Step flaps for photovoltaic and roofing shingles

Patent metadata

Field	Value
Publication number	US-2024421753-A1
Application number	US-202418641952-A
Country	US
Kind code	A1
Filing date	Apr 22, 2024
Priority date	Dec 2, 2020
Publication date	Dec 19, 2024
Grant date	—

Abstract

A system including a plurality of photovoltaic shingles installed on a roof deck, a plurality of roofing shingles, such as asphalt shingles, installed on the roof deck, and a plurality of step flaps. One end of the roofing shingle overlays a first side of a corresponding one of the step flaps, and one end of photovoltaic shingle overlays a second side of the corresponding one of the step flaps.

First claim

1 - 14 . (canceled)

15 . A system, comprising:
a plurality of photovoltaic modules installed on a roof deck,
wherein each of the plurality of photovoltaic modules includes
a first end and a second end opposite the first end,
a first side lap at the first end,
a second side lap at the second end,
a reveal portion between the first side lap and the second side lap,
wherein the reveal portion includes a plurality of solar cells;

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 of the roofing shingle; and

a plurality of step flaps, wherein each of the plurality of step flaps includes
a first side,
a second side opposite the first side,
a first edge extending from the first side to the second side,
a second edge opposite the first edge and extending from the first
side to the second side, and
an upper surface,
wherein the upper surface extends from the first side to the second side and from the first edge to the second edge,
wherein the upper surface is flat,

wherein the second end of a first roofing shingle of the plurality of roofing shingles overlays the first side of a first step flap of the plurality of step flaps on the upper surface of the first step flap,
wherein the first side lap of a first photovoltaic module of the plurality of photovoltaic modules overlays the second side of the first step flap on the upper surface thereof,
wherein the second end of the first roofing shingle is adjacent to the first side lap of the first photovoltaic module,
wherein the second side lap of a second photovoltaic module of the plurality of photovoltaic modules overlays the first side of a second step flap of the plurality of step flaps on the upper surface of the second step flap, and
wherein the first end of a second roofing shingle of the plurality of roofing shingles overlays at least the second side of the second step flap on the upper surface of the second step flap.

16 . The system of claim 15 , wherein the first end of the second roofing shingle overlays the second side lap of the second photovoltaic module.

17 . The system of claim 15 , wherein each of the plurality of roofing shingles is an asphalt roofing shingle.

18 . The system of claim 15 , wherein the first edge of the first step flap is vertically offset from a first edge of the first roofing shingle by 1 inch to 5 inches.

19 . The system of claim 15 , wherein each of the plurality of step flaps is composed of a polymer.

20 . The system of claim 19 , wherein each of the plurality of step flaps is composed of thermoplastic polyolefin (TPO).

21 . The system of claim 15 , wherein each of the plurality of step flaps has a thickness of 0.1 mm to 5 mm.

22 . The system of claim 15 , wherein the first step flap includes a first timing mark extending from the first edge to the second edge and between the first side and the second side, wherein the first timing mark extends substantially midway between the first edge and the second edge, and wherein the first step flap includes a second timing mark extending from the first side to the second side and between the first edge and the second edge, and wherein the second timing mark extends substantially midway between the first side and the second side.

23 . The system of claim 15 , wherein the upper surface of the first step flap includes an adhesive.

24 . The system of claim 23 , wherein the upper surface of the first step flap includes at least one release line that extends from the first edge of the first step flap to the second edge of the first step flap and between the first side of the first step flap and the second side of the first step flap.

25 . The system of claim 24 , further comprising a film removably attached to the upper surface of the first step flap.

26 . The system of claim 15 , wherein the plurality of photovoltaic modules is arranged in an array on the roof deck, and wherein the second photovoltaic module is horizontally adjacent to the first photovoltaic module.

27 . The system of claim 26 , wherein the first side lap of the second photovoltaic module overlays the second side lap of the first photovoltaic module.

28 . The system of claim 26 , wherein the plurality of photovoltaic modules includes a third photovoltaic module, and wherein the third photovoltaic module is vertically adjacent to the first photovoltaic module.

29 . The system of claim 28 , wherein the each of the plurality of photovoltaic modules includes a bracket on the first side lap, wherein the bracket of the first photovoltaic module is substantially aligned with the bracket of the third photovoltaic module, wherein each of the brackets is configured to receive at least one electrical component, and wherein the bracket of the first photovoltaic module and the bracket of the third photovoltaic module form a wireway.

30 . The system of claim 29 , further comprising a first cover removably attached to the bracket of the first photovoltaic module and the bracket of the second photovoltaic module.

31 . The system of claim 30 , wherein the plurality of step flaps includes a third step flap, wherein the plurality of roofing shingles includes a third roofing shingle, wherein the second end of the third roofing shingle overlays the first side of the third step flap on the upper surface of the third step flap, wherein the first side lap of the third photovoltaic module overlays the second side of the third step flap on the upper surface thereof, and wherein the second end of the third roofing shingle is adjacent to the first side lap of the third photovoltaic module.

32 . The system of claim 31 , wherein the third step flap overlays at least a portion of the first step flap.

33 . The system of claim 31 , further comprising a first flashing base installed on the roof deck, wherein the plurality of step flaps includes fourth step flap, wherein the fourth step flap is installed on the roof deck proximate to an upper end of the wireway, wherein the first flashing base overlays the fourth step flap, and wherein the first flashing base is aligned with the upper end of the wireway.

34 . A method, comprising:
obtaining a plurality of photovoltaic modules,
wherein each of the plurality of photovoltaic modules includes
a first end and a second end opposite the first end,
a first side lap at the first end,
a second side lap at the second end,
a reveal portion between the first side lap and the second side lap, wherein the reveal portion includes a plurality of solar cells;

obtaining a plurality of roofing shingles,
wherein each of the plurality of roofing shingles includes
a first end and a second end opposite the first end of the roofing shingle;

obtaining a plurality of step flaps, wherein each of the plurality of step flaps includes
a first side,
a second side opposite the first side,
a first edge extending from the first side to the second side,
a second edge opposite the first edge and extending from the first side to the second side, and
an upper surface,
wherein the upper surface extends from the first side to the second side and from the first edge to the second edge,
wherein the upper surface is flat;
overlaying the second end of a first roofing shingle of the plurality of roofing shingles over the first side of a first step flap of the plurality of step flaps on the upper surface of the first step flap; overlaying

Assignees

• GAF Energy LLC

Inventors

• Wray Evan Michael
• Kuiper Michael David
• Nguyen Thierry
• Clemente Peter
• Tonascia Toby

Classifications

• E04D1/20

  of plastics; {of asphalt;} of fibrous materials · CPC title

• E04D1/365

  Sealing strips between lateral sides of roof-covering elements · CPC title

• Y02B10/10

  Photovoltaic [PV] · CPC title

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• H02S20/25 Primary

  Roof tile elements · CPC title