solar Integrated Technologies, Inc.
• Original Assignee: Solar Integrated Technologies, Inc.
• Inventors: Stevenson, Edward J., Khouri, Bruce M.
• Granted Patent: US 7,342,171 B2
• Time in Patent Office: Days
• US Class Current: 52/173.3
• CPC Class Codes: E04D 5/00 Roof covering by making use of flexible material, e.g. supplied in roll form using stiff sheets E04D3/00; gravelling of flat roofs E04D7/00 ; granulated roof covering E04D7/005; built-up roofs E04D11/02
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02P 80/20 using renewable energy
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A combination roofing panel and solar module includes a flexible membrane sheet, such as a single-ply membrane sheet, and a plurality of elongated solar or photovoltaic modules arranged side-by-side, end-to-end, or adjacent each other. The modules are adhered to the flexible membrane, and the edges of the modules having electrical connectors or electrodes are arranged to face each other or be aligned with each other. The electrical connectors are connected by a solder connection to module electrodes through apertures in a bottom surface of the flexible membrane and are connected in series. The series electrical connectors are connected directly to direct current (DC) electric devices, to a combiner box, to another panel or to an inverter which provides coverts direct current (DC) to alternating current electricity for use in residential, commercial or industrial building structures. The ends and elongated edges of a roofing component or panel having the flexible membrane and modules can be sealed for protection.

Claims

1. An integrated photovoltaic roofing component for attachment to a roofing surface, comprising:

a flexible membrane having a top surface and a bottom surface, said bottom surface for application to the roofing surface;

a plurality of elongated photovoltaic modules arranged side-by-side and attached to said top surface of said flexible membrane; and

one or more electrical leads in electrical connection with said modules and located at adjacent ends of the modules.

2. The component of claim 1, wherein said plurality of modules are attached to said top surface of said flexible membrane with an adhesive.

3. The component of claim 1, wherein said flexible membrane comprises a single-ply membrane.

4. The component of claim 3, wherein said single-ply membrane is a thermoplastic membrane sheet, an elastomeric membrane sheet, or a reinforced bituminous membrane sheet.

5. The component of claim 1, wherein each module includes a plurality of solar cells.

6. The component of claim 5, wherein each module includes about 22 solar cells.

7. The component of claim 1, wherein each module is flexible.

8. The component of claim 1, wherein said one or more electrical leads are connected in series.

9. The component of claim 1, wherein said one or more electrical leads of different modules are connected in series.

10. The component of claim 1, wherein said one or more electrical leads extend through said flexible membrane.

11. The component of claim 10, wherein said flexible membrane defines apertures through which said one or more electrical leads extend.

12. The component of claim 11, further comprising an insulative layer applied to said bottom surface of said flexible membrane that covers said apertures defined by said flexible membrane.

13. The component of claim 1, further comprising a seal along an elongated edge between said flexible membrane and an elongated photovoltaic module.

14. The component of claim 1, further comprising a seal along an end of said flexible membrane and an elongated photovoltaic module.

15. The component of claim 1, further comprising an insulative strip applied to said bottom surface of said flexible membrane.

16. The component of claim 15, wherein said insulative strip is applied to the roofing surface.

17. The component of claim 15, wherein said insulative strip encapsulates said one or more electrical leads.

18. The component of claim 1, wherein said flexible membrane and said plurality of elongated photovoltaic modules attached to said flexible membrane can be rolled upon themselves.

19. The component of claim 1, wherein said one or more electrical leads are located in a central area.

20. The component of claim 1, wherein said plurality of modules are attached to a single sheet of flexible membrane.

21. The component of claim 1, wherein a first group of two or more modules is arranged side-by-side and a second group of two or more modules is arranged side-by-side, wherein said first and second groups are also arranged end-to end so that said one or more electrical leads are located at adjacent ends of the modules of said first group and said second group.

22. The component of claim 21, wherein said one or more electrical leads of said first and second groups of modules are located in a central area.

23. The component of claim 1, wherein a first group of two or more modules are arranged side-by-side, and a second group of two or more modules are arranged side-by-side, said modules of said first and second groups being staggered.

24. The component of claim 23, wherein said one or more electrical leads of said first and second groups of modules are adjacent each other.

25. An integrated photovoltaic roofing panel for attachment to a roofing surface, comprising:

a flexible membrane having a top surface and a bottom surface, said bottom surface for application to the roofing surface;

a first group of elongated photovoltaic modules arranged side-by-side and having one or more electrical leads at adjacent ends of said first group of modules; and

a second group of elongated modules arranged side-by-side and having electrical leads at adjacent ends of said second group of modules, wherein said first and second groups of modules are attached to said top surface of said flexible membrane.

26. The panel of claim 25, wherein said first and second groups of elongated photovoltaic modules are arranged end-to-end so that said one or more electrical leads of said first and second groups are located in a central area.

27. The panel of claim 25, wherein said first and second groups of modules are attached to said top surface of said flexible membrane with an adhesive.

28. The panel of claim 25, wherein said flexible membrane comprises a single-ply membrane.

29. The panel of claim 28, wherein said single-ply membrane is a thermoplastic membrane sheet, an elastomeric membrane sheet, or a reinforced bituminous membrane sheet.

30. The panel of claim 25, wherein each module of said first and second groups of modules includes a plurality of solar cells.

31. The panel of claim 30, wherein each module includes about 22 solar cells.

32. The panel of claim 25, wherein each module of said first and second groups of modules is flexible.

33. The panel of claim 25, wherein said one or more electrical leads are connected in series.

34. The panel of claim 25, wherein said one or more electrical leads of said first group of modules are connected in series.

35. The panel of claim 25, wherein said one or more electrical leads of said second group of modules are connected in series.

36. The panel of claim 25, wherein an electrical lead of said first group and an electrical lead of said second group are connected in series.

37. The panel of claim 25, wherein said one or more electrical leads extend through said flexible membrane.

38. The panel of claim 37, wherein said flexible membrane defines apertures through which said one or more electrical leads extend.

39. The panel of claim 38, further comprising an insulative layer applied to said bottom surface of said flexible membrane that covers said apertures defined by said flexible membrane.

40. The panel of claim 25, further comprising a seal along an elongated edge between said flexible membrane and an elongated photovoltaic module.

41. The panel of claim 25, further comprising a seal along an end of said flexible membrane and an elongated photovoltaic module.

42. The panel of claim 25, further comprising an insulative strip applied to said bottom surface of said flexible membrane.

43. The panel of claim 42, wherein said insulative strip is applied to the roofing surface.

44. The panel of claim 42, wherein said insulative strip encapsulates said one or more electrical leads.

45. The panel of claim 25, wherein said flexible membrane and said plurality of elongated photovoltaic modules attached to said flexible membrane can be rolled upon themselves.

46. The panel of claim 25, wherein said first and second groups of modules are attached to a single sheet of flexible membrane.

47. The panel of claim 25, wherein said first group of modules includes six modules arranged side-by-side, said second group of modules includes six modules arranged side-by-side, and said first and second groups of six modules are also arranged end-to-end.