Photovoltaic Shingle Wireway Layout for Durable Roof Integration

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Solution Overview

Problem

There is a need for an efficient method to install photovoltaic shingles on roofing systems that meets specific installation standards and integrates seamlessly with existing roofing materials while ensuring durability and moisture resistance.

Innovation Solution

The method involves obtaining photovoltaic shingles with a layered structure, including a head lap portion and a layer with solar cells, which are directly attached to a roof deck using fasteners or adhesives, and installing wireways proximate to the shingles to form a roof-integrated photovoltaic system that conforms to ASTM E 96 standards, using materials like thermoplastic polyolefin and other polymers for durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If photovoltaic shingles are directly attached to the roof deck using fasteners or adhesives, then installation efficiency and durability are improved, but the complexity of the installation process increases

Engineering Contradiction:

Improveinstallation durabilityVSAvoidinstallation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The photovoltaic shingle is divided into multiple functional layers including a head lap portion, a decorative layer, and a photovoltaic layer with solar cells. This segmentation allows each layer to perform its specific function independently while simplifying the overall installation process through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple functions into a single integrated shingle unit: the head lap portion integrates with traditional roofing shingles, the decorative layer provides aesthetic appearance, and the photovoltaic layer generates electricity. This merging eliminates the need for separate installation of multiple components.

Inventive Principle:

Principle #5Merging (Combining)

2Shape

If photovoltaic shingles with layered structure are used, then aesthetic appeal and integration with roofing materials are improved, but manufacturing complexity increases

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Different regions of the shingle are assigned different properties: the head lap portion is designed to match traditional roofing shingles for aesthetic integration, while the photovoltaic layer contains solar cells for energy generation. This local differentiation of qualities allows the shingle to serve multiple purposes without requiring entirely separate components.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The shingle is constructed as a composite structure combining traditional roofing materials (asphalt, fiberglass) with photovoltaic materials (solar cells, encapsulants). This composite approach allows integration of aesthetic and functional requirements while utilizing established manufacturing processes for each material type.

Inventive Principle:

Principle #40Composite materials

3Reliability

If wireways are installed proximate to photovoltaic shingles, then electrical connectivity and system functionality are improved, but installation time and labor requirements increase

Engineering Contradiction:

Improvesystem functionalityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Wireways are pre-installed on the roof deck before the photovoltaic shingles are attached. This preliminary action allows electrical conduits to be in place and ready, eliminating the need to cut or modify the shingles during installation and reducing overall installation time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Wireways serve as intermediary elements between the photovoltaic shingles and the electrical system. These pre-installed conduits provide a ready-made pathway for electrical connections, simplifying the integration process and reducing installation complexity.

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

This approach enables efficient and durable installation of photovoltaic shingles that meet installation standards, integrates well with roofing materials, and provides moisture resistance, enhancing the overall performance and aesthetic appeal of the roofing system.

Implementation Method 1

the second layer includes at least one solar cell

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

the first layer includes a polymer... the polymer of the first layer includes thermoplastic polyolefin (TPO)... conforms to standards under ASTM E 96, Procedure B test standards

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Data Source

PatentUS11876480B2Photovoltaic shingles and methods of installing same

Publication Date: 2024.01.16 GAF ENERGY LLC

AI summary

A system includes a plurality of photovoltaic shingles installed on a roof deck, each of the shingles having a first layer including a head lap portion, and a second layer including at least one solar cell. A first photovoltaic shingle overlays at least a part of the head lap portion of a second photovoltaic shingle. The system includes at least one wireway installed proximate to a first end of at least the first photovoltaic shingle.