Multi-Region Solar Roofing Modules for Aesthetic Roof Integration

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Solution Overview

Problem

The adoption of solar technology is limited by aesthetic concerns, as existing solar systems stand out from traditional roofs, and the mismatch between the lifespan of solar systems and roofing materials, requiring costly replacements.

Innovation Solution

The development of multi-region solar modules that can be installed over existing tile or composition shingle roofs, blending in aesthetically and extending the lifespan of solar systems, while allowing for flexible installation and modular replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional solar modules are installed over existing roofs, then solar energy generation is achieved, but aesthetic appearance deteriorates as the solar array stands out separately from the existing roof

Engineering Contradiction:
Improvesolar energy generationVSAvoidaesthetic appearance
Core Design Contradiction:
Use of energy by moving objectVSShape

Solution Approach 1:

The patent combines solar panels with roofing materials into a single integrated unit. The solar cells are encapsulated within shingle-like structures that mimic traditional roofing materials, merging the energy generation function with the aesthetic roofing function into one unified component that serves both purposes simultaneously.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The invention applies different visual characteristics to different regions of the solar module. The solar cells are positioned to create patterns that resemble traditional shingle arrangements, with varying opacities and arrangements that mimic natural roofing material patterns, allowing the module to blend aesthetically while maintaining solar functionality.

Inventive Principle:
Principle #3Local quality

2Use of energy by moving object

If solar panels are installed as separate modules over existing roofs, then solar functionality is achieved, but installation complexity increases due to mounting and connecting procedures

Engineering Contradiction:
Improvesolar functionalityVSAvoidinstallation complexity
Core Design Contradiction:
Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the roofing material itself. The solar cells, mounting structure, and roofing material are integrated into a single component that performs structural support, weather protection, and energy generation simultaneously, eliminating separate mounting brackets and fastening systems.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The solar roofing module serves multiple functions: it provides structural roofing coverage, weather protection, aesthetic appearance, and solar energy generation all in one component. This multi-functionality reduces the number of separate systems needed and simplifies the overall installation process.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Use of energy by moving object

If solar systems are installed on existing roofs, then solar adoption is enabled, but cost increases when roof replacement is needed before solar system replacement

Engineering Contradiction:
Improvesolar adoptionVSAvoidtotal cost
Core Design Contradiction:
Use of energy by moving objectVSQuantity of substance

Solution Approach 1:

By integrating solar functionality directly into the roofing material, the invention creates a single component that serves both as roof covering and energy generator. This integration means that when the roof needs replacement, the solar system is replaced simultaneously, eliminating the need for separate costly roof and solar system replacement projects.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The solar roofing module provides both roofing protection and energy generation in one system, meaning that maintenance and replacement cycles for both the roof and solar system are synchronized. This reduces long-term costs by eliminating redundant replacement expenses.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Shape

If solar panels are made to blend with traditional roofing materials, then aesthetic appearance improves, but manufacturing complexity increases

Engineering Contradiction:
Improveaesthetic appearanceVSAvoidmanufacturing complexity
Core Design Contradiction:
ShapeVSEase of manufacture

Solution Approach 1:

The solar module is divided into multiple shingle-like segments, each containing solar cells arranged to mimic traditional shingle patterns. This segmentation allows for standardized manufacturing of individual units that can be assembled to create larger solar roofs, simplifying production while maintaining aesthetic appearance.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The invention applies aesthetic design elements selectively to specific regions of the module. The solar cells are positioned and configured in particular patterns that resemble traditional shingles only where needed for visual blending, while other areas can use simpler configurations, balancing manufacturing ease with aesthetic requirements.

Inventive Principle:
Principle #3Local quality

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 solution reduces installation time, costs, and enhances the visual appeal of solar systems, ensuring they match traditional roofing materials, thus increasing adoption and extending the operational lifespan of solar installations.

Implementation Method 1

a multi-region solar or photovoltaic module having a plurality of photovoltaic (PV) elements

Methodology Applied
Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS11258398B2Multi-region solar roofing modules
Publication Date: 2022.02.22 TESLA INC
  • US11258398B2 patent drawing
  • US11258398B2 patent drawing
  • US11258398B2 patent drawing

AI summary

Building integrated photovoltaic (BIPV) systems provide for solar panel arrays that can be aesthetically pleasing to an observer. BIPV systems can be incorporated as part of roof surfaces as built into the structure of the roof, particularly as multi-region roofing modules that have photovoltaic elements embedded or incorporated into the body of the module, in distinct tiles-sized regions. Such multi-region photovoltaic modules can replicate the look of individual roofing tiles or shingles. Further, multi-region photovoltaic modules can include support structures between the distinct regions having a degree of flexibility, allowing for a more efficient installation process.