Photovoltaic shingles and methods of installing same

Patent metadata

Field	Value
Publication number	US-11876480-B2
Application number	US-202217877315-A
Country	US
Kind code	B2
Filing date	Jul 29, 2022
Priority date	Jun 4, 2020
Publication date	Jan 16, 2024
Grant date	Jan 16, 2024

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 system, comprising:
a roof deck of a steep slope roof;
a plurality of photovoltaic shingles installed on the roof deck,
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 intermediate the first edge and the second edge,
a first side lap located at the first end, wherein the first side lap extends from the first end to a location between the first end and the second end,
a second side lap located at the second end, wherein the second side lap extends from the second end to a location between the first end and the second end,
wherein a first photovoltaic shingle of the plurality of photovoltaic shingles overlays at least a part of the head lap portion of a second photovoltaic shingle of the plurality of photovoltaic shingles,
wherein the first side lap of the first photovoltaic shingle overlays at least a part of the first side lap of the second photovoltaic shingle,
wherein the second side lap of the first photovoltaic shingle overlays at least a part of the second side lap of the second photovoltaic shingle,
wherein the first side lap of a third photovoltaic shingle overlays the second side lap of the first photovoltaic shingle;

a first wireway installed proximate to the first ends of the first and second photovoltaic shingles, wherein the first wireway overlays the first side lap of each of the first and second photovoltaic shingles;
at least one first electrical component, wherein the at least one first electrical component is installed in the first wireway, wherein the at least one first electrical component is electrically connected to the first and second photovoltaic shingles;
a second wireway installed proximate to the second ends of the first and second photovoltaic shingles and the first end of the third photovoltaic shingle, wherein the second wireway overlays the first side lap of the third photovoltaic shingle and the second side laps of the first and second photovoltaic shingle;
at least one second electrical component, wherein the at least one second electrical component is installed in the second wireway, wherein the at least one second electrical component is electrically connected to at least the third photovoltaic shingle, and
wherein the at least one second electrical component is electrically connected to the at least one first electrical component.

2. The system of claim 1 , wherein the first wireway includes at least one base and at least one cover, wherein the at least one cover is removably attached to the at least one base.

3. The system of claim 2 , wherein the at least one first electrical component is installed on the at least one base.

4. The system of claim 3 , wherein the at least one first electrical component is a first junction box.

5. The system of claim 3 , wherein the at least one base includes a plurality of bases, wherein the at least one first electrical component includes a plurality of first electrical components, and wherein each of the plurality of first electrical components is installed on a corresponding one of the plurality of bases.

6. The system of claim 5 , wherein each of the plurality of bases is installed on a corresponding one of the first side laps of the first and second photovoltaic shingles.

7. The system of claim 5 , wherein the at least one cover includes a plurality of covers.

8. The system of claim 7 , wherein each of the plurality of covers is removably attached to a corresponding one of the plurality of bases.

9. The system of claim 7 , wherein each of the plurality of covers is removably attached to at least two of the plurality of bases.

10. The system of claim 9 , wherein each of the plurality of covers is connected to at least one other of the plurality of covers.

11. The system of claim 1 , wherein the second wireway includes at least one base and at least one cover, wherein the at least one cover of the second wireway is removably attached to the at least one base of the second wireway.

12. The system of claim 11 , wherein the at least second first electrical component is installed on the at least one base of the second wireway.

13. The system of claim 12 , wherein the at least one second electrical component is a second junction box.

14. The system of claim 12 , wherein the at least one base of the second wireway includes a plurality of bases, wherein the at least second electrical component includes a plurality of second electrical components, and wherein each of the plurality of second electrical components is installed on a corresponding one of the plurality of bases of the second wireway.

15. The system of claim 14 , wherein the plurality of photovoltaic shingles includes a fourth photovoltaic shingle, and wherein each of the plurality of bases of the second wireway is installed on a corresponding one of the first side lap of the third photovoltaic shingle and the first side lap of the fourth photovoltaic shingle.

16. The system of claim 15 , further comprising a third wireway installed proximate to the second ends of the third and fourth photovoltaic shingles, wherein the third wireway overlays the second side laps of the third and fourth photovoltaic shingles.

17. The system of claim 11 , wherein the third wireway includes at least one base and at least one cover, wherein the at least one cover of the third wireway is removably attached to the at least one base of the third wireway.

18. The system of claim 17 , wherein the third wireway does not include any electrical components.

19. The system of claim 17 , wherein at least one of the first, second and third wireways includes an end cap located at a lower end thereof.

20. A method, comprising:
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 intermediate the first edge and the second edge, a first side lap located at the first end,
wherein the first side lap extends from the first end to a location between the first end and the second end, a second side lap located at the second end,
wherein the second side lap extends from the second end to a location between the first end and the second end;

installing at least first, second, and third photovoltaic shingles of the plurality of shingles on a steep slope roof deck,
wherein the first photovoltaic shingle overlays at least a part of the head lap portion of the second photovoltaic shingle,
wherein the first side lap of the first photovoltaic shingle overlays at least a part of the first side lap of the second photovoltaic shingle,
wherein the second side lap of the first photovoltaic shingle overlays at least a part of the second side lap of the second photovoltaic shingle,

wherein the first side lap of the third photovoltaic shingle overlays the second side lap of the first photovoltaic shingle, wherein a first wireway is located proximate to the first ends of the first an

Assignees

• GAF Energy LLC

Inventors

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

Classifications

• H02S20/25 Primary

  Roof tile elements · CPC title

• E04D1/26

  Strip-shaped roofing elements {simulating a repetitive pattern, e.g.} appearing as a row of shingles · CPC title

• E04D1/28

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

• E04D1/30

  Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles (E04D3/40 takes precedence) · CPC title

• E04D1/34

  Fastenings for attaching roof-covering elements to the supporting elements · CPC title