PV tile mounting system

Patent metadata

Field	Value
Publication number	US-10505495-B2
Application number	US-201815909880-A
Country	US
Kind code	B2
Filing date	Mar 1, 2018
Priority date	Mar 1, 2018
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

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 photovoltaic tiles. Each photovoltaic module may comprise an inner sheet, an outer sheet, photovoltaic cells, and a bracket. When installed the bracket may be covered by up-roof tiles, giving the overall roof a uniform appearance.

First claim

The invention claimed is:

1. A photovoltaic tile comprising:
a light transmissive outer sheet;
an inner sheet;
at least one photovoltaic cell, encapsulated between the light transmissive outer sheet and inner sheet; and
a bracket at a first edge of the photovoltaic tile comprising a first plate positioned between the light transmissive outer sheet and inner sheet, and a mounting portion configured to secure the photovoltaic tile to a roof structure;
wherein the bracket further comprises:
a second plate; and
a third plate,
wherein the first plate and the second plate define a first channel and the light transmissive outer sheet is positioned within the first channel, and
wherein the first plate and the third plate define a second channel and the inner sheet is positioned within the second channel.

2. The photovoltaic tile of claim 1 , wherein the first plate defines a first plurality of holes, wherein the light transmissive outer sheet and the inner sheet are adhered to an encapsulation material, and wherein the encapsulation material is present within the plurality of holes.

3. The photovoltaic tile of claim 2 , wherein the third plate defines a second plurality of holes corresponding to the first plurality of holes of the first plate.

4. The photovoltaic tile of claim 1 , further comprising:
electrical wiring, wherein the electrical wiring is electrically connected to the at least one photovoltaic cell and is positioned between the light transmissive outer sheet and the inner sheet,
wherein the bracket comprises an electrical connector configured to connect the photovoltaic tile to an electrical distribution system,
wherein the bracket defines a gap between a first portion of the first plate and a second portion of the first plate, and
wherein the wiring extends through the gap and connects to the electrical connector.

5. The photovoltaic tile of claim 1 , wherein the first edge extends in a first direction,
wherein the light transmissive outer sheet and the inner sheet are offset from each other in the first direction so that a portion of the light transmissive outer sheet along a second edge, perpendicular to the first edge, is not overlapped by the inner sheet and forms an upper lap joint portion, and a portion of the inner sheet along a third edge, opposite the second edge, is not overlapped by the light transmissive outer sheet and forms a lower lap joint portion, and
wherein the upper lap joint portion and the lower lap joint portions are configured to form lap joints with substantially identical photovoltaic tiles when installed as part of a roof assembly.

6. The photovoltaic tile of claim 1 , further comprising a sealing strip attached to an outer surface of the light transmissive outer sheet, wherein the sealing strip is configured to contact and form a seal with an outer surface of an inner sheet of a substantially identical photovoltaic tile when installed as part of a roof assembly.

7. The photovoltaic tile of claim 1 , wherein the inner sheet and the light transmissive outer sheet have substantially identical thicknesses and are composed of substantially identical materials.

8. The photovoltaic tile of claim 1 , wherein the mounting portion comprises batten hooks configured to engage battens secured to the roof structure.

9. The photovoltaic tile of claim 1 , further comprising:
a second edge opposite the first edge; and
a third edge and a fourth edge, each perpendicular to the first edge and the second edge,
wherein the second edge, the third edge and the fourth edge are frameless.

10. A building integrated photovoltaic system, comprising:
a plurality of photovoltaic tiles, comprising a first photovoltaic tile and a second photovoltaic tile, attached to an underlying roof structure, wherein each of the plurality of photovoltaic tiles comprise:
a light transmissive outer sheet;
an inner sheet;
at least one photovoltaic cell, encapsulated between the light transmissive outer sheet and inner sheet; and
a bracket at a first edge of the photovoltaic tile comprising a first plate positioned between the light transmissive outer sheet and inner sheet, and a mounting portion configured to secure the photovoltaic tile to the underlying roof structure, wherein the bracket of the first photovoltaic tile is attached to the underlying roof structure at a first position, and
wherein the bracket of the second photovoltaic tile is attached to the underlying roof structure at a second position up-roof and adjacent to the first position so that at least a first portion of the bracket of the first photovoltaic tile is covered by the inner sheet of the second photovoltaic tile;
wherein for each of the plurality of photovoltaic tiles the light transmissive outer sheet and the inner sheet are offset from each other in the first direction so that a portion of the light transmissive outer sheet along a second edge, perpendicular to the first edge, is not overlapped by the inner sheet and forms an upper lap joint portion, and a portion of the inner sheet along a third edge, opposite the second edge, is not overlapped by the light transmissive outer sheet and forms a lower lap joint portion,
wherein the plurality of photovoltaic tiles further comprise a third photovoltaic tile,
wherein the bracket of the third photovoltaic tile is attached to the underlying roof structure at a third position side-roof adjacent to the second position so that at least a second portion of the bracket of the first photovoltaic tile is covered by the inner sheet of the third photovoltaic tile, and
wherein the upper lap joint portion of the third photovoltaic tile overlaps the lower lap joint portion of the second photovoltaic tile to form a lap joint.

11. The system of claim 10 , wherein the first photovoltaic tile comprises a sealing strip attached to an outer surface of the light transmissive outer sheet, and
wherein the respective inner sheets of the second photovoltaic tile and the third photovoltaic tile contact the sealing strip and form a seal.

12. The system of claim 10 , further comprising:
a trunk line;
a first wire harness comprising a first connector and a second connector, wherein the first wire harness is electrically connected to the trunk line; and
a second wire harness comprising a third connector wherein the second wire harness is electrically connected to the trunk line,
wherein the bracket of the first photovoltaic module comprises a first electrical connector electrically connected to the at least one photovoltaic cell of the first photovoltaic tile, and the first connector is electrically connected to the first electrical connector;
wherein the bracket of the second photovoltaic module comprises a second electrical connector electrically connected to the at least one photovoltaic cell of the second photovoltaic tile, and the second connector is electrically connected to the second electrical connector; and
wherein the bracket of the third photovoltaic module comprises a third electrical connector electrically connected to the at least one photovoltaic cell of the third photovoltaic tile, and the third connector is electrically connected to the third electrical connector.

Assignees

• Tesla Inc

Inventors

• Almy Charles Bernardo
• Karkheck Johann Fritz

Classifications

• H02S20/25 Primary

  Roof tile elements · CPC title

• H02S40/36

  characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection · CPC title

• H01B7/0045

  Cable-harnesses · CPC title

• E04D12/006

  Batten-supporting means · CPC title

• H02S40/34

  comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes · CPC title