Step Flap Assembly for Water-Shedding Solar Shingle Joints
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Solution Overview
Problem
Photovoltaic systems face challenges in efficient installation and water shedding on roofing structures, particularly at butt joints between photovoltaic and roofing shingles, where water can enter and cause issues.
Innovation Solution
The use of step flaps, made from materials like thermoplastic polyolefin (TPO) with specific dimensions and configurations, including timing marks and adhesive surfaces, to facilitate straight edge installations and provide water shedding functionality at butt joints between photovoltaic and roofing shingles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If step flaps are installed at butt joints between photovoltaic and roofing shingles, then water shedding capability is improved, but device complexity increases
Solution Approach 1:
The roofing system is segmented into distinct components: photovoltaic shingles, roofing shingles, and step flaps. The step flap acts as a separate waterproofing element installed at the butt joint interface, dividing the waterproofing function from the structural roofing layers and enabling targeted water shedding without complicating the entire roofing system.
Solution Approach 2:
The step flap serves as an intermediary element between the photovoltaic shingle and the roofing shingle. It is installed underneath the photovoltaic shingle's overhang and extends beneath the roofing shingle, creating a waterproof barrier at the joint interface without requiring modification of the primary shingle structures.
2Productivity
If step flaps with adhesive surfaces are used, then installation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The adhesive surface is merged directly into the step flap structure during manufacturing. The step flap is produced as a single integrated component with adhesive applied to its upper surface, eliminating the need for separate adhesive application steps during installation and simplifying the overall manufacturing process through consolidation of functions.
Solution Approach 2:
The adhesive is applied to the step flap during manufacturing before installation occurs. This preliminary action ensures the adhesive is already positioned and prepared on the step flap, allowing installers to simply place the step flap into position without requiring additional adhesive application steps, thereby improving installation efficiency.
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 step flaps enable efficient installation of photovoltaic and roofing shingles while effectively shedding water, preventing water entry at butt joints and ensuring durability under wind resistance, as demonstrated by tests at 110 miles per hour winds.
Implementation Method 1
the at least one step flap includes a surface and an adhesive on the surface
Data Source
AI summary
A system including a plurality of photovoltaic shingles installed on a roof deck, a plurality of roofing shingles, such as asphalt shingles, installed on the roof deck, and a plurality of step flaps. One end of the roofing shingle overlays a first side of a corresponding one of the step flaps, and one end of photovoltaic shingle overlays a second side of the corresponding one of the step flaps.