Roofing shingles for mimicking the appearance of photovoltaic modules

Patent metadata

Field	Value
Publication number	US-11824486-B2
Application number	US-202318157407-A
Country	US
Kind code	B2
Filing date	Jan 20, 2023
Priority date	Jan 20, 2022
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A system including a plurality of photovoltaic modules and a plurality of roofing shingles installed on a roof deck. Each of the photovoltaic modules includes a plurality of solar cells. Each of the plurality of roofing shingles includes a core layer and a cap layer composed of a first polymer material and having a first surface and a pattern printed on the first surface. The pattern includes a depiction of a plurality of solar cells that extends between the first end and the second end.

First claim

What is claimed is:

1. A system, comprising:
a plurality of photovoltaic modules installed on a roof deck,
wherein each of the plurality of photovoltaic modules includes a plurality of solar cells; and

a plurality of roofing shingles installed on the roof deck, wherein each of the plurality of roofing shingles includes:
a first end and a second end opposite the first end,
a cap layer, wherein the cap layer is composed of a first polymer material, and
wherein the cap layer includes a first surface and a pattern printed on the first surface,
wherein the pattern includes a depiction of a plurality of solar cells,
wherein the depiction of a plurality of solar cells extends between the first end and the second end,
wherein the pattern includes a plurality of pads, wherein the plurality of pads depict a visual appearance of electrical bussing of the depiction of the plurality of solar cells, wherein the plurality of pads is arranged in a plurality of sets, each of which includes a first pad and a second pad, and wherein the sets of the first and second pads are arranged in a matrix including a plurality of rows and a plurality of columns, and

a core layer underneath the cap layer.

2. The system of claim 1 , wherein the core layer includes:
a first layer, wherein the first layer is composed of a continuous fiber thermoplastic composite tape (CFT),
a second layer, wherein the second layer is composed of a continuous fiber thermoplastic composite tape (CFT), and
a third layer between the first layer and the second layer, wherein the third layer is composed of a second polymer material.

3. The system of claim 2 , wherein at least one of the first polymer material and the second polymer material is thermoplastic polyolefin (TPO).

4. The system of claim 1 , wherein the cap layer has a thickness of 10 mil to 50 mil.

5. The system of claim 2 , wherein each of the first layer of the core layer and the second layer of the core layer has a thickness of 4 mil to 15 mil, and wherein the third layer has a thickness of 20 mil to 100 mil.

6. The system of claim 1 , wherein the first pad and the second pad in each set of each column are spaced apart from one another by 20 mm to 150 mm, and wherein each of the sets of pads of one of the rows in each column is spaced apart from another of the sets of pads in another adjacent one of the rows by 10 mm to 50 mm.

7. The system of claim 6 , wherein the second pad of each of the sets of pads in one of the rows in one of the columns is spaced apart from the first pad of another of set sets of pads in the one of the rows of another adjacent one of the columns by 1 mm to 15 mm.

8. The system of claim 6 , wherein each of the plurality of pads includes a length of 5 mm to 30 mm and a width of 1 mm to 10 mm.

9. The system of claim 1 , the depiction of a plurality of solar cells is composed of a plurality of dots, and wherein each of the plurality of dots has a diameter of 1 mm to 5 mm.

10. The system of claim 1 , wherein the pattern includes shading that is composed of a color in a CMYK color bracket of [0, 0, 0, X], and wherein X is 60 to 100.

11. The system of claim 10 , wherein the shading of the pattern is substantially constant from the first end to the second end.

12. The system of claim 10 , wherein X increases from the first end to the second end.

13. The system of claim 10 , wherein X decreases from the first end to the second end.

14. A roofing shingle, comprising:
a first end and a second end opposite the first end,
a cap layer, wherein the cap layer is composed of a first polymer material, and
wherein the cap layer includes a first surface and a pattern printed on the first surface,
wherein the pattern includes a depiction of a plurality of solar cells,
wherein the depiction of a plurality of solar cells extends between the first end and the second end,
wherein the pattern includes a plurality of pads, wherein the plurality of pads depict a visual appearance of electrical bussing of the depiction of the plurality of solar cells, wherein the plurality of pads is arranged in a plurality of sets, each of which includes a first pad and a second pad, and wherein the sets of the first and second pads are arranged in a matrix including a plurality of rows and a plurality of columns, and

a core layer underneath the cap layer.

15. The roofing shingle of claim 14 , wherein the first pad and the second pad in each set of each column are spaced apart from one another by 20 mm to 150 mm, and wherein each of the sets of pads of one of the rows in each column is spaced apart from another of the sets of pads in another adjacent one of the rows by 10 mm to 50 mm.

16. The roofing shingle of claim 14 , the depiction of a plurality of solar cells is composed of a plurality of dots, and wherein the each of the plurality of dots has a diameter of 1 mm to 5 mm.

17. The roofing shingle of claim 14 , wherein the pattern includes shading that is composed of a color in a CMYK color bracket of [0, 0, 0, X], and wherein X is 60 to 100.

18. A kit, comprising:
a plurality of photovoltaic modules configured to be installed on a roof deck,
wherein each of the plurality of photovoltaic modules includes a plurality of solar cells; and

a plurality of roofing shingles configured to be installed on the roof deck, wherein each of the plurality of roofing shingles includes:
a first end and a second end opposite the first end,
a cap layer, wherein the cap layer is composed of a first polymer material, and
wherein the cap layer includes a first surface and a pattern printed on the first surface,
wherein the pattern includes a depiction of a plurality of solar cells,
wherein the depiction of a plurality of solar cells extends between the first end and the second end,

wherein the pattern includes a plurality of pads, wherein the plurality of pads depict a visual appearance of electrical bussing of the depiction of the plurality of solar cells, wherein the plurality of pads is arranged in a plurality of sets, each of which includes a first pad and a second pad, and wherein the sets of the first and second pads are arranged in a matrix including a plurality of rows and a plurality of columns, and
a core layer underneath the cap layer.

Assignees

• GAF Energy LLC

Inventors

• Nguyen Thierry
• Grigsby Matthew
• Wojtowicz Anna
• Perkins Richard
• Krevor Henry
• Cheung Caleb
• Runser Rory
• Hua Dan

Classifications

• H10F19/804

  Materials of encapsulations · CPC title

• H10F19/80

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

• H10F77/00

  Constructional details of devices covered by this subclass (constructional details of integrated devices, or assemblies of multiple devices, comprising at least one element in which radiation controls the flow of current H10F39/00) · CPC title

• E04D1/265

  the roofing elements being rigid, e.g. made of metal, wood or concrete · CPC title

• H02S20/25 Primary

  Roof tile elements · CPC title