Photovoltaic Roofing Assembly With Flashing and Protected Wiring

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Solution Overview

Problem

Existing photovoltaic roofing systems face challenges in installation on steep surfaces, ensuring water tightness, and aesthetic integration with conventional roofing, while also risking wire damage during installation due to pinching or bending, which can lead to power loss, injury, or fire.

Innovation Solution

A frame structure with an upward-facing and downward-facing surface, including an attachment zone and exposure zone, with sidelap portions for interlocking with adjacent elements to provide water drainage channels, and a wiring containment structure to prevent wire pinching, along with side flashing elements for enhanced water resistance and aesthetic integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If photovoltaic roofing elements are installed on steep surfaces, then photovoltaic power generation coverage is improved, but installation difficulty increases and water tightness becomes compromised

Engineering Contradiction:

Improvephotovoltaic power generation coverageVSAvoidinstallation difficulty

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The photovoltaic roofing system is divided into modular elements that can be independently handled and installed. Each element contains integrated wiring channels that segment the wiring path from potential damage zones, allowing installers to work more easily on steep surfaces while maintaining both power generation coverage and installation safety.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional wiring methods are used to interconnect photovoltaic roofing elements, then electrical connectivity is achieved, but wiring is vulnerable to pinching, bending, and damage during installation

Engineering Contradiction:

Improveelectrical connectivityVSAvoidwire damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The wiring is nested within protective channels that are integrated into the structure of the photovoltaic roofing elements themselves. This nesting protects the wiring from external damage during installation while maintaining reliable electrical connectivity between elements.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The protective wiring channels act as intermediaries between the wiring and the harsh installation environment. These channels mediate the mechanical stresses of installation by providing a protected pathway that prevents direct contact between the wiring and potential damage sources such as pinching points or sharp edges.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If photovoltaic roofing elements are used to maximize power generation coverage, then energy production is improved, but aesthetic integration with conventional roofing and transition zones become compromised

Engineering Contradiction:

Improveenergy productionVSAvoidaesthetic integration

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The system allows for local variation in the appearance and configuration of photovoltaic roofing elements to match different architectural styles and roof sections. Transition zones can be designed with specific aesthetic qualities that blend photovoltaic elements with conventional roofing, while maintaining overall power generation efficiency.

Inventive Principle:

Principle #3Local quality

4Reliability

If photovoltaic roofing elements are installed to ensure water tightness, then closure against elements is improved, but installation complexity on steep surfaces increases

Engineering Contradiction:

Improvewater tightnessVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functions are merged into the photovoltaic roofing elements themselves: the structural body provides both the mounting surface for power generation and the waterproofing barrier. The wiring channels are merged into the element structure rather than being separate components, simplifying installation while maintaining water tightness.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enables easier and safer installation of photovoltaic roofing systems on steep surfaces, ensures water tightness, and prevents wire damage, thereby enhancing safety and efficiency while maintaining an aesthetic transition with conventional roofing.

Implementation Method 1

components that convert light energy into electrical energy. Such 'photovoltaic cells' are often made from semiconductor-type materials

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

sidelap portions for interlocking with adjacent elements to provide water drainage channels

Methodology Applied

Scientific EffectGravity-driven water flow: Gravitation

Data Source

PatentUS8631614B2Roofing product with integrated photovoltaic elements and flashing system

Publication Date: 2014.01.21 CERTAINTEED LLC

AI summary

The present invention relates generally to the photovoltaic generation of electrical energy. The present invention relates more particularly to photovoltaic arrays for use in photovoltaically generating electrical energy. Aspects of the present invention provide a variety of photovoltaic roofing elements and systems that include, for example, interlocking geometries to provide for water handling and integration with conventional roofing materials; and wire management features that can protect wiring and associated electrical components from physical and/or environmental damage.