Through Roof Connector Assembly for PV Sheathing
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Solution Overview
Problem
Existing photovoltaic (PV) systems integrated into building structures are costly to install, not visually appealing, and prone to environmental degradation, failing to meet durability and aesthetic standards, while also allowing water ingress and being complex to install like conventional roofing materials.
Innovation Solution
A through-roof connector assembly comprising an edge piece with an electrical connector, a wire guiding member, and an under-roof junction device that securely transfers electrical energy from PV sheathing elements into a building structure, using components like polymeric materials and push-on connectors to ensure durability and water resistance, while being designed for easy installation and visual compatibility with conventional roofing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PV devices are directly mounted to building structure or mounted on stand-offs, then electrical energy can be transferred, but installation becomes complicated and expensive
Solution Approach 1:
The connector assembly is divided into separate components: a connector body with electrical contacts, a mounting flange with fasteners, and wire access features. This segmentation allows each component to be optimized independently and simplifies installation by enabling pre-assembly and modular installation steps
Solution Approach 2:
The connector assembly serves as an intermediary device between the PV device and building structure, providing a standardized interface that simplifies the connection process. The flange and fastener system acts as a mediator that distributes mechanical loads and simplifies mounting compared to direct attachment methods
2Strength
If PV devices are mounted using stand-offs every 2-4 feet, then structural support is provided, but installation cost increases significantly
Solution Approach 1:
The connector assembly performs multiple functions: electrical connection, mechanical mounting, wire routing, and structural load distribution. By consolidating these functions into a single integrated component, the system eliminates the need for separate stand-offs and reduces the number of fasteners required, thereby reducing installation cost and complexity
Solution Approach 2:
The electrical connector and mechanical mounting features are merged into a single integrated assembly. The flange with integrated fasteners combines the mounting function with the electrical connection point, eliminating the need for separate stand-off structures and reducing the total number of components and installation steps
3Ease of operation
If conventional mounting systems are used, then PV devices can be installed, but they are not visually appealing and do not look like conventional building materials
Solution Approach 1:
The connector assembly is designed with aesthetic considerations at the local level, where the flange and body can be finished to match conventional roofing materials. The wire access features are positioned and shaped to minimize visual impact, and the overall form factor is designed to blend with the surrounding building envelope rather than stand out as a separate mechanical component
4Reliability
If PV devices are integrated into building structures, then durability and sealing are improved, but water ingress prevention becomes more difficult
Solution Approach 1:
The connector assembly incorporates sealing features that create flexible barriers against water ingress. The design includes gasket surfaces, sealed wire access points, and flange configurations that work with flexible sealing membranes to prevent water penetration while maintaining the integrated building envelope. The connector body and flange are designed to interface with waterproofing layers, creating a continuous seal that prevents water ingress at the penetration point
Data Source
AI summary
The present invention is premised upon a through-roof connector assembly comprising one or more photovoltaic building sheathing elements capable of being affixed on a building structure, the photovoltaic building sheathing element including a sheathing element electrical connector along a sheathing element peripheral edge; a through-roof connector edge piece assembly that abuts a portion of the photovoltaic building sheathing element and includes: a body portion, an edge piece electrical connector, one or more wire leads that are connected on one end to the edge piece electrical connector; a wire guiding member with at least one conduit hole, the wire guiding member located under the through-roof connector edge piece assembly when assembled; and an under-roof junction device that is removably connected to the wire guiding member.