Multi-region solar roofing modules

Patent metadata

Field	Value
Publication number	US-11258398-B2
Application number	US-201715686109-A
Country	US
Kind code	B2
Filing date	Aug 24, 2017
Priority date	Jun 5, 2017
Publication date	Feb 22, 2022
Grant date	Feb 22, 2022

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.

First claim

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.

Assignees

• Tesla Inc

Inventors

• Almy Charles
• Pesce Kathryn Austin
• Molina David

Classifications

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• Y02B10/10

  Photovoltaic [PV] · CPC title

• H10F19/80

  Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells · CPC title

• H10F19/904

  characterised by the shapes of the structures · CPC title

• H10F77/955

  for photovoltaic devices · CPC title