Photovoltaic Roofing Connector Shield for Moisture Protection
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Solution Overview
Problem
Photovoltaic roofing products face challenges with moisture ingress and aesthetic issues due to bulky electrical connectors, which can lead to stress points and wear on roofing materials, and existing low-profile connectors are difficult to integrate with thin roofing products like asphalt shingles.
Innovation Solution
A photovoltaic roofing element with a roofing substrate, a photovoltaic element, and an electrical connector having a top side, a down-roof side, and an electrical terminus, where a shield is disposed adjacent to the electrical terminus on its down-roof side, top side, or both to protect the electrical connection from moisture and maintain a flat appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bulky electrical connectors are used to ensure robust electrical connection, then reliability of electrical connection is improved, but aesthetic appearance deteriorates and stress points are created on roofing material
Solution Approach 1:
The electrical connector system is segmented into multiple components: the electrical connector itself, a flat shield component, and an optional recess in the roofing substrate. This segmentation allows each component to perform its specific function while collectively achieving both robust electrical connection and aesthetic appearance by distributing the structural requirements across multiple elements rather than requiring a single bulky connector
Solution Approach 2:
A flat shield component is introduced as an intermediary element between the electrical connector and the roofing substrate. This shield spans the interface between adjacent roofing elements and provides mechanical support for the electrical connector, allowing the connector to maintain its robust construction while preventing it from creating stress points or distorting the aesthetic appearance of the roofing material
2Shape
If low-profile connectors are used to improve aesthetic appearance, then shape is improved, but ease of integration with thin roofing products deteriorates
Solution Approach 1:
The flat shield acts as an intermediary that provides the necessary structural support and integration interface for electrical connectors on thin roofing products. The shield can be integrated into the roofing substrate or positioned beneath the roofing element, providing a stable base that enables easy integration of robust electrical connectors without requiring the connectors to be low-profile
Solution Approach 2:
The solution moves the structural support function from the vertical dimension (requiring low-profile connectors) to the horizontal dimension (using a flat shield that spans the interface). This dimensional shift allows robust electrical connectors to be used while maintaining a flat profile at the visible surface, as the shield provides support in the plane of the roofing substrate rather than requiring vertical clearance
3Shape
If electrical connectors are disposed beneath roofing elements to improve aesthetic appearance, then shape is improved, but moisture ingress susceptibility increases
Solution Approach 1:
The flat shield serves as a protective intermediary that extends beyond the electrical connector to provide a moisture barrier. By positioning the shield to span the interface between adjacent roofing elements and extend over the electrical connector, it creates a protective overhang that prevents wind-driven moisture from reaching the electrical connection while allowing the connector to be positioned beneath the roofing element for aesthetic purposes
Solution Approach 2:
The shield is positioned in advance to create a protective barrier before moisture ingress can occur. By extending the shield beyond the electrical connector and positioning it to span the interface between roofing elements, a preliminary protective structure is established that prevents wind-driven moisture from reaching the electrical connection during installation and throughout the product's service life
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 shield effectively prevents moisture ingress and maintains a flat, aesthetically pleasing surface by spanning the interface between electrical connectors, reducing stress points and wear on the roofing material.
Implementation Method 1
components that convert light energy into electrical energy. Such 'photovoltaic cells' are often made from semiconductor-type materials
Implementation Method 2
a shield disposed adjacent the electrical terminus of the electrical connector on its down-roof side, its top side, or both... The shield effectively prevents moisture ingress and maintains a flat, aesthetically pleasing surface by spanning the interface between electrical connectors
Data Source
AI summary
The present invention relates generally to the photovoltaic generation of electrical energy. The present invention relates more particularly to photovoltaic roofing products for use in photovoltaically generating electrical energy. One aspect of the invention is a photovoltaic roofing element including a roofing substrate; a photovoltaic element disposed on the roofing substrate; an electrical connector operatively connected to the photovoltaic element, the electrical connector having a top side, a down-roof side and an electrical terminus; and a shield disposed adjacent the electrical terminus of the electrical connector on its down-roof side, its top side, or both.