ABSTRACT
Abstract
Building integrated photovoltaic (BIPV) systems provide for solar panel arrays that can be aesthetically pleasing and appear seamless to an observer. BIPV systems can be on-roof systems, elevated from the surface of a roof, being flush or forming a substantively uniform plane with roof panels or other panels mimicking a solar panel appearance. Pans supporting BIPV solar panels can be coupled by standing seams to other photovoltaic-supporting pans or pans supporting non-photovoltaic structures, having both functional and aesthetic advantages. In some configurations, inverted seams can couple photovoltaic-supporting pans and non-photovoltaic structures, forming a substantively planar surface. In some configurations, the appearance of BIPV systems can be particularly aesthetically pleasing and generally seamless to an observer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This claims the benefit of: U.S. Provisional Application No. 62/294,743, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Feb. 12, 2016; U.S. Provisional Application No. 62/308,828, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Mar. 15, 2016; U.S. Provisional Application No. 62/313,678, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Mar. 25, 2016; U.S. Provisional Application No. 62/354,599, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Jun. 24, 2016; U.S. Provisional Application No. 62/357,329, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Jun. 30, 2016; and U.S. Provisional Application No. 62/374,704, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Aug. 12, 2016, which are all herein incorporated by reference in their entireties. This is also related to concurrently filed non-provisional applications U.S. Ser. No. 15/246,475, filed Aug. 24, 2016 and U.S. Ser. No. 15/246,495, filed Aug. 24, 2016, both entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ, filed on the same day as this paper, and which are both hereby incorporated herein by reference in their entireties.
TECHNICAL FIELD
This generally relates to photovoltaic arrays.
BACKGROUND
Solar is becoming increasingly popular in the United States and abroad, but penetration remains relatively low versus the number of homes that could benefit from solar. The price per kilowatt for solar is now competitive with or below that of utility power in most areas, however, solar largely remains a niche product for those who value saving money, reducing CO 2 emissions, or both.
One factor that may limit the adoption of solar technology is aesthetics. Most residential solar systems are installed as modules on an existing tile or composition shingle roof. The solar array, which often only covers a portion of the roof, or even a portion of one mounting plane on the roof, stands out as separate and distinct from the existing roof, both in height and material. This structure is therefore visible even from the street level and over large distances.
Another obstacle to solar adoption in existing homes is the dissonance between the age of the existing roof and the solar system, particularly where the existing roof is made from composition shingle. The expected life of a solar system and a composition shingle roof are both about 25 years depending on the local climate, but the existing roof may be several years, if not decades, into that lifespan when a prospective customer is contacted. So the customer may be presented with the dilemma of getting a new roof first, increasing the cost of going solar, or installing a 25-year solar system on a roof, which may have a relatively shorter remaining operational lifespan.
Accordingly, there is a need to resolve the dissonance between the expected life of the solar system and the remaining life of the roof that also blends in more aesthetically with the complete roof surface or at least the mounting plane and that doesn't require the prospective customer to pay for a new roof and a new solar system over that roof.
BRIEF SUMMARY
Various embodiments provide a new and improved approach to installing solar on existing roofs, and in particular, existing composition shingle roofs. Some fit over an existing composition shingle roof and/or other suitable roof surfaces (e.g., a metal seam roof, roof deck, underlayment or insulation layer). Some have improved aesthetics that reduce the visual differences between solar and non-solar portions of the roof. Some are more modular and/or simplify the replacement capability of individual photovoltaic (âPVâ) modules of the system. In addition, some cost less to make and install compared to conventional solar systems. And some solar systems can be installed as a new roof rather than a re-roof or mounted to an existing roof. These and other embodiments are discussed in greater detail in the detailed description and drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative aspects of the present disclosure are described in detail below with reference to the following drawing figures. It is intended that that embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
FIG. 1A shows an example of a prior art photovoltaic array installed on a roof.
FIG. 1B shows an exemplary prior art photovoltaic module.
FIG. 2A shows a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 2B shows an exemplary photovoltaic module usable with a building integrated photovoltaic system according to various embodiments of this technology.
FIGS. 2C and 2D show exploded cross-sectional views of the PV module of FIG. 2B showing the different layers of the PV module according to various embodiments of this technology.
FIG. 3A shows a partial cutaway view of a portion of a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 3B shows a cross-sectional view of a structurally integrated non-PV roof pan or panel configured in accordance with certain embodiments of this technology.
FIG. 3C shows a cross-sectional view of a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 4A shows a cross-sectional, close up end view of a portion of a building integrated photovoltaic system including coupled seams according to certain embodiments of this technology.
FIG. 4B shows a cross-sectional view of a seam cover, seam clip, and standing seams according to certain embodiments of this technology.
FIGS. 4C and 4D show cross-sectional views of a building integrated photovoltaic system including seams that are coupled according to yet further embodiments of this technology.
FIGS. 4E-4G further show different views of a seam clip configured in accordance with an embodiment of this technology.
FIGS. 4H and 4I show spacing and a filling or wedge member between photovoltaic modules and proximate side walls, in accordance with aspects of this technology.
FIGS. 5-9A show a perspective view, cross-sectional front view, and various side views respectively of a portion of a building integrated photovoltaic system according to other various embodiments of this technology
FIG. 9B shows a close-up view of roof eave portion of a roof including a louvered vent portion configured in accordance with embodiments of this technology.
FIGS. 10A-10H show an example of a building integrated photovoltaic (âBIPVâ) system installation on a building including one or more features or components (e.g., roofing components, transition pans, PV module assemblies, roof pans, underlayment layers), in whole or in part, according to various embodiments of this technology.
FIGS. 11A-11H show different views of a grounding clip for use with a PV system according to certain embodiments of this technology.
FIGS. 12A-12C show different views of wiring caps and clips for use with a PV system according to various embodiments of this technology.
FIGS. 13A-13M show various wiring systems, circuits, and pathways in accordance with various embodiments of this technology.
FIGS. 14A-14G show other wiring features and support pan structures in accordance with certain embodiments of this technology.
FIGS. 15A-15D show various views of a photovoltaic module pan assembly capable of supporting a heat transfer or phase change material usable with a building integrated photovoltaic system as described herein according to various embodiments of this technology.
FIGS. 16A-16J are a series of diagrams showing schematic wiring options for solar cell sections of a photovoltaic module accounting for shading caused by standing seams, in accordance with various embodiments of this technology.
FIG. 16K shows incident solar energy on a photovoltaic panel and standing seam roof panel on the longitudinal sides thereof.
FIG. 17 shows an embodiment of a PV column of a solar panel array, where the PV column is configured to take advantage of convection and related heat transfer, in accordance with various embodiments of this technology.
FIG. 18 shows a schematic representation of vent modules, in accordance with various embodiments of this technology.
FIG. 19A shows a perspective view of a PV module with attached rails, in accordance with certain embodiments.
FIG. 19B shows a perspective view of another PV module with attached rails, in accordance with certain embodiments.
FIG. 19C shows an exploded perspective view of a PV module with different rail options according to various embodiments.
FIGS. 20A, 20B, and 20C show perspective, cross-section, and detail views of a corrugated PV pan with seam clips, in accordance with certain embodiments.
FIGS. 21A and 21B show perspective and cross-section views of a corrugated PV pan with seam clips and a PV module mounted thereto, according to other embodiments.
FIGS. 22A, 22B, and 22C show perspective, cross-section, and detail views of a corrugated PV pan with seam clips securing a PV module thereto in accordance with certain embodiments.
FIGS. 23A and 23B show perspective and cross-section views of a corrugated PV pan with seam clips and a PV module mounted thereon according to other various embodiments.
FIGS. 24A, 24B, and 24C show perspective views of photovoltaic modules and non-photovoltaic modules installed on support pans in accordance with certain embodiments.
FIG. 25 and FIG. 26 show transition pans forming openings within a photovoltaic array configured for the passage of precipitation and airflow, according to various embodiments.
FIGS. 27A-27E show latching assembly features for photovoltaic module assemblies, according to various embodiments.
FIGS. 28A-28H show rail mounted assembly features for photovoltaic module assemblies according to various embodiments.
FIGS. 29A-29B show assembly features for photovoltaic module assemblies mounted without support pan structures according to various embodiments.
FIG. 30 shows a PV module-pan assembly using inverted seam structures according to various embodiments.
DETAILED DESCRIPTION
The present disclosure describes various embodiments of photovoltaic roofing systems and associated systems and methods. Some embodiments relate to building integrated photovoltaic module assemblies and associated systems and methods. In various embodiments, the systems described herein lower costs of conventional systems in which a PV system is installed over a roof, and at the same time can provide an improved aesthetic for a PV roof system.
Certain details are set forth in the following description and in the Figures to provide a thorough understanding of various embodiments of the present technology. Other details describing well-known structures and systems often associated with PV systems, roofs, etc., however, are not set forth below to avoid unnecessarily obscuring the description of the various embodiments of the present technology.
Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments. Accordingly, other embodiments can include other details, dimensions, angles and features without departing from the spirit or scope of the present invention. Various embodiments of the present technology can also include structures other than those shown in the Figures and are expressly not limited to the structures shown in the Figures. Moreover, the various elements and features shown in the Figures may not be drawn to scale. In the Figures, identical reference numbers identify identical or at least generally similar elements.
As used herein, the term âsubstantiallyâ refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is âsubstantiallyâ uniform in height to another object would mean that the objects are either completely or nearly completely uniform in height. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context, however, generally speaking, the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.
As used herein, the term âaboutâ is used to provide flexibility to a numerical range endpoint by providing that a given value may be âaboveâ or âbelowâ the value. For example, the given value modified by about may be, for example, by ±5%, ±10%, ±15%, ±20%.
Wherever used throughout the disclosure and claims, the term âgenerallyâ has the meaning of âapproximatelyâ or âcloselyâ or âwithin the vicinity or range ofâ. The term âgenerallyâ as used herein is not intended as a vague or imprecise expansion on the term it is selected to modify, but rather as a clarification and potential stop gap directed at those who wish to otherwise practice the appended claims, but seek to avoid them by insignificant, or immaterial or small variations. A
CROSS-REFERENCE TO RELATED APPLICATIONS
This claims the benefit of: U.S. Provisional Application No. 62/294,743, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Feb. 12, 2016; U.S. Provisional Application No. 62/308,828, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Mar. 15, 2016; U.S. Provisional Application No. 62/313,678, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING SYSTEMâ and filed on Mar. 25, 2016; U.S. Provisional Application No. 62/354,599, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Jun. 24, 2016; U.S. Provisional Application No. 62/357,329, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Jun. 30, 2016; and U.S. Provisional Application No. 62/374,704, entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ and filed on Aug. 12, 2016, which are all herein incorporated by reference in their entireties. This is also related to concurrently filed non-provisional applications U.S. Ser. No. 15/246,475, filed Aug. 24, 2016 and U.S. Ser. No. 15/246,495, filed Aug. 24, 2016, both entitled âBUILDING INTEGRATED PHOTOVOLTAIC ROOFING ASSEMBLIES AND ASSOCIATED SYSTEMS AND METHODSâ, filed on the same day as this paper, and which are both hereby incorporated herein by reference in their entireties.
TECHNICAL FIELD
This generally relates to photovoltaic arrays.
BACKGROUND
Solar is becoming increasingly popular in the United States and abroad, but penetration remains relatively low versus the number of homes that could benefit from solar. The price per kilowatt for solar is now competitive with or below that of utility power in most areas, however, solar largely remains a niche product for those who value saving money, reducing CO 2 emissions, or both.
One factor that may limit the adoption of solar technology is aesthetics. Most residential solar systems are installed as modules on an existing tile or composition shingle roof. The solar array, which often only covers a portion of the roof, or even a portion of one mounting plane on the roof, stands out as separate and distinct from the existing roof, both in height and material. This structure is therefore visible even from the street level and over large distances.
Another obstacle to solar adoption in existing homes is the dissonance between the age of the existing roof and the solar system, particularly where the existing roof is made from composition shingle. The expected life of a solar system and a composition shingle roof are both about 25 years depending on the local climate, but the existing roof may be several years, if not decades, into that lifespan when a prospective customer is contacted. So the customer may be presented with the dilemma of getting a new roof first, increasing the cost of going solar, or installing a 25-year solar system on a roof, which may have a relatively shorter remaining operational lifespan.
Accordingly, there is a need to resolve the dissonance between the expected life of the solar system and the remaining life of the roof that also blends in more aesthetically with the complete roof surface or at least the mounting plane and that doesn't require the prospective customer to pay for a new roof and a new solar system over that roof.
BRIEF SUMMARY
Various embodiments provide a new and improved approach to installing solar on existing roofs, and in particular, existing composition shingle roofs. Some fit over an existing composition shingle roof and/or other suitable roof surfaces (e.g., a metal seam roof, roof deck, underlayment or insulation layer). Some have improved aesthetics that reduce the visual differences between solar and non-solar portions of the roof. Some are more modular and/or simplify the replacement capability of individual photovoltaic (âPVâ) modules of the system. In addition, some cost less to make and install compared to conventional solar systems. And some solar systems can be installed as a new roof rather than a re-roof or mounted to an existing roof. These and other embodiments are discussed in greater detail in the detailed description and drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative aspects of the present disclosure are described in detail below with reference to the following drawing figures. It is intended that that embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
FIG. 1A shows an example of a prior art photovoltaic array installed on a roof.
FIG. 1B shows an exemplary prior art photovoltaic module.
FIG. 2A shows a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 2B shows an exemplary photovoltaic module usable with a building integrated photovoltaic system according to various embodiments of this technology.
FIGS. 2C and 2D show exploded cross-sectional views of the PV module of FIG. 2B showing the different layers of the PV module according to various embodiments of this technology.
FIG. 3A shows a partial cutaway view of a portion of a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 3B shows a cross-sectional view of a structurally integrated non-PV roof pan or panel configured in accordance with certain embodiments of this technology.
FIG. 3C shows a cross-sectional view of a building integrated photovoltaic system according to various embodiments of this technology.
FIG. 4A shows a cross-sectional, close up end view of a portion of a building integrated photovoltaic system including coupled seams according to certain embodiments of this technology.
FIG. 4B shows a cross-sectional view of a seam cover, seam clip, and standing seams according to certain embodiments of this technology.
FIGS. 4C and 4D show cross-sectional views of a building integrated photovoltaic system including seams that are coupled according to yet further embodiments of this technology.
FIGS. 4E-4G further show different views of a seam clip configured in accordance with an embodiment of this technology.
FIGS. 4H and 4I show spacing and a filling or wedge member between photovoltaic modules and proximate side walls, in accordance with aspects of this technology.
FIGS. 5-9A show a perspective view, cross-sectional front view, and various side views respectively of a portion of a building integrated photovoltaic system according to other various embodiments of this technology
FIG. 9B shows a close-up view of roof eave portion of a roof including a louvered vent portion configured in accordance with embodiments of this technology.
FIGS. 10A-10H show an example of a building integrated photovoltaic (âBIPVâ) system installation on a building including one or more features or components (e.g., roofing components, transition pans, PV module assemblies, roof pans, underlayment layers), in whole or in part, according to various embodiments of this technology.
FIGS. 11A-11H show different views of a grounding clip for use with a PV system according to certain embodiments of this technology.
FIGS. 12A-12C show different views of wiring caps and clips for use with a PV system according to various embodiments of this technology.
FIGS. 13A-13M show various wiring systems, circuits, and pathways in accordance with various embodiments of this technology.
FIGS. 14A-14G show other wiring features and support pan structures in accordance with certain embodiments of this technology.
FIGS. 15A-15D show various views of a photovoltaic module pan assembly capable of supporting a heat transfer or phase change material usable with a building integrated photovoltaic system as described herein according to various embodiments of this technology.
FIGS. 16A-16J are a series of diagrams showing schematic wiring options for solar cell sections of a photovoltaic module accounting for shading caused by standing seams, in accordance with various embodiments of this technology.
FIG. 16K shows incident solar energy on a photovoltaic panel and standing seam roof panel on the longitudinal sides thereof.
FIG. 17 shows an embodiment of a PV column of a solar panel array, where the PV column is configured to take advantage of convection and related heat transfer, in accordance with various embodiments of this technology.
FIG. 18 shows a schematic representation of vent modules, in accordance with various embodiments of this technology.
FIG. 19A shows a perspective view of a PV module with attached rails, in accordance with certain embodiments.
FIG. 19B shows a perspective view of another PV module with attached rails, in accordance with certain embodiments.
FIG. 19C shows an exploded perspective view of a PV module with different rail options according to various embodiments.
FIGS. 20A, 20B, and 20C show perspective, cross-section, and detail views of a corrugated PV pan with seam clips, in accordance with certain embodiments.
FIGS. 21A and 21B show perspective and cross-section views of a corrugated PV pan with seam clips and a PV module mounted thereto, according to other embodiments.
FIGS. 22A, 22B, and 22C show perspective, cross-section, and detail views of a corrugated PV pan with seam clips securing a PV module thereto in accordance with certain embodiments.
FIGS. 23A and 23B show perspective and cross-section views of a corrugated PV pan with seam clips and a PV module mounted thereon according to other various embodiments.
FIGS. 24A, 24B, and 24C show perspective views of photovoltaic modules and non-photovoltaic modules installed on support pans in accordance with certain embodiments.
FIG. 25 and FIG. 26 show transition pans forming openings within a photovoltaic array configured for the passage of precipitation and airflow, according to various embodiments.
FIGS. 27A-27E show latching assembly features for photovoltaic module assemblies, according to various embodiments.
FIGS. 28A-28H show rail mounted assembly features for photovoltaic module assemblies according to various embodiments.
FIGS. 29A-29B show assembly features for photovoltaic module assemblies mounted without support pan structures according to various embodiments.
FIG. 30 shows a PV module-pan assembly using inverted seam structures according to various embodiments.
DETAILED DESCRIPTION
The present disclosure describes various embodiments of photovoltaic roofing systems and associated systems and methods. Some embodiments relate to building integrated photovoltaic module assemblies and associated systems and methods. In various embodiments, the systems described herein lower costs of conventional systems in which a PV system is installed over a roof, and at the same time can provide an improved aesthetic for a PV roof system.
Certain details are set forth in the following description and in the Figures to provide a thorough understanding of various embodiments of the present technology. Other details describing well-known structures and systems often associated with PV systems, roofs, etc., however, are not set forth below to avoid unnecessarily obscuring the description of the various embodiments of the present technology.
Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments. Accordingly, other embodiments can include other details, dimensions, angles and features without departing from the spirit or scope of the present invention. Various embodiments of the present technology can also include structures other than those shown in the Figures and are expressly not limited to the structures shown in the Figures. Moreover, the various elements and features shown in the Figures may not be drawn to scale. In the Figures, identical reference numbers identify identical or at least generally similar elements.
As used herein, the term âsubstantiallyâ refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is âsubstantiallyâ uniform in height to another object would mean that the objects are either completely or nearly completely uniform in height. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context, however, generally speaking, the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.
As used herein, the term âaboutâ is used to provide flexibility to a numerical range endpoint by providing that a given value may be âaboveâ or âbelowâ the value. For example, the given value modified by about may be, for example, by ±5%, ±10%, ±15%, ±20%.
Wherever used throughout the disclosure and claims, the term âgenerallyâ has the meaning of âapproximatelyâ or âcloselyâ or âwithin the vicinity or range ofâ. The term âgenerallyâ as used herein is not intended as a vague or imprecise expansion on the term it is selected to modify, but rather as a clarification and potential stop gap directed at those who wish to otherwise practice the appended claims, but seek to avoid them by insignificant, or immaterial or small variations. All such insignificant, or immaterial or small variations should be covered as part of the appended claims by use of the term âgenerallyâ.
As used herein, the term âbuilding integrated photovoltaic systemâ of âBIPVâ generally refers to photovoltaic systems integrated with building materials to form at least a portion of a building envelope. For example, the BIPV system can form the roof or roofing membrane of a building. The BIPV systems described herein can be retrofitted, can be a part of a new construction roof, or a combination of both. The PV modules, PV module pans, or both (depending on the particular embodiment) can be used as the actual building envelope (e.g., roofing membrane) to provide a watertight or substantially watertight seal. Alternatively, in other embodiments, the PV components (e.g., photovoltaic modules and associated wiring) of the system may be affixed over the building envelope in a manner that simulates the appearance of BIPV without having the PV system components be part of the building envelope. In other words, the PV modules may be installed over a metal roof pan or support pan that makes up part of the building envelope. As used herein, the term âBIPV systemâ may be used to refer to either configuration.
As used herein, the terms âup-roofâ and âdown-roofâ are used to provide orientation, direction, position, or a reference point relative to or in context of a roof or roofing surface upon which the systems described herein are installed on and/or form a portion of. Up-roof generally refers to an orientation that is relatively closer to the roof ridge while down-roof refers to an orientation that is relatively closer to the roof eave.
As used herein, the singular forms âaâ, âanâ, and âtheâ are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms âincludesâ and/or âincludingâ, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Spatially relative terms, such as âbeneathâ, âbelowâ, âlowerâ, âaboveâ, âupperâ, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as shown in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as âbelowâ or âbeneathâ other elements or features would then be oriented âaboveâ the other elements or features. Thus, term such as âbelowâ can encompass both an orientation of above and below, depending on the context of its use. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein are interpreted accordingly.
Although the terms âfirstâ, âsecondâ, etc. may be used herein to describe various elements, components, regions, layers and/or sections, it should be understood that they should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the present invention.
As used herein, the terms âand/orâ and âat least one ofâ include any and all combinations of one or more of the associated listed items.
Rapid shutdown devices (âRSDâ) for PV systems can be applied to the systems described herein, and can be located or positioned in various locations. In some embodiments, a recess or other opening can be made in structural support pans (e.g. a transition pan or a non-PV pan) through insulation such that RSD can be inset or positioned inside recessed opening. Vents can be positioned on top of opening to conceal or cover opening. Structural support pans can be elements of roofing frames or array systems that provide stability or integrity to the overall structures, as described in further detail below. RSD can be positioned within a box or other suitable container prior to positioning within recess. In other embodiments, RSD can be positioned under eaves, or eave flashings or gutters. In yet other embodiments, RSD can be positioned within attic portions of a building.
Generally, PV modules are crystalline-based solar panels, which can be either or both of monocrystalline solar panels or polycrystalline (multi-crystalline) solar panels. The laminate or wafer forming the solar energy-collecting surface of such PV modules can be mechanically coupled, adhered, or bonded to structurally supporting pans. In some embodiments, PV modules can include layers of amorphous silicon or thin film variations of solar energy-collecting laminates (unlike traditional thin-film solar materials directly applied to continuous metal sheets of a roof). Generally, PV pan-module assemblies as considered herein, including PV modules, solar panels and laminates, have individual structures that can be used in combination to form larger solar arrays and/or building structures, as set forth below. Alternatively, thin-film PV modules, such as cadmium telluride, copper indium gallium diselenide, or amorphous thin-film silicon may be used. In still further embodiments, cells based on perovskite or other as of yet non-commercialized materials may be used. The particular type of cell technology used is a design choice and not critical to the various embodiments of the invention.
FIG. 1A shows a prior art PV array installed on roof 100 . The exemplary PV array of FIG. 1A includes six solar panels 101 or modules (identified individually as solar panels 101 A- 101 F). Though not shown in detail, panels 101 A- 101 F are mounted on roof 100 using one of various known rail-based or rail-free mounting systems, as are currently employed by solar installers, such as San Mateo, Calif.-based SolarCity Corporation.
FIG. 1B shows one type of conventional solar panel 101 in more detail. Solar panel 101 includes PV laminate 102 , which in conventional silicon-based cells, consists of a silicon sandwich of p-doped and n-doped silicon layers, a top glass sheet protecting the laminate, and a back sheet that can include a plurality of layersâand rigid metal frame 103 , supporting PV laminate 102 . Although shown as a unitary structure, laminate 102 may include a plurality of individual solar cells that are wired together to form a single unit under the top glass sheet. In the example shown in FIG. 1B , frame 103 is a grooved frame with groove 104 surrounding the outer face of frame 103 on all sides. Grooved frame modules such as module 101 are manufactured and sold by SolarCity Corporation of San Mateo, Calif. In such a module, groove 104 serves as mechanism for attaching other mounting hardware (e.g., a leveling foot, an interlock) to join modules together and to support the modules over a roof surface. Those of ordinary skill in the art will appreciate that panel 101 may also have a plain, non-grooved frame. Non-grooved frames are typically interconnected to one another and connected to the roof using connectors that clamp down between the top and bottom edges of the frame.
Although these types of framed PV modules achieve their structural function, they are aesthetically suboptimal and have material usage inefficiencies. First, conventional PV systems, such as that shown in FIG. 1A , are typically installed over an existing roof, essentially requiring redundant structure since the PV array will shield most of the portion of the roof that it is installed over. Second, conventional systems are deemed by some people to be unaesthetic. Conventional PV modules usually come in one of two colors: blue, signifying a poly-crystalline silicon structure, and black, signifying a mono-crystalline silicon or thin-film structure. The metal frame portion can be painted black to help it blend in with the roof surface, or it can simply be raw aluminum. Regardless of whether blue or black modules are used, the difference between the look of the portion of the roof that is covered with solar and the remainder of the roof is generally quite dramatic. As a result, roofs that are partially covered with solar panels have an aesthetic contrast that can be seen from very far distances due to the difference in reflectivity, elevation, height, and/or color between these two very different surfaces.
Building Integrated Photovoltaic Array & Coupling Seams
FIG. 2A shows BIPV system 200 installed on a plane of roof surface 203 . System 200 is arranged in vertical pans on existing roof 203 to mimic the look of an all metal standing seam metal (e.g., steel, aluminum, galvanized) roof with evenly spaced vertical seams running from the roof ridge to the eave. The resultant BIPV system is comprised of six vertical pan sections containing PV modules 201 A- 201 R, regular roof pans 210 , and dummy or transition pans 205 that complete the six vertical columns (e.g., col. 1= 201 A, 201 G, 201 M; col. 2= 201 B, 201 H, 201 N; col. 3= 201 C, 201 I, 201 O; col. 4= 201 D, 201 J, 201 P; col. 5= 201 E, 201 K, 201 Q; and col. 6= 201 F, 201 L, 201 R). As discussed in greater detail herein, in some embodiments, the PV modules in each column (e.g., 1, 2, 3, 4, 5, and 6) may be affixed to a roof pan containing raised seams on either side. In other embodiments, the PV modules in each column may make up a portion of the roof-facing portion of the pan. Ridge cap 215 sits at the top of the resultant array, and as discussed herein may be used for venting, heat dissipation, and wire management. Together, these elements form an integrated PV roofing system 200 that reduces the redundancy inherent in conventional PV systems while providing a uniform look.
Standing seam as understood herein refers to the raised seams running up-roof to down-roof on both sides of a roof pan that are used to interlocking adjacent pans. The standing seams can be vertically or upwardly extending sidewalls or flanges and may be held together with clips or other fasteners. The seams between pans may be covered with a cap or other feature that keeps them watertight while concealing the seam. While shown as extending substantially perpendicular to a base planar surface portion (e.g., the plane of the roof surface or PV modules), in other embodiments, the standing seams can extend at angles other than ninety degree. Systems and features described herein can also be applied to non-metal (e.g., comp shingle, tile) roofs.
The seams (e.g., raised seams) of adjacent roof pans used in the PV systems described herein can be interlocked (e.g., coupled or secured together) in a variety of manners. For example, seams can be interlocked by folding (e.g., bending, rolling) one seam over the another seam and crimping them together (see e.g., FIG. 3C ), which creates equally spaced, interlocked seams running from roof ridge 209 to roof eave 213 . In some embodiments, seams are interlocked or snap-locked by clips, clamps, covers, or other suitable mechanical fasteners (e.g., rivets and screws) that fit over the entire seam as described in more detail below with reference to FIGS. 4A-4D . In yet further embodiments, seams can be welded or otherwise bonded or adhered together. As noted above, in certain embodiments seams of systems described herein can be inverted (e.g., extended or bent in a downward direction such that they are positioned below the roof or PV module surfaces) as compared to the standing or raised seams.
In yet further embodiments, the seams can be hemmed, folded, or bent into different configurations to provide improved engagement features as described in more detail below (see e.g., FIG. 4B ). For example, a clip used to engage and couple the hemmed seams can include one or more hook portions that can engage (e.g., be âsnap-lockedâ) the seams in a manner to provide increased resistance to pullout in response to uplift forces (e.g., wind uplift). Further, having such hemmed or bent seams can provide improved safety when shipping and installing such components by reducing the number of exposed sharp edges. In yet other embodiments, the seams can be inverted or extended (e.g., bent) downward such that ends of the seams are positioned below the planar, roof surface portions of the metal roof.
System 200 includes a solar array of eighteen low profile building integrated PV modules 201 (identified individually as PV modules 201 A- 201 R arranged in six columns and three rows of PV modules). PV modules 201 can, in some contexts, also be referred to as PV panels or solar panels. In other embodiments, system 200 can include a different number of columns or rows of PV modules (e.g., two rows). Further, the columns and/or rows can be spaced apart as desired (e.g., not directly adjacent to each other). System 200 can also include dummy modules 205 (alternatively referred to as dummy panels) and columns of standard roof pans 210 that contain no solar PV modules. Dummy modules 205 generally refer to roof structures that can mimic the appearance of PV modules 201 , serving a function similar to standard roof pans 210 . In some contexts, roof pans 210 can alternatively be referred to as general support pans or non-PV pans.
As discussed above, PV modules 201 A- 201 R can be placed or mounted within ordinary pans that are substantially the same as non-PV pans 210 . Alternatively, they may be installed in, or part of special pans (e.g., pans 220 in FIG. 3A ) so that the height of modules 201 A-R is substantially equal to the height of non-PV pans 210 . Moreover, as discussed in greater detail herein, the pans holding modules 201 A- 201 R, in columns 1-6, may be specifically configured with additional recesses (e.g., 224 ) to accommodate module junction boxes 217 and route power cables as shown in FIGS. 3A and 3C . In contrast, standard roof pans 210 generally refer to traditional structures and panels used for the tiling or construction of roofs, which do not include PV electricity generation components. Such non-PV pans 210 may be installed over roof battens 211 as seen in the partial cutaway view of FIG. 3A . Alternatively, they may be installed directly on the roof deck. Dummy modules 205 are roof pans that are used to complete a column of PV pans, after the PV portion stops. Dummy modules 205 may not only mimic the appearance of PV modules 201 , but they may be mounted on PV pans 220 instead of PV module 201 . In such a case, dummy modules 205 can maintain a uniform appearance alongside PV modules and provide space beneath the generally uniform planar surface of PV modules 201 of system 200 , in which electrical components can be centralized, ventilation can be achieved, or where access to underlying roof 203 (e.g. sub-roofing, an attic, etc.) can be provided.
Dummy modules 205 can be substituted for, or configured to appear similar to, roof pans 210 and/or PV modules 201 . For example, dummy modules 205 can be painted to match in color or appearance of roof pans 210 and/or PV modules 201 . In some embodiments, dummy modules 205 can be used as transition pans at up-roof (e.g. at ridge 209 of roof 203 ) or down-roof portions (e.g., at eave 213 of roof 203 ) at the beginning and/or end of a column of PV modules 201 , as described in more detail below. In other embodiments, roof pans 210 can be used as transition pans, such as part of a column of PV modules 201 . As used herein, the term transition pan refers to sections of roof pan that are used to transition between different pan types (e.g., PV pan 220 and non-PV pan 210 ) or to complete a column before PV modules start or after they stop. In certain embodiments, dummy modules 205 can be installed adjacent to side portions of roof 203 , in place of, or along with roof pans 210 . In other embodiments, roof pans 210 can be used or substituted for one or more dummy modules 205 . In some embodiments, dummy modules 205 can include roof pan 210 or panel or a PV module layer (e.g., glass, backsheet, etc.) positioned on a batten or other pan mount.
System 200 can include ridge cap 215 to cover roof ridge 209 and may be used to conceal and protect wires (e.g., conduits or cables) or other equipment (e.g., fans, vents, connectors, inverters, jumpers, home-run connections). System 200 can also include other roofing components (e.g., flashings, gutters, vents, caps, covers, trims), for example, at eave 213 , or at hips, valleys, or sides of the roof (not shown). While FIG. 2A shows system 200 including eighteen PV modules 201 A- 201 R, in some embodiments, system 200 includes a solar array with more or less than eighteen PV modules 201 . Further, in some embodiments, a column of roof pans 210 can also include dummy modules 205 and/or PV modules 201 .
FIG. 2B shows exemplary low-profile BIPV module 20 . In various embodiments, PV modules 201 can include any number of cells, including more or less than conventional 60-cell or 72-cell solar panels. For example, PV module 201 may have 3 columns of 11 cells, 3 columns of 10 cells, or, in a shingled configuration, 3 columns of thirty-three 33 sub-cells, where each cell is cut into 3 shingled cells. PV modules 201 can also include bi-facial, shingled cells, or a combination thereof. As shown, PV modules 201 can be about half the width of conventional, full-width modules. Further embodiments of PV modules 201 can have a specific number of solar cells, such as 12-cell, 20-cell, 24-cell, 30-cell, 36-cell, 40-cell, 42-cell, 48-cell, 54-cell, or 56-cell embodiments. Other embodiments of the present technology can include PV modules having 60-cell, 70-cell, 80-cell, or 92-cell solar panels, or other such solar panels as known in the field. Further embodiments can have PV modules 201 with other number-of-cell embodiments within the above-considered ranges. The various embodiments of PV modules 201 with different numbers of solar cells allows for flexibility in selecting solar panels appropriate for any given system installation.
PV modules 201 can also be frameless or have a minimized frame structure, as shown in FIG. 2B . In other words, PV modules 201 can be constructed without a rigid frame (e.g., made of metal, plastic) surrounding or enclosing the edges of the panel, or in some embodiments, surrounding only a portion of the bottom and sides but not the top of the module. Individual PV modules 201 can include layer of top glass 208 and a back sheet that will sandwich the internal PV layers as described in more detail below with respect to FIGS. 2C and 2D without any framing. In certain embodiments, because PV modules 201 A- 201 R can be supported by PV pans 220 (e.g., tray, plateâas shown, for example in FIG. 3A ), where PV pans 220 with raised portions 222 , whereas PV pans 220 sit on and/or are secured to roof 203 or other suitable roof surface at valleys 224 , PV modules 201 A- 201 R may not need to be as strong as framed panels in an ordinary or conventional array. In other words, in an ordinary or conventional array, the panel frame can become part of the mounting system and is subject to the same forces and moments as the mounting system, whereas in contrast, PV pans 220 can primarily bear load instead of PV modules 201 . PV modules 201 and PV pans 220 form PV module-pan assemblies when bonded or otherwise coupled to each other. Frameless, low profile solar PV modules are not required. For example, a framed module can used and the frame can be color matched to PV pan 220 .
Generally, in various embodiments, either or both of non-PV metal roof pans and transition pans can be painted to appear like PV modules, for example, replicating solar cell lines, color, and other visual characteristics of PV modules. Similarly, either or both of non-PV metal roof pans and transition pans can have visual or structural characteristics to track PV module-pan assemblies. The combination of these elements can provide for an overall roof appearance that is visually pleasing, with minimal points of contrast or sharp edges to distract the eye of an observer.
It should be understood that in these embodiments, roof pitches where such systems are installed are non-zero, and that the systems are installed to account for the angle or slope of (non-flat) roofs. The distances or gaps between various pans, modules, and assemblies, and the degree to which such gaps are concealed will be dependent on roof pitch, the distance a viewer is from the roof, and the height of the viewer.
FIGS. 2C and 2D show in further detail the layers of exemplary PV modules 201 . In some embodiments, PV modules 201 described herein refer to crystalline-type (e.g., non-thin film or amorphous solar) solar modules. However, PV modules 201 are not limited to crystalline-type solar cell technology. For example, in other embodiments, thin-film or amorphous solar (e.g., amorphous silicon) can be used as laminate layers with certain embodiments of PV modules 201 described herein. In yet further embodiments, hybrid crystalline and amorphous solar modules can be used with PV modules 201 systems described herein. In other embodiments, other types of solar cells (e.g., non-silicon based semiconductors, partial silicon, non-crystalline, partial crystalline, organic, carbon-based, perovskite, cadmium-telluride, copper-indium-gallium-selenide (âCIGSâ), dye sensitized, transparent luminescent solar concentrator, polymer, transparent cells) can be provided as part of PV modules 201 .
As shown in FIG. 2C and noted above, in some embodiments, PV module 201 can include PV layers 202 (e.g., solar cells, semiconductor layers, bussing, insulation, laminate) sandwiched between encapsulation layers 204 (e.g., EVA). PV modules 201 can further include one or more backsheets 206 (e.g., polyvinyl fluoride film) and/or glass layers 208 . As shown in FIG. 2D , PV modules 201 can include first and second glass layers 208 (e.g., âglass on glassâ) sandwiching encapsulation layers 204 . The glass on glass PV modules 201 can also eliminate or reduce the need for additional intermediate material layers (e.g., a pan portion, underlayment, felt paper) between a bottom of PV module 201 and existing roofing surfaces, which may otherwise be used for fire protection or other purposes. In certain embodiments, PV modules 201 can include both glass layer 208 and one or more backsheet layers 206 . In yet further embodiments, <figure-callout id="201" label="PV modules" filenames="US10505492-20191210-D00002.png,US10505492-20191210-D00003.png" state="{{st
CLAIMS
Claims ( 20 )
The invention claimed is:
1. A solar roof assembly, comprising:
a support material covering a portion of a roof surface;
a plurality of standing seam metal roof pans arranged in columns on the roof surface over the support material such that a top surface of each of the metal roof pans is elevated at a first height above the roof surface;
a plurality of support pans arranged in columns on the roof surface adjacent to at least one column of standing seam metal roof pan, each support pan comprising a pair of standing seams running a length of each side edge thereof and having a plurality of ridges and valleys and between each side edge;
a plurality of photovoltaic modules arranged end to end in columns over the plurality of support pans on the plurality of ridges such that the plurality of photovoltaic modules covers the plurality of ridges and valleys of the underlying plurality support pans, wherein each of the plurality of photovoltaic modules comprises an electrical connection that is disposed within a valley of an underlying support pan;
at least one transition pan in each column of photovoltaic modules down-roof from the last photovoltaic module, the at least one transition pan comprising a pair of standing seams running a length of each side edge and a lapping portion extending under the corresponding up-roof support pan; and
a seam cap covering all standing seam portions of adjacent pans,
wherein each of the support pans elevates a top surface of a respective photovoltaic module thereon to the first height above the roof surface.
2. The solar roof assembly of claim 1 , wherein the plurality of standing seam metal roof pans comprise one or more of non-photovoltaic pans, dummy pans, or roof pans.
3. The solar roof assembly of claim 1 , further comprising at least a first seam clip and a second seam clip attached to the photovoltaic modules, configured to mechanically couple with a first standing seam portion and a second standing seam portion, of the metal roof pans or the support pans.
4. The solar roof assembly of claim 3 , wherein the seam clips include tab portions configured to bend away from each other and to cover metal roof pan portions or support pan portions on either side of the seam clips.
5. The solar roof assembly of claim 4 , further comprising module rails bonded to the bottom surface of each of the photovoltaic modules, and pan rails bonded to the upper surface of each of the support pans.
6. The solar roof assembly of claim 1 , further comprising a heat storage material positioned between at least one pairing of the photovoltaic modules and support pans, wherein the heat storage material comprises at least one compartment having a phase change material can transition from a first phase to a second phase at a transition temperature.
7. The solar roof assembly of claim 6 , wherein the support pan further comprises stand-off sections forming one or more wells in which pouches of heat storage material are contained.
8. The solar roof assembly of claim 1 , further comprising at least one transition pan in each column of photovoltaic modules up-roof from the photovoltaic module closest to a roof ridge, the at least one up-roof transition pan comprising a pair of standing seams running a length of each side edge and a lapping portion extending under the corresponding down-roof support pan, wherein up-roof transition are configured to form openings to allow heat to escape from underneath the plurality of photovoltaic modules.
9. The solar roof assembly of claim 1 , wherein the transition pans in each column of photovoltaic modules down-roof from the last photovoltaic module further comprise down-roof transition pans proximate the roof eave, the down-roof transition pans configured to form openings to allow for precipitation drainage and airflow underneath the photovoltaic module.
10. The solar roof assembly of claim 1 , further comprising one or more non-photovoltaic modules within one or more of the columns photovoltaic modules, the one or more non-photovoltaic modules being configured to mimic the appearance of the photovoltaic modules.
11. The solar roof assembly of claim 1 , wherein the seam covers, the photovoltaic modules, the standing seam metal roof pans, and the transition pans form a surface with a generally uniform appearance.
12. The solar roof assembly of claim 1 , further comprising grounding clips configured to engage with and electrically ground one or more of the photovoltaic modules and the standing seam metal roof pans.
13. The solar roof assembly of claim 1 , wherein each photovoltaic module further comprises bypass diodes configured to bypass one or more solar cell sub-strings affected by a shade pattern of one or more of the standing seams.
14. The solar roof assembly of claim 1 , wherein the plurality of photovoltaic modules comprise crystalline-based solar cells.
15. A solar roof assembly for mounting on a roof surface comprising:
a plurality of standing seam metal roof pans configured for mounting in columns on the roof surface such that a top surface of each of the metal roof pans is elevated at a first height above the roof surface;
a plurality of support pans configured for mounting in columns on the roof surface adjacent to at least one column of metal roof pans, each support pan comprising a pair of standing seams running a length of each side edge thereof and having a plurality of ridges and valleys and between each side edge; and
a plurality of photovoltaic modules configured for mounting end to end in columns over the plurality of support pans on the plurality of ridges such that the plurality of photovoltaic modules covers the plurality of ridges and valleys of the underlying plurality of support pans, wherein each of the plurality of photovoltaic modules comprises an electrical connection that is disposed within a valley of an underlying support pan;
wherein each of the support pans elevates a top surface of a respective photovoltaic module thereon to the first height above the roof surface.
16. The solar roof assembly of claim 15 , wherein the plurality of metal roof pans comprise one or more of non-photovoltaic pans, dummy pans, or roof pans.
17. The solar roof assembly of claim 15 , further comprising at least a first seam clip and a second seam clip attached to the photovoltaic modules, configured to mechanically couple with a first seam portion and a second seam portion, of the metal roof pans or the support pans.
18. The solar roof assembly of claim 17 , wherein the seam clips include tab portions configured to bend away from each other and to cover metal roof pan portions or support pan portions on either side of the seam clips.
19. The solar roof assembly of claim 18 , further comprising module rails bonded to the bottom surface of each of the photovoltaic modules, and pan rails bonded to the upper surface of each of the support pans.
20. The solar roof assembly of claim 15 , wherein the plurality of photovoltaic modules comprise crystalline-based solar cells.
US15/246,486
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