Building integrated photovoltaic system

Patent metadata

Field	Value
Publication number	US-12506330-B2
Application number	US-202418405766-A
Country	US
Kind code	B2
Filing date	Jan 5, 2024
Priority date	Sep 3, 2020
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

A building integrated photovoltaic system includes a plurality of photovoltaic modules installed in an array on a roof deck. Each of the photovoltaic modules at least one solar cell, a first encapsulant encapsulating the at least one solar cell, a frontsheet juxtaposed with a first surface of the first encapsulant, and a backsheet juxtaposed with a second surface of the first encapsulant. The frontsheet includes a glass layer, a second encapsulant, and a first polymer layer. The backsheet includes a first layer and a second polymer layer attached to the first layer. Each of the photovoltaic modules includes a wire cover bracket, which is configured to overlap the wire cover bracket of an adjacent one of the photovoltaic modules.

First claim

What is claimed is:

1 . A system, comprising:
a plurality of photovoltaic modules installed on a roof deck,
wherein the photovoltaic modules are arranged in an array on the roof deck,
wherein the array includes a first subarray and a second subarray,

wherein each of the photovoltaic modules includes
at least one solar cell,
a first side lap,
a first electrical component on the first side lap, and
a second side lap,
wherein the first side laps of the photovoltaic modules of the first subarray form a first wire channel,
wherein the second side laps of the photovoltaic modules of the second subarray form a second wire channel;

at least one first cover overlaying the first wire channel; and
a transition box installed on the roof deck above an upper end of the first wire channel,
wherein the transition box includes a sidewall and a cover portion extending from the sidewall,
wherein the cover portion of the transition box is attached to an uppermost one of the at least one first cover,
wherein the transition box is electrically connected to the first electrical component, and
wherein the transition box is electrically connected to an electrical system below the roof deck.

2 . The system of claim 1 , wherein the transition box includes a second electrical component, and wherein the second electrical component is electrically connected to the first electrical component.

3 . The system of claim 2 , wherein the first electrical component is a first junction box.

4 . The system of claim 3 , wherein the second electrical component is a rapid shutdown device, a middle circuit interrupter or a second junction box.

5 . The system of claim 1 , further comprising a first flashing base installed on the roof deck above the upper end of the first wire channel, wherein the transition box is installed on the first flashing base.

6 . The system of claim 5 , wherein the first flashing base includes a base portion having a first surface, a second surface opposite the first surface, and an aperture extending from the first surface to the second surface, wherein the first electrical component of an uppermost one of the photovoltaic modules in the first subarray is located within the aperture of the first flashing base.

7 . The system of claim 6 , wherein the cover portion of the transition box covers at least a portion of the aperture of the first flashing base.

8 . The system of claim 7 , wherein the first flashing base includes a sidewall extending from the first surface and adjacent the aperture, wherein the cover portion of the transition box overlays the sidewall of the first flashing base.

9 . The system of claim 8 , wherein the aperture extends from a lower end of the first flashing base and to a second end located intermediate the lower end and an upper end of the first flashing base.

10 . The system of claim 9 , wherein the sidewall of the first flashing base is substantially aligned with the first wire channel.

11 . The system of claim 5 , wherein the transition box includes a base portion having an aperture, wherein at least a portion of the aperture of the base portion is substantially aligned with the aperture of the first flashing base.

12 . The system of claim 11 , wherein the aperture of the base portion of the transition box and the aperture of the first flashing base substantially align with an aperture of a roof deck.

13 . The system of claim 5 , further comprising a second flashing base installed on the roof deck above an upper end of the second wire channel, wherein the second flashing base includes a base portion having a first surface, a second surface opposite the first surface of the base portion of the second flashing base, and an aperture extending from the first surface of the base portion of the second flashing base to the second surface of the base portion of the second flashing base, wherein an uppermost one of the photovoltaic modules of the second subarray includes a second electrical component, and wherein the second electrical component is located within the aperture of the second flashing base.

14 . The system of claim 13 , wherein the second electrical component is on the first side lap of the uppermost one of the photovoltaic modules of the second subarray.

15 . The system of claim 14 , further comprising at least one second cover overlaying the second wire channel.

16 . The system of claim 15 , wherein the second flashing base includes a sidewall extending from the first surface of the second flashing base and adjacent the aperture of the second flashing base, and wherein the second flashing base includes a cover overlaying the sidewall of the second flashing base, wherein the cover of the second flashing base is substantially aligned with an uppermost one of the at least one second cover.

17 . The system of claim 16 , wherein the cover of the second flashing base is attached to the uppermost one of the at least one second cover.

18 . A system, comprising:
a plurality of photovoltaic modules installed on a roof deck,
wherein the photovoltaic modules are arranged in an array on the roof deck,
wherein each of the photovoltaic modules includes
at least one solar cell,
a first side lap,
a first electrical component on the first side lap, and
wherein the first side laps of the photovoltaic modules of the array form a first wire channel;

at least one first cover overlaying the first wire channel; and
a transition box installed on the roof deck above an upper end of the first wire channel,
wherein the transition box includes a sidewall and a cover portion extending from the sidewall,
wherein the cover portion of the transition box is attached to an uppermost one of the at least one first cover,
wherein the transition box is electrically connected to the first electrical component, and
wherein the transition box is electrically connected to an electrical system under the roof deck.

19 . The system of claim 18 , wherein the transition box includes a second electrical component, and wherein the second electrical component is electrically connected to the first electrical component.

20 . The system of claim 1 , wherein the plurality of photovoltaic modules includes a first photovoltaic module and a second photovoltaic module, wherein the second photovoltaic module overlays the first photovoltaic module, wherein a first electrical connector is electrically connected to the first electrical component of the first photovoltaic module, wherein a second electrical connector is electrically connected to the first electrical component of the second photovoltaic module, wherein the first electrical connector is connected to the second electrical connector, and wherein the first electrical connector and the second electrical connector are located in a space formed between the first photovoltaic module and the second photovoltaic module.

Assignees

• GAF Energy LLC

Inventors

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

Classifications

• H10F19/807

  Double-glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets · CPC title

• H02S40/34

  comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• H10F19/80

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

• H10F19/85

  Protective back sheets · CPC title