Roof integrated photovoltaic system

Patent metadata

Field	Value
Publication number	US-11398795-B2
Application number	US-202017123831-A
Country	US
Kind code	B2
Filing date	Dec 16, 2020
Priority date	Dec 20, 2019
Publication date	Jul 26, 2022
Grant date	Jul 26, 2022

Abstract

A roof integrated photovoltaic system includes a starter bar having a foot base and configured to be installed to a roof deck, a plurality of water shedding layers, and a photovoltaic module. One of the plurality of water shedding layers is configured to be installed over the foot base of the starter bar, and one of another of which is configured to overlap and be installed over the one of the plurality of water shedding layers. The system further includes a foot module configured to be attached to an upper portion of the photovoltaic module. A lower portion of the photovoltaic module is configured to align with the foot base of the starter bar, and the foot module is configured to be affixed on a last overlapping layer of the plurality of water shedding layers to the roof deck.

First claim

What is claimed is:

1. A method, comprising:
installing a starter bar to a roof deck,
wherein the starter bar includes first and second foot bases;
wherein the first and second foot bases extend along a length of the starter bar;

installing one of a first plurality of water shedding layers over the first and second foot bases of the starter bar;
overlapping at least one of another of the first plurality of water shedding layers over the one of the first plurality of water shedding layers;
installing first and second foot modules on at least one of the first plurality of water shedding layers;
overlapping one layer of a second plurality of water shedding layers over both
the first and second foot modules, and
at least one of the first plurality of water shedding layers;

installing a first photovoltaic module, the first photovoltaic module having
a top surface,
a bottom surface,
an upper portion,
a lower portion, and
a pair of side portions, each of which extends from the upper portion to the lower portion,
wherein the upper portion of the first photovoltaic module attaches to the first and second foot modules,
wherein the lower portion of the first photovoltaic module overlaps the first and second foot bases of the starter bar and connects to the starter bar,
wherein the starter bar extends along the entire length of the lower portion of the photovoltaic module.

2. The method of claim 1 , wherein the last overlapping layer of the at least one of another of the first plurality of water shedding layers includes a second water shedding layer.

3. The method of claim 2 , further comprising the step of affixing the one of the first plurality of water shedding layers and the second water shedding layer to the roof deck.

4. The method of claim 1 , wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, and a third water shedding layer overlapping the second water shedding layer, the third water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.

5. The method of claim 4 , further comprising the step of affixing the one of the first plurality of water shedding layers and the second and third water shedding layers to the roof deck.

6. The method of claim 4 , wherein the second water shedding layer includes a first edge that is positioned offset from the first foot base of the starter bar, and the third water shedding layer includes a first edge that is positioned offset from the first edge of the second water shedding layer.

7. The method of claim 1 , wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, a third water shedding layer overlapping the second water shedding layer, and a fourth water shedding layer overlapping the third water shedding layer, the fourth water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.

8. The method of claim 7 , further comprising the step of affixing the one of the first plurality of water shedding layers and the second, third and fourth water shedding layers to the roof deck.

9. The method of claim 7 , wherein the second water shedding layer includes a first edge that is positioned offset from the first foot base of the starter bar, the third water shedding layer includes a first edge that is positioned offset from the first edge of the second water shedding layer, and the fourth water shedding layer includes a first edge that is positioned offset from the first edge of the third water shedding layer.

10. The method of claim 7 , further comprising the step of:
installing third and fourth foot modules; and
installing at least one second photovoltaic module, the at least one second photovoltaic module having
a top surface,
a bottom surface,
an upper portion,
a lower portion, and
a pair of side portions, each of which extends from the upper portion of the at least one second photovoltaic module to the lower portion of the second photovoltaic module, and
wherein the upper portion of the second photovoltaic module attaches to the third and fourth foot modules,
wherein the lower portion of the second photovoltaic module is aligned with the first and second foot modules, and
wherein third and fourth foot modules are affixed on a last overlapping layer of the second plurality of water shedding layers to the roof deck.

11. A system, comprising:
a starter bar installed on a roof deck,
wherein the starter bar includes first and second foot bases;
wherein the first and second foot bases extend along a length of the starter bar;

a first plurality of water shedding layers, one of which installed over the first and second foot bases of the starter bar, and at least one of another of which installed over the one of the first plurality of water shedding layers;
first and second foot modules installed on at least one of the first plurality of water shedding layers;
a second plurality of water shedding layers, one of which installed over both
the first and second foot modules, and
at least one of the first plurality of water shedding layers;

a first photovoltaic module having
a top surface,
a bottom surface,
an upper portion,
a lower portion, and
a pair of side portions, each of which extends from the upper portion to the lower portion; and
wherein the upper portion of the first photovoltaic module attached to the first and second foot modules,
wherein the lower portion of the first photovoltaic module overlapping the first and second foot base of the starter bar and connecting to the starter bar, and
wherein the starter bar extends along the entire length of the lower portion of the photovoltaic module.

12. The system of claim 11 , wherein the last overlapping layer of the at least one of another of the first plurality of water shedding layers includes a second water shedding layer.

13. The system of claim 11 , wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, and a third water shedding layer overlapping the second water shedding layer, the third water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.

14. The system of claim 11 , wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, a third water shedding layer overlapping the second water shedding layer, and a fourth water shedding layer overlapping the third water shedding layer, the fourth water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.

15. The system of claim 11 , further comprising:
a second photovoltaic module,
the second photovoltaic module having
a top surface,
a bottom surface,
an upper portion,
a lower portion, and
a pair of side portions, each of which extends from the upper portion of the second photovoltaic module to the lower portion of the second photovoltaic module; and

third and fourth foot modules attached to the upper portion of the at least one second photovoltaic module,
wherein the lower portion o

Assignees

• GAF Energy LLC

Inventors

• Atchley Brian Edward
• Clemente Peter
• Dzoba Nazar
• Folk Anthony
• Ochsenrieter Amy
• East Daniel

Classifications

• E04D5/148

  fastening by gluing · CPC title

• E04D5/144

  Mechanical fastening means · CPC title

• E04D1/12

  Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface (E04D1/28, E04D1/30 take precedence) · CPC title

• F24S2020/12

  Coplanar arrangements with frame overlapping portions · CPC title

• E04D3/38

  Devices for sealing spaces or joints between roof-covering elements (E04D3/36 takes precedence; sealing joints not restricted to roof-covering elements E04B1/68) · CPC title