Photovoltaic shingles and methods of installing same

Patent metadata

Field	Value
Publication number	US-11404997-B2
Application number	US-202217668636-A
Country	US
Kind code	B2
Filing date	Feb 10, 2022
Priority date	Jun 4, 2020
Publication date	Aug 2, 2022
Grant date	Aug 2, 2022

Abstract

A system includes a plurality of photovoltaic shingles installed on a roof deck, each of the shingles having a first layer including a head lap portion, and a second layer including at least one solar cell. A first photovoltaic shingle overlays at least a part of the head lap portion of a second photovoltaic shingle. The system includes at least one wireway installed proximate to a first end of at least the first photovoltaic shingle.

First claim

What is claimed is:

1. A method, comprising the steps of:
obtaining a plurality of photovoltaic shingles,
wherein each of the photovoltaic shingles includes
a first end,
a second end opposite the first end,
a first edge extending from the first end to the second end, and
a second edge opposite the first edge and extending from the first end to the second end,
a head lap portion,
wherein the head lap portion extends from the first end to the second end and from the first edge to a location between the first edge and the second edge,

a step flap located at the first end,
wherein the step flap includes a length extending from the first end to a location between the first end and the second end;

installing at least three of the photovoltaic shingles on a slope of a roof deck,
wherein a first photovoltaic shingle of the at least three of the photovoltaic shingles is horizontally adjacent to a second photovoltaic shingle of the at least three of the photovoltaic shingles,
wherein a third photovoltaic shingle of the at least three of the photovoltaic shingles is vertically adjacent to the first photovoltaic shingle,
wherein the first ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the second ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the first photovoltaic shingle overlays at least a part of the head lap portion of the third photovoltaic shingle,
wherein the second photovoltaic shingle overlays at least a part of the step flap of the first photovoltaic shingle; and

installing at least one wireway proximate to the first end of at least the first end of the first photovoltaic shingle.

2. The method of claim 1 , wherein the at least one wireway is installed between the first end of the first photovoltaic shingle and the second end of the second photovoltaic shingle.

3. The method of claim 1 , wherein the at least one wireway includes a lid, and wherein the lid is removably attached to the at least one wireway.

4. The method of claim 3 , wherein the at least one wireway includes at least one slot and the lid includes at least one rail, and wherein the at least one slot removably receives the at least one rail.

5. The method of claim 1 , wherein the at least one wireway includes an inner surface having at least one support member extending outwardly therefrom.

6. The method of claim 1 , wherein the at least one wireway overlays a corresponding one of the step flaps.

7. The method of claim 1 , wherein the at least one wireway has a height of 1 mm to 20 mm.

8. The method of claim 1 , wherein the at least one wireway includes a single wireway installed proximate to the first end of each of the first and third photovoltaic shingles.

9. The method of claim 1 , wherein the at least one wireway is moisture resistant.

10. The method of claim 1 , further comprising the step of installing an end cap at an end of the at least one wireway, wherein the end cap includes a plurality of vents.

11. A method, comprising the steps of:
obtaining a plurality of photovoltaic shingles,
wherein each of the photovoltaic shingles includes
a first end,
a second end opposite the first end,
a first edge extending from the first end to the second end, and
a second edge opposite the first edge and extending from the first end to the second end,
a step flap located at the first end,
wherein the step flap includes a length extending from the first end to a location between the first end and the second end;

installing at least three of the photovoltaic shingles on a slope of a roof deck,
wherein a first photovoltaic shingle of the at least three of the photovoltaic shingles is horizontally adjacent to a second photovoltaic shingle of the at least three of the photovoltaic shingles,
wherein a third photovoltaic shingle of the at least three of the photovoltaic shingles is vertically adjacent to the first photovoltaic shingle,
wherein the first ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the second ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the first photovoltaic shingle overlays at least a part of the third photovoltaic shingle,
wherein the second photovoltaic shingle overlays at least a part of the step flap of the first photovoltaic shingle; and

installing at least one wireway proximate to the first end of at least the first end of the first photovoltaic shingle.

12. The method of claim 11 , wherein the at least one wireway is installed between the first end of the first photovoltaic shingle and the second end of the second photovoltaic shingle.

13. The method of claim 11 , wherein the at least one wireway includes a lid, and wherein the lid is removably attached to the at least one wireway.

14. The method of claim 13 , wherein the at least one wireway includes at least one slot and the lid includes at least one rail, and wherein the at least one slot removably receives the at least one rail.

15. The method of claim 11 , wherein the at least one wireway includes an inner surface having at least one support member extending outwardly therefrom.

16. The method of claim 11 , wherein the at least one wireway overlays a corresponding one of the step flaps.

17. The method of claim 11 , wherein the at least one wireway has a height of 1 mm to 20 mm.

18. The method of claim 11 , wherein the at least one wireway includes a single wireway installed proximate to the first end of each of the first and third photovoltaic shingles.

19. The method of claim 11 , wherein the at least one wireway is moisture resistant.

20. The method of claim 11 , further comprising the step of installing an end cap at an end of the at least one wireway, wherein the end cap includes a plurality of vents.

21. A method, comprising the steps of:
obtaining a plurality of photovoltaic shingles,
wherein each of the photovoltaic shingles includes
a first end,
a second end opposite the first end,
a first edge extending from the first end to the second end, and
a second edge opposite the first edge and extending from the first end to the second end,

installing at least three of the photovoltaic shingles on a slope of a roof deck,
wherein a first photovoltaic shingle of the at least three of the photovoltaic shingles is horizontally adjacent to a second photovoltaic shingle of the at least three of the photovoltaic shingles,
wherein a third photovoltaic shingle of the at least three of the photovoltaic shingles is vertically adjacent to the first photovoltaic shingle,
wherein the first ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the second ends of the first and third photovoltaic shingles are substantially aligned with each other,
wherein the first photovoltaic shingle overlays at least a part of the third photovoltaic shingle,
wherein the second photovoltaic shingle overlays at least a part of the first photovoltaic shingle; and

installing at least one wireway proximate to the first end of at least the first end of the first photovoltaic shingle.

22. The method of claim 21 , wherein the at least one wireway is installed between the first end of the first photovoltaic shingle and the second end of the second photovoltaic shingle.

23. The method of claim 21 , wherein the at least one wi

Assignees

• GAF Energy LLC

Inventors

• Bunea Gabriela
• Nguyen Thierry
• Kuiper Michael David
• Wray Evan Michael
• Abra Lewis
• Clemente Peter
• West Brian

Classifications

• E04D2001/3435

  Adhesive, hardenable or heat-sensitive material · CPC title

• E04D1/28

  Roofing elements comprising two or more layers, e.g. for insulation · CPC title

• E04D2001/308

  for special purposes not otherwise provided for, e.g. turfing tiles, step tiles · CPC title

• E04D13/17

  Ventilation of roof coverings not otherwise provided for (ventilation of rooms or spaces F24F) · CPC title

• H02S20/25 Primary

  Roof tile elements · CPC title