ABSTRACT
Abstract
Building integrated photovoltaic (BIPV) systems provide for solar panel arrays that can be aesthetically pleasing to an observer. BIPV systems can be incorporated as part of roof surfaces as built into the structure of the roof, particularly as multi-region roofing modules that have photovoltaic elements embedded or incorporated into the body of the module, in distinct tiles-sized regions. Such multi-region photovoltaic modules can replicate the look of individual roofing tiles or shingles. Further, multi-region photovoltaic modules can include support structures between the distinct regions having a degree of flexibility, allowing for a more efficient installation process.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 62/515,434, titled âMULTI-REGION SOLAR ROOFING MODULESâ, filed on Jun. 5, 2017, the entirety of which is herein incorporated by reference. This application is also related to U.S. patent application Ser. No. 15/686,064 (Applicant Reference No.: P367-1NUS), titled âSIDELAP INTERCONNECT FOR SOLAR ROOFING MODULESâ, filed concurrently with the present application, the entirety of which is herein incorporated by reference
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 fossil fuel-based 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 over 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 of the roof, stands out as separate and distinct from the existing roof, both in height and material. This difference is therefore visible from the street level and even over large distances.
Further, the time and complexity of a solar array installation can be an obstacle to the adoption of solar technology. Many improvements have been made to streamline and improve the process of installing, mounting, and connecting individual solar panels, but there remains an opportunity for innovating and even better refining the systems and methods of installing different types of photovoltaic arrays.
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 shingles. The expected life of a modern-day solar system is 25 years or more, and the expected life of a composition shingle roof is also about 25-35 years, depending on the local climate and specific materials. At the time a customer is considering going solar, their existing roof may be several years, if not decades, into that lifespan. 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 does not 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 new roofs and existing roofs, and in particular, presenting a roof that appears to be a tile roof. Some aspects fit over an existing tile roof and/or other suitable roof surfaces (e.g., a metal roof, composite shingle, roof deck, underlayment or insulation layer). In particular, aspects of the invention are modular and flexible, which simplifies installation as well as replacement of individual photovoltaic modules of the system. In addition, some aspects cost less to make and install compared to conventional solar systems. Further, some arrangements of photovoltaic portions (and/or non-photovoltaic portions) of modules can generate a visual pattern and aesthetic that appears consistent with traditional roofing materials. 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.
In some embodiments, the present disclosure is directed toward a multi-region solar or photovoltaic module having a plurality of photovoltaic (PV) elements including: a module frame having lateral sides and longitudinal sides; a first PV region; a second PV region; a third PV region, the first PV region, second PV region, and third PV region being arranged linearly within the module frame, with a spacing zone between each of the PV regions; midlap structures on an underside of the PV module at locations corresponding to the spacing zones between the first PV region and the second PV region and the second PV region and the third PV region; and electrical power connections adapted to electrically connect the PV module with a circuit. In some implementations, the multi-region PV module can also include: track mounting structures coupled to the underside of each PV region of the PV module, the track mounting structures being in alignment along a single axis batten hooks configured to slidably latch within the track mounting structures and, mounted within the track mounting structures, arranged to mechanically secure the module to battens of an underlying roof structure; and offset structures secured to the underside of the PV module, adapted to mechanically couple the module to portions of an underlying roof structure.
In some aspects, the midlap structure of the multi-region PV module can further include: a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In other aspects, multi-region solar modules as disclosed herein can have PV region further include two solar cells, and where the solar cells of each PV region are electrically connected to each other. In further aspects, the multi-region PV module can further include: a fourth PV region, arranged linearly with and adjacent to the third PV region; and a midlap structure on the underside of the PV module at a location corresponding to the spacing zone between the third PV region and the fourth PV region
In some aspects, the batten hooks of the multi-region PV modules can be formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body. In other aspects, the track mounting structure of the multi-region PV modules can include a rail, and where the rail is configured to fit in the rail gap between the upper-fore ledge and the upper-aft ledge of the batten hook, such that the batten hook is configured to both slide along the rail and of secure the multi-region PV module on the underlying roof structure.
In other embodiments, the present disclosure is directed toward a building integrated photovoltaic (BIPV) roofing system including: a plurality of multi-region solar modules, where the multi-region solar modules each have an appearance that is similar to three or more individual roofing tiles; a plurality of PV roof tiles; and an underlying roof structure having battens, where courses of a roof envelope are formed by the plurality of multi-region solar modules mounted to the roof structure, where individual members of the plurality of photovoltaic roof tiles are arranged at ends of the courses of the roof envelope, and where the plurality of multi-region solar modules and the plurality of photovoltaic roof tiles are electrically connected to each other to form a solar array. In particular, the individual multi-region solar modules of the plurality of multi-region solar modules can include: a first PV region; a second PV region; a third PV region, the first PV region, second PV region, and third PV region being arranged linearly with each other, with a spacing zone between each of the PV regions; midlap structures on an underside of the PV module at locations corresponding to the spacing zones between the first PV region and the second PV region and the second PV region and the third PV region; and electrical power connections adapted to electrically connect the PV module with a circuit.
In some aspects, each midlap structure includes a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In other aspects, the PV modules also includes: track mounting structures coupled to the underside of each PV region of the PV module, the track mounting structures being in alignment along a single axis, batten hooks configured to slidably latch within the track mounting structures and, mounted within the track mounting structures, arranged to mechanically secure the module to the battens of the underlying roof structure; and offset structures secured to the underside of the PV module, adapted to mechanically couple the module to battens of the underlying roof structure. In further aspects, each of the batten hooks can be formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body. In particular, each track mounting structure can have a rail, where the rail is configured to fit in the rail gap between the upper-fore ledge and the upper-aft ledge of the batten hook, such that the batten hook is configured to both slide along the rail and to secure the multi-region PV module to a batten of on the underlying roof structure. Further, a BIPV roofing system can have individual members of the plurality of photovoltaic roof tiles are arranged in gaps between multi-region solar modules.
In further embodiments, the present disclosure is directed toward a method of assembling a multi-region solar module, including: providing a module with three photovoltaic regions in a linear arrangement, with gap sections between each photovoltaic region; setting two paired, solar cells within each photovoltaic region; electrically and structurally connecting paired solar cells in adjacent photovoltaic regions; attaching a track structure to the underside of each of the three photovoltaic regions, the track structures being in alignment along a single axis, each track structure having a rail; mounting a batten hook onto each rail, each batten hook being slidable along the length of each respective rail; and connecting power outputs to outermost solar cells set within the module. In some aspects, each gap section is about three centimeters wide. In other aspects, the method also includes attaching a midlap structure to the underside of the module at each gap section. In particular, the midlap structure can include: a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In further aspects, the method can also include securing offset structures to the underside of the PV module, the offset structures being adapted to mechanically couple the module to a batten of an underlying roof structure. In some as aspects, each of the batten hooks are formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body.
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 schematic of a partially-installed building integrated photovoltaic system having multi-region photovoltaic modules, in accordance with aspects of the disclosure.
FIG. 2B shows a schematic of a fully-installed building integrated photovoltaic system having multi-region photovoltaic modules, in accordance with aspects of the disclosure.
FIG. 2C is a mixed schematic and block diagram, showing connection of an exemplary multi-region photovoltaic module to a power grid output, in accordance with aspects of the disclosure.
FIG. 3A shows a top surface perspective view of an exemplary multi-region photovoltaic module, having three PV regions, in accordance with aspects of the disclosure.
FIG. 3B shows a bottom surface perspective view of an exemplary multi-region photovoltaic module, as shown in FIG. 3A , in accordance with aspects of the disclosure.
FIG. 3C shows a cross-sectional side view of an exemplary multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 4 shows a first exemplary track for mounting a batten hook to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 5 shows a second exemplary track for mounting a batten hook to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 6 shows an exemplary batten hook for mounting a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 7 shows an exemplary offset for mounting to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 8 is an illustration of a PV glass mounted to battens of a roof, having an offset, track, and batten hook, in accordance with aspects of the disclosure.
FIG. 9A shows an exemplary schematic of the underside of a multi-region flexible photovoltaic module having midlap structures, in accordance with aspects of the disclosure.
FIG. 9B shows an exemplary schematic rear side view of the multi-region flexible photovoltaic module shown in FIG. 9A , in accordance with aspects of the disclosure.
FIG. 9C shows a detail section of the exemplary schematic of the multi-region flexible photovoltaic module shown in FIG. 9A , in accordance with aspects of the disclosure.
FIG. 9D is a schematic illustration of the midlap structure and reversible configurations of the midlap structure, in accordance with aspects of the disclosure.
DETAILED DESCRIPTION
The present disclosure describes various embodiments of photovoltaic roofing systems and associated systems and methods, and in particular building integrated photovoltaic roofing systems. 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 photovoltaic (âPVâ) system is installed over a roof, and at the same time can provide an improved aesthetic for a PV roof syste
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 62/515,434, titled âMULTI-REGION SOLAR ROOFING MODULESâ, filed on Jun. 5, 2017, the entirety of which is herein incorporated by reference. This application is also related to U.S. patent application Ser. No. 15/686,064 (Applicant Reference No.: P367-1NUS), titled âSIDELAP INTERCONNECT FOR SOLAR ROOFING MODULESâ, filed concurrently with the present application, the entirety of which is herein incorporated by reference
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 fossil fuel-based 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 over 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 of the roof, stands out as separate and distinct from the existing roof, both in height and material. This difference is therefore visible from the street level and even over large distances.
Further, the time and complexity of a solar array installation can be an obstacle to the adoption of solar technology. Many improvements have been made to streamline and improve the process of installing, mounting, and connecting individual solar panels, but there remains an opportunity for innovating and even better refining the systems and methods of installing different types of photovoltaic arrays.
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 shingles. The expected life of a modern-day solar system is 25 years or more, and the expected life of a composition shingle roof is also about 25-35 years, depending on the local climate and specific materials. At the time a customer is considering going solar, their existing roof may be several years, if not decades, into that lifespan. 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 does not 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 new roofs and existing roofs, and in particular, presenting a roof that appears to be a tile roof. Some aspects fit over an existing tile roof and/or other suitable roof surfaces (e.g., a metal roof, composite shingle, roof deck, underlayment or insulation layer). In particular, aspects of the invention are modular and flexible, which simplifies installation as well as replacement of individual photovoltaic modules of the system. In addition, some aspects cost less to make and install compared to conventional solar systems. Further, some arrangements of photovoltaic portions (and/or non-photovoltaic portions) of modules can generate a visual pattern and aesthetic that appears consistent with traditional roofing materials. 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.
In some embodiments, the present disclosure is directed toward a multi-region solar or photovoltaic module having a plurality of photovoltaic (PV) elements including: a module frame having lateral sides and longitudinal sides; a first PV region; a second PV region; a third PV region, the first PV region, second PV region, and third PV region being arranged linearly within the module frame, with a spacing zone between each of the PV regions; midlap structures on an underside of the PV module at locations corresponding to the spacing zones between the first PV region and the second PV region and the second PV region and the third PV region; and electrical power connections adapted to electrically connect the PV module with a circuit. In some implementations, the multi-region PV module can also include: track mounting structures coupled to the underside of each PV region of the PV module, the track mounting structures being in alignment along a single axis batten hooks configured to slidably latch within the track mounting structures and, mounted within the track mounting structures, arranged to mechanically secure the module to battens of an underlying roof structure; and offset structures secured to the underside of the PV module, adapted to mechanically couple the module to portions of an underlying roof structure.
In some aspects, the midlap structure of the multi-region PV module can further include: a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In other aspects, multi-region solar modules as disclosed herein can have PV region further include two solar cells, and where the solar cells of each PV region are electrically connected to each other. In further aspects, the multi-region PV module can further include: a fourth PV region, arranged linearly with and adjacent to the third PV region; and a midlap structure on the underside of the PV module at a location corresponding to the spacing zone between the third PV region and the fourth PV region
In some aspects, the batten hooks of the multi-region PV modules can be formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body. In other aspects, the track mounting structure of the multi-region PV modules can include a rail, and where the rail is configured to fit in the rail gap between the upper-fore ledge and the upper-aft ledge of the batten hook, such that the batten hook is configured to both slide along the rail and of secure the multi-region PV module on the underlying roof structure.
In other embodiments, the present disclosure is directed toward a building integrated photovoltaic (BIPV) roofing system including: a plurality of multi-region solar modules, where the multi-region solar modules each have an appearance that is similar to three or more individual roofing tiles; a plurality of PV roof tiles; and an underlying roof structure having battens, where courses of a roof envelope are formed by the plurality of multi-region solar modules mounted to the roof structure, where individual members of the plurality of photovoltaic roof tiles are arranged at ends of the courses of the roof envelope, and where the plurality of multi-region solar modules and the plurality of photovoltaic roof tiles are electrically connected to each other to form a solar array. In particular, the individual multi-region solar modules of the plurality of multi-region solar modules can include: a first PV region; a second PV region; a third PV region, the first PV region, second PV region, and third PV region being arranged linearly with each other, with a spacing zone between each of the PV regions; midlap structures on an underside of the PV module at locations corresponding to the spacing zones between the first PV region and the second PV region and the second PV region and the third PV region; and electrical power connections adapted to electrically connect the PV module with a circuit.
In some aspects, each midlap structure includes a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In other aspects, the PV modules also includes: track mounting structures coupled to the underside of each PV region of the PV module, the track mounting structures being in alignment along a single axis, batten hooks configured to slidably latch within the track mounting structures and, mounted within the track mounting structures, arranged to mechanically secure the module to the battens of the underlying roof structure; and offset structures secured to the underside of the PV module, adapted to mechanically couple the module to battens of the underlying roof structure. In further aspects, each of the batten hooks can be formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body. In particular, each track mounting structure can have a rail, where the rail is configured to fit in the rail gap between the upper-fore ledge and the upper-aft ledge of the batten hook, such that the batten hook is configured to both slide along the rail and to secure the multi-region PV module to a batten of on the underlying roof structure. Further, a BIPV roofing system can have individual members of the plurality of photovoltaic roof tiles are arranged in gaps between multi-region solar modules.
In further embodiments, the present disclosure is directed toward a method of assembling a multi-region solar module, including: providing a module with three photovoltaic regions in a linear arrangement, with gap sections between each photovoltaic region; setting two paired, solar cells within each photovoltaic region; electrically and structurally connecting paired solar cells in adjacent photovoltaic regions; attaching a track structure to the underside of each of the three photovoltaic regions, the track structures being in alignment along a single axis, each track structure having a rail; mounting a batten hook onto each rail, each batten hook being slidable along the length of each respective rail; and connecting power outputs to outermost solar cells set within the module. In some aspects, each gap section is about three centimeters wide. In other aspects, the method also includes attaching a midlap structure to the underside of the module at each gap section. In particular, the midlap structure can include: a branched head; a wedge groove, running along a longitudinal axis of the midlap structure, configured to allow for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut. In further aspects, the method can also include securing offset structures to the underside of the PV module, the offset structures being adapted to mechanically couple the module to a batten of an underlying roof structure. In some as aspects, each of the batten hooks are formed to have: a hook body; an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body.
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 schematic of a partially-installed building integrated photovoltaic system having multi-region photovoltaic modules, in accordance with aspects of the disclosure.
FIG. 2B shows a schematic of a fully-installed building integrated photovoltaic system having multi-region photovoltaic modules, in accordance with aspects of the disclosure.
FIG. 2C is a mixed schematic and block diagram, showing connection of an exemplary multi-region photovoltaic module to a power grid output, in accordance with aspects of the disclosure.
FIG. 3A shows a top surface perspective view of an exemplary multi-region photovoltaic module, having three PV regions, in accordance with aspects of the disclosure.
FIG. 3B shows a bottom surface perspective view of an exemplary multi-region photovoltaic module, as shown in FIG. 3A , in accordance with aspects of the disclosure.
FIG. 3C shows a cross-sectional side view of an exemplary multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 4 shows a first exemplary track for mounting a batten hook to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 5 shows a second exemplary track for mounting a batten hook to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 6 shows an exemplary batten hook for mounting a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 7 shows an exemplary offset for mounting to the underside of a multi-region photovoltaic module, in accordance with aspects of the disclosure.
FIG. 8 is an illustration of a PV glass mounted to battens of a roof, having an offset, track, and batten hook, in accordance with aspects of the disclosure.
FIG. 9A shows an exemplary schematic of the underside of a multi-region flexible photovoltaic module having midlap structures, in accordance with aspects of the disclosure.
FIG. 9B shows an exemplary schematic rear side view of the multi-region flexible photovoltaic module shown in FIG. 9A , in accordance with aspects of the disclosure.
FIG. 9C shows a detail section of the exemplary schematic of the multi-region flexible photovoltaic module shown in FIG. 9A , in accordance with aspects of the disclosure.
FIG. 9D is a schematic illustration of the midlap structure and reversible configurations of the midlap structure, in accordance with aspects of the disclosure.
DETAILED DESCRIPTION
The present disclosure describes various embodiments of photovoltaic roofing systems and associated systems and methods, and in particular building integrated photovoltaic roofing systems. 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 photovoltaic (âPVâ) system is installed over a roof, and at the same time can provide an improved aesthetic for a PV roof system, and particularly for a building integrated photovoltaic (âBIPVâ) 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.
There is a constant need to improve upon the speed and efficiency of the installation process of PV systems, the visual aesthetic of an installed PV array, as well as the resilience and operational lifetime of PV systems and arrays. Innovations as considered by the present disclosure employ a multi-region PV module, generally spanning a width equal to three PV tiles (or shingles), that provides for a structural component that reduces installation time, is visually appealing, and includes non-rigid features that can improve upon the functional lifespan of each PV module. In particular, the flexibility of the multi-region PV modules disclosed herein allows for an ease of installation due to the slack and ability to adjust the edges of the PV modules as they are being arranged as part of an array, thereby improving upon the installation and assembly process which generally takes less time than assembly of a traditional, rigid PV structure. Further, the multi-region PV module having a form factor equivalent to having three PV tiles built into the module, but distinct from each other and spaced to appear as if they are physically separate, improves the installation time (installing âthree PV tilesâ at once as opposed to only one at a time) and reduces connector counts over individual roof tiles, while concurrently presenting a visually pleasing roof structure to an average observer. The flexibility of the multi-region PV modules can result in a structure that can better withstand environmental strains (e.g., wind shear, uplift, thermal expansion & contraction, etc.) and uneven roof surfaces due to the range of tilting freedom provided between paired solar cells or PV tiles of the multi-region PV module. Particularly, the multi-region PV modules of the present disclosure have a reinforced flexible region, such that the multi-region PV modules retain the advantages of flexibility for installation and operational lifespan, while controlling the degree of flexibility with reinforcing structures that further protect the spaces between individual regions of the multi-region PV modules from physical wear and stress. Further details of these advantages are discussed below.
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 ±10% relative to the given value.
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 or 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. Such building integrated photovoltaic structures can be alternatively referred to as building integrable photovoltaic (âBIPâ) or building applied photovoltaics (âBAPVâ). Components of a BIPV system used, in part, as part of the actual building envelope (e.g., roofing membrane), can provide a watertight or substantially watertight seal for the roof surface.
For the sake of distinguishing between structural elements of the present BIPV system, as used herein, the term âsolar cellâ refers to the structures of the system with solar energy collecting elements, the term âPV roof tileâ refers to such solar collecting elements as mounted or adhered to a single structural roof tile, and the term âPV moduleâ refers to a set of solar cells, PV regions of a PV module, and/or other PV units that are mechanically and electrically connected to each other as part of a single structural unit. In the context of a PV module, the term âPV regionâ refers to sections of the PV modules that can each appear similar to a PV roof tile, and are configured to support solar cells similarly to a single PV roof tile.
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 from a portion of. Up-roof generally refers to an orientation or portion that is relatively closer to the roof ridge while down-roof refers to an orientation or portion 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 (e.g., rotated 90° 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.
Generally, PV modules include 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 tiles. In some embodiments, PV modules can include layers of amorphous silicon or thin film variations of solar energy-collecting laminates, or thin-film solar materials directly applied as continuous sheets. Generally, PV elements as considered herein, which can include solar cells and laminates, have individual structures that can be used in combination to form larger solar arrays and/or building structures such as PV modules, as set forth below. Alternatively, thin-film PV modules, such as cadmium telluride, copper-indium-gallium-diselenide (âCIGSâ), 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 for any given installation can be selected both for solar energy collecting functionality and for aesthetic qualities, as related to the present disclosure.
The present disclosure is directed toward a particular implementation of a multi-region PV module and further toward the assembling of PV arrays on a roof with such modules. In many embodiments, such PV arrays are configured as BIPV roofing systems. In several aspects, the present PV module is formed of three PV regions, each PV region having solar cells mounted therein. The PV regions are generally configured linearly, giving the PV module an elongate shape. It is understood that PV modules as considered herein are not limited to three-PV region embodiments, but rather can also include modules having two, four, or more than four PV regions. Moreover, it should be appreciated that PV or BIPV arrays formed with such PV modules can also include single PV roof tiles deployed in combination with the PV modules, where appropriate for specific spacing, gaps, or edges of the overall PV array. Further, the junction or interface between each of the PV regions of a PV module is constructed to allow for flexibility and a degree of bending between adjacent PV regions, which provides for advantages in assembly and resilience over the lifetime of a PV array installation using such PV modules. In some aspects, the flexibility of PV modules at junctions between PV regions allows the PV modules to follow the contour of an underlying roof surface (which may not be perfectly flat), thereby forming a better fitting and more securely sealed roof envelope. As with standard structural roof tiles, for BIPV implementations, these construction elements are used to form the envelope of a roof, often as part of a re-roofing job replacing an existing roof, for example an original roof that has reached its end-of-life
The flexible, multi-region PV module according to the various embodiments of the invention provides for improved ease of construction, as assembling (or disassembling) a PV array with a structural unit three tiles wide is often quicker than assembling a similar PV array one tile at a time. In some alternative embodiments, the modules can have two tiles, four tiles, five tiles, or more than five tiles (all connected in similar fashion as the embodiments described below, and all with similar structural and electrical connection considerations). A BIPV roofing system can use three-tile-width flexible PV modules along with single PV tile components, where the single PV tiles can be placed on the roof at the edges or in locations where a three-tile-width flexible PV module may not fit due to size or arrangement on the underlying roof. The underlying roof structure, in combination with the flexible PV modules and single PV tile components, can form a roof envelope for a BIPV roofing system.
PV elements that are distributed over all roof surfaces can have a visual uniformity that is neat, generally continuous, and elegant. Adjusting the density of PV elements on a roof surface changes both the appearance of the overall roof and the energy production of the solar array on the roof, typically measured in kilowatts (kW) or kilowatt-hours (kWh). Accordingly, the density of PV elements can be adjusted to achieve a desired kilowatt-hour production goal while maintaining an even distribution of the PV elements with a consistent visual aesthetic. In some aspects, PV elements can be distributed on the surface of a roof in a randomized, semi-randomized, or non-regular pattern to achieve the aesthetically pleasing neat, generally continuous, and elegant appearance.
Referring now to the drawing figures, in contrast with embodiments of the present disclosure, FIG. 1A shows an exemplary prior art PV array installed on roof 100 . The exemplary PV array of FIG. 1A includes six solar panels 101 or modules which (though not shown in detail) 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 Palo Alto, Calif.-based Tesla, Inc. (formerly SolarCity).
FIG. 1B shows one type of conventional solar panel 101 in more detail. Solar panel 101 includes PV laminate 102 , which with 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 in FIG. 1B , 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 Tesla, Inc., of Palo Alto, 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 for some would-be customers and have material usage inefficiencies. First, conventional PV systems, such as that shown in FIG. 1A , are typically installed over an existing roof, and not as part of the 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 unappealing, having a choppy, discontinuous, and/or extraneous aesthetic. 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. Alternatively, thin-film solar materials are deposited in continuous sheets and are typically black. The metal frame portion can be painted black to help it blend in with the roof surface, or it can simply be raw aluminum in either case, the contrast between the look of the portion of the roof that is covered with solar panels and the remainder of the roof is generally quite dramatic. This contrast can be particularly jarring when a conventional PV array is mounted on a tile roof because the tile roof will differ not only in color and texture, but also in contour. As a result, roofs that are partially covered with solar panels that can be seen from very far distances due to the relative differences in reflectivity, elevation, height, and/or color between these two very different surfaces.
Multi-Region Solar Module Building Integrated Photovoltaic Arrays
As discussed herein, solar cells that are integrated as part of PV regions, which in turn make up flexible PV modules, can be connected together as and laid down so that they make up the main surface of a roof, and in particular, a solar roof that has the appearance and aesthetic of a uniform tile roof. By having the PV regions individually contain solar cells, because the PV regions form part of the roof through the PV modules, advantages can be obtained in comparison to traditional âover-roofâ arrays that are slightly elevated from the surface of a roof. For example, roof surfaces formed of PV modules that are directly built onto the framing structure of a roof can be lighter than over-roof installations, at least because the built-in BIPV solar array does not require a second structure above an existing roof. Further, a roof that is being replaced in a re-roofing installation can replace older or traditional roof tiles with PV modules (and optionally, some PV roof tiles) that may reduce the amount of materials needed for a re-roofing installation. Also, electrical connections, junction boxes, and wiring can be generally housed underneath PV roof tiles or PV modules of such BIPV assemblies, protecting such components from precipitation, wind, and excess heat, and further hiding such components from an observer so as to make the overall BIPV system visually attractive or uniform.
Designers of BIPV solar arrays generally aspire to provide for an advantage over traditional on-roof PV systems by having a less drastic topological difference, thereby reducing visually noticeable differences in height on regions of the roof. However, previous implementations of BIPV systems do not necessarily provide for further visual qualities or designs that effectively minimize noticeable differences between solar materials and standard roofing materials that form the overall PV system in the same manner as the presently disclosed system. In fact, they are typically quite different. Embodiments of the present disclosure provide for a BIPV system, with solar cells contained inside individual tile-like regions within a PV module and electrically connected in strings or other circuits, which is visually appealing at least in that the solar elements and roofing materials are combined and assembled in a layout that minimizes or camouflages the differences between the solar components and the standard construction materials.
A part of the advantage of the present system is that the installation process implements much of the straightforward nature of laying a tile roof, but accounts for PV elements on flexible, multi-region modules (within individual PV regions) and making electrical connections between the solar cells on PV modules, and thus requires only minimal additional work and training. In addition to being faster to install than individual tile modules, having built-in flexibility between individual tile portions in an N-tile portion PV module allows for variations in roof planarity to be compensated for. A rigid PV module composed of N interconnected tile portions would propagate any such variations through the installation and result in a visually uneven installation. A BIPV tile roof as considered herein is mounted in generally the same manner as a standard tile roof, for example: securing and sealing underlayment or other sheathing to frame elements of the roof, adding battens as needed to portions of the roof frame, installing modules and/or tiles to form the main surface of the roof, working around obstacles (e.g., chimneys, skylights, vents, etc.) as needed, and installing ridge and edge tiles in combination with flashing or other trim structures of the roof. Each PV module further includes respective V+ and Vâ power outputs for connecting to other electrical component of a solar roof. Cell to cell connections are protected internally within the module. In the present system, the PV modules must have a structural integrity capable of accommodating and supporting PV elements within the tile-like regions, in terms of weight, heat generated, ability to connect electronics, and retaining strength to serve as a portion of a roof surface. The modules and tiles used can be of standard sizes as known in the industry. Further, modules and tiles used for systems considered herein can have a wide range of colors to match or blend with PV elements, including, but not limited to, blue, blacks, grays, browns, and natural clay colorations. It is understood that these same advantages can be applied to shingle roofs, with a corresponding PV module shaped to match shingles instead of tile.
In many aspects, embodiments of the present disclosure are directed to multi-region PV modules that have three regions that approximate or are functionally similar to three separate PV tile areas. The sections between each individual region have a flexible structure, to allow for bending of the PV module during installation in or removal from a PV array. As part of a PV array, for example on a roof, rows and courses of such PV modules can look like rows of separate PV roof tiles, and indeed, such an aesthetic is desirable. For flexible multi-region PV modules considered herein having three PV regions, such PV modules can alternatively be referred to as âthree-tileâ modules, âseries tripleâ modules, or the like.
FIG. 2A shows a schematic of a partially-installed exemplary BIPV system 200 having multi-region PV modules 204 , installed in a plane as part of roof surface 202 . FIG. 2B shows a schematic of a fully-installed BIPV system 200 having multi-region PV modules 204 . BIPV system 200 is arranged from PV modules 204 in horizontal rows or courses along the length of roof surface 202 . Each PV module 204 in exemplary BIPV system 200 includes three PV regions 205 , where each PV region 205 includes two solar cells 206 . Each PV module 204 has an appearance that simulates or replicates the appearance of three individual adjacent PV roof tiles. The separation between PV regions 205 on PV modules 204 and between adjacent modules can mimic the width and appearance of seams or breaks that would exist between adjacent conventional roof tiles. In other words, inter-tile gaps between individual PV regions 205 in PV module 204 may be set to mimic the distance between adjacent PV modules 204 so that the array appears to be composed entirely of individual roof tiles (PV or non-PV roof tiles). Roof surface 202 further includes ridge flashing 208 at the top of roof surface 202 and eave flashing 210 at the bottom of roof surface 202 . Flashing 208 may conceal wires and roof/batten connections of the top course of PV modules 204 , and also provide for ventilation under the array.
In some embodiments, vertically adjacent courses of PV modules 204 can be offset from each other by half the width of a tile area such that the apparent seams or breaks between two vertically adjacent rows of PV modules 204 do not form the appearance of a single seam or break along the full slope of roof surface 202 as is commonly done with conventional non-solar roof tiles. Rather, the vertically adjacent rows of PV modules 204 can form an alternating pattern of seams, where breaks between adjacent PV modules 204 are relatively equidistant from each other. In alternative embodiments, vertically adjacent courses of PV modules 204 can be offset from each other by one-third the width of a tile area, again such that the apparent seams or breaks between two vertically adjacent rows of PV modules 204 do not form the appearance of a single seam or break along the full slope of roof surface 202 as is commonly done with conventional non-solar roof tiles.
Roof surface 202 can further include other roofing elements, such as standard (traditional, non-PV) roof tiles 212 or individual PV roof tiles 214 , which can be used and placed within the overall roof surface 202 . In some aspects, individual PV roof tiles 214 can be used to fill gaps between PV modules 204 , to finish off ends of rows or courses of PV elements close to the edge of roof surface 202 , or to otherwise accommodate and connect portions of a PV array on the roof surface where PV modules 204 do not fit or would not be ideal for BIPV system 200 . In other aspects, standard roof tiles 212 can be used to finish off ends of rows or courses of PV elements close to the edge of roof surface 202 , to cover spaces between PV elements of the roof surface and flashing or trim components of roof surface 202 (e.g., the most down-roof course of tiles), or for sections of roof surface 202 where the tile needs to be cut to accommodate other roof structures (e.g., vents, chimneys, etc.) and thus cutting PV roof tile 214 or PV module 204 would be an inefficient use of materials. In various embodiments, to speed installation, standard roof tiles 212 may also be formed into N-tile modules, where N is an integer greater than 1.
As shown in FIG. 2A , BIPV system 200 can be installed to form a roof envelope as part of roof surface 202 , where PV modules 204 (and optional standard roof tiles 212 and/or PV roof tiles 214 ) are mounted to battens 216 . PV modules 204 (and other roof tiling components) can be mechanically mounted to battens 216 by various hardware connections discussed herein. However, cross-battens 218 (alternatively referred to as âcounter-battensâ) that form part of the roof structure can be positioned at various locations between battens 216 , creating physical conflicts with mounting apparatuses that would otherwise mount PV modules 204 to battens 216 . Accordingly, as provided herein, mounting structures having a variable or adjustable location on the underside of PV modules 204 allows for secure mounting of PV modules to battens 216 , regardless of the regular or irregular placement of cross-battens 218 relative to battens 216 .
Several different types of PV modules 204 (and/or PV roof tiles 214 ) can be used with roof surface 202 as considered herein. PV modules 204 (and/or PV roof tiles 214 ) can be made of materials including, but not limited to: stone, quartz, slate, granite, cera
CLAIMS
Claims ( 11 )
The invention claimed is:
1. A multi-region photovoltaic (PV) module comprising:
a first PV region;
a second PV region;
a third PV region, the first PV region, second PV region, and third PV region being arranged linearly within the module, with a spacing zone between each of the PV regions;
a module frame comprising first, second and third frame portions for supporting the first, second and third PV regions, respectively, each module frame portion having lateral sides and longitudinal sides,
wherein the module frame further comprises bendable discrete midlap structures disposed on an underside of the PV module between (i) the first PV region and the second PV region and (ii) the second PV region and the third PV region that couple the respective frame portions, wherein each midlap structure comprises a wedge groove running along a longitudinal axis of the midlap structure that allows for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and
electrical power connections adapted to electrically connect the PV module with a circuit.
2. The multi-region PV module of claim 1 , wherein each midlap structure further comprises:
a branched head;
and
a restraint strap; configured to allow for the midlap structure to bend outward until the restraint strap is taut.
3. The multi-region PV module of claim 2 , wherein the branched head comprises a plurality of branches extending outwardly at an angle from the midlap structure.
4. The multi-region PV module of claim 1 , wherein each PV region further comprises two solar cells, and wherein the solar cells of each PV region are electrically connected to each other.
5. The multi-region PV module of claim 1 further comprising:
track mounting structures coupled to the underside of each PV region of the PV module, the track mounting structures being in alignment along a single axis
batten hooks configured to slidably latch within the track mounting structures and, mounted within the track mounting structures, arranged to mechanically secure the module to battens of an underlying roof structure; and
offset structures secured to the underside of the PV module, adapted to mechanically couple the module to portions of the underlying roof structure.
6. The multi-region PV module of claim 5 , wherein each of the batten hooks are formed to have:
a hook body;
an upper-fore ledge and an upper-aft ledge positioned opposite of each other at the top of the hook body and forming a rail gap therebetween; and
a lower ledge positioned at the bottom of the hook body, extending laterally from the hook body.
7. The multi-region PV module of claim 5 , further comprising a plurality of gaskets coupled to the underside of the PV region of the PV module, arranged to form a watertight seal between the module and the underlying roof structure.
8. The multi-region PV module of claim 1 , wherein the first frame portion is separated from the second frame portion by one of the spacing zones.
9. The multi-region PV module of claim 1 , further comprising:
a fourth PV region, arranged linearly with and adjacent to the third PV region; and
a midlap structure on the underside of the PV module at a location corresponding to the spacing zone between (iii) the third PV region and the fourth PV region.
10. The multi-region PV module of claim 1 , wherein the midlap structure further comprises a stiffening element which spans a part of the width of the midlap structure, wherein the stiffening element is configured to further control the degree the midlap structure bends.
11. A multi-region photovoltaic (PV) module comprising:
a first PV region;
a second PV region;
a third PV region, the first PV region, second PV region, and third PV region being arranged linearly within the module, with a spacing zone between each of the PV regions;
a module frame comprising bendable discrete midlap structures disposed on an underside of the PV module between (i) the first PV region and the second PV region and (ii) the second PV region and the third PV region that couple the respective PV regions together, wherein each midlap structure comprises a wedge groove running along a longitudinal axis of the midlap structure that allows for the midlap structure to bend inward until opposing walls of the wedge groove abut each other; and
electrical power connections adapted to electrically connect the PV module with a circuit.
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