Roof Integrated PV Module Spacer for Impact and Thermal Management

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Solution Overview

Problem

Solar modules installed on building roofs are vulnerable to damage and efficiency loss due to elevated temperatures and impacts, with high temperatures reducing efficiency and potential harm from hail, tools, or other objects, and junction boxes, cables, and connectors needing to be kept off the roof for reliability and safety reasons.

Innovation Solution

The integration of spacers with a density of 40 kg/m3 to 150 kg/m3 and crush strength of 29 psi to 200 psi, made from materials like fiber wool, between the photovoltaic modules and the roof deck, providing impact protection, ventilation to manage temperature, and cable routing features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If solar modules are installed directly on the roof deck, then installation simplicity is improved, but the modules are vulnerable to impact damage from hail, tools, or other objects

Engineering Contradiction:

Improveinstallation simplicityVSAvoidimpact damage vulnerability

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by installing spacers between the solar module backsheet and the roof deck before final installation. These spacers create a protective air gap that cushions the module against impact forces from hail, tools, or other objects, preventing direct contact damage while maintaining installation simplicity through integration into the mounting system.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent uses spacers as an intermediary element positioned between the solar module and the roof deck. This intermediary component serves multiple functions: it provides impact protection, enables ventilation for thermal management, and offers attachment points for mounting hardware, thereby resolving the contradiction between direct installation simplicity and impact vulnerability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If solar modules are installed with spacing from the roof deck, then impact protection is improved, but installation complexity increases

Engineering Contradiction:

Improveimpact protectionVSAvoidinstallation complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into the spacer component: impact protection, ventilation provision, and mounting attachment. By combining these functions into a single integrated element rather than separate components, the system achieves impact protection without proportionally increasing installation complexity, as the spacer serves multiple purposes simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spacer is designed as a multi-functional universal component that provides impact protection, enables airflow for thermal management, and serves as an attachment point for mounting hardware. This universality reduces overall system complexity by eliminating the need for separate components for each function, thereby achieving impact protection without excessive installation complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If junction boxes and cables are kept off the roof, then reliability and safety are improved, but installation flexibility is reduced

Engineering Contradiction:

Improveelectrical component reliabilityVSAvoidinstallation flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The spacer acts as an intermediary that provides designated locations for routing and securing cables and junction boxes. By incorporating cable management features into the spacer structure, the system keeps electrical components off the roof deck (improving reliability) while maintaining installation flexibility through integrated routing options within the spacer design.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The spacers effectively mitigate impact damage, regulate temperatures, and ensure reliable cable routing, enhancing the durability and efficiency of solar modules while maintaining safety and reliability by absorbing shocks and allowing airflow.

Implementation Method 1

the at least one spacer includes a crush strength of 29 psi to 200 psi

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the at least one spacer includes a fiber wool

Methodology Applied

Scientific EffectAbsorption (physical): Absorption (physical)

Implementation Method 3

providing impact protection, ventilation to manage temperature

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11309828B2Roof integrated photovoltaic module with spacer

Publication Date: 2022.04.19 GAF ENERGY LLC

AI summary

A photovoltaic module including a surface and at least one spacer juxtaposed with the surface. The at least one spacer is positioned intermediate the surface and the roof deck. The photovoltaic module is elevated from the roof deck by the spacer to promote air flow underneath the photovoltaic module. The spacer is made from a material that provides impact resistance and walkability.