Solar Roofing Shingle Assembly with Integrated Micro-Inverters
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Solution Overview
Problem
Traditional building applied photovoltaic (BAPV) and building integrated photovoltaic (BIPV) systems are labor-intensive to install and often require concurrent roof replacement, leading to increased costs and complexity, especially when installed on existing roofs over ten years old, as they need to be removed and reinstalled during subsequent roof replacements.
Innovation Solution
A solar roofing shingle assembly that includes an attachment panel with a substrate and solar shingles, where the attachment panel is designed for easy installation on a roof deck, similar to conventional roofing shingles, with integrated micro-inverters and bus bar channels, allowing for direct attachment to the roof without the need for extensive framing or replacement during roof renovations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional BAPV or BIPV systems are installed on existing roofs, then photovoltaic functionality is achieved, but the system must be removed and reinstalled during subsequent roof replacements, increasing cost and labor
Solution Approach 1:
The patent merges the photovoltaic system with the roof covering itself by integrating solar shingles directly into the roofing assembly. The solar shingles are installed as the primary roof covering, eliminating the need for separate mounting structures and frames. This integration ensures the solar system remains permanently attached to the roof throughout its service life, resolving the contradiction between system permanence and installation complexity.
Solution Approach 2:
The solar shingles serve multiple functions simultaneously: they provide weather protection as the primary roof covering, generate electricity through photovoltaic cells, and maintain aesthetic appearance. This multi-functionality eliminates the need for separate roofing and solar installation processes, allowing the same component to fulfill both protective and energy-generating roles permanently.
2Strength
If traditional BAPV systems use brackets and frame rails, then structural support is achieved, but labor-intensive installation and concurrent roof replacement requirements result
Solution Approach 1:
The patent combines the structural support function with the roof covering function by making the solar shingles themselves the structural element. The rigid substrate and integrated mounting features of each solar shingle provide direct structural attachment to the roof deck, eliminating the need for separate brackets and frame rails. This merging of functions maintains structural integrity while dramatically improving installation efficiency.
Solution Approach 2:
The roofing system is segmented into individual solar shingle units that can be installed independently in a shingle-by-shingle manner. Each unit contains its own integrated mounting features and structural capabilities, allowing installers to work efficiently without assembling complex frame structures. This segmentation enables faster installation while maintaining overall structural support.
3Shape
If solar shingles are installed as primary roof covering, then aesthetic appearance is improved, but integration with roof deck requires simplified attachment mechanism
Solution Approach 1:
The patent merges the attachment mechanism with the solar shingle structure itself. Mounting features such as nailing surfaces, adhesive layers, or interlocking elements are integrated directly into the shingle construction, eliminating the need for separate attachment hardware. This integration maintains aesthetic appearance by keeping all mounting components concealed within or beneath the shingle structure while simplifying the manufacturing process.
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 solar roofing shingle assembly simplifies installation, reduces costs by allowing existing roofs to retain the solar system during re-roofing, and provides a cost-effective, aesthetically pleasing solution for building-integrated photovoltaics on sloped roofs, eliminating the need for concurrent roof replacements.
Implementation Method 1
The solar array includes a plurality of photovoltaic cells
Data Source
AI summary
A solar roofing shingle assembly includes an attachment panel configured for attachment to a roof deck and a solar shingle mounted to the attachment panel.