Textured Roofing Modules Matching Photovoltaic Appearance

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Solution Overview

Problem

Existing roofing systems do not aesthetically match photovoltaic modules, leading to visually inconsistent appearances on structures, and lack flexible, cuttable solutions for installation around obstacles.

Innovation Solution

Development of flexible and cuttable roofing modules with textured surfaces that mimic the appearance of photovoltaic modules, composed of thermoplastic polyolefin (TPO) and fiberglass, allowing for installation proximate to photovoltaic modules while maintaining a uniform appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional roofing materials are used, then installation simplicity is maintained, but aesthetic consistency with photovoltaic modules is lost

Engineering Contradiction:

Improveaesthetic consistencyVSAvoidroofing system complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The roofing module copies the visual appearance of photovoltaic modules by incorporating a textured frontsheet with a pattern that mimics solar cell arrangements. This allows the roofing material to aesthetically match adjacent photovoltaic panels while maintaining its function as a non-electrically active roofing component.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The roofing module uses a composite structure consisting of multiple layers including a textured frontsheet, intermediate layers, and a backsheet. This composite construction enables both the aesthetic matching capability and the structural integrity needed for roofing applications.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If rigid roofing modules are used, then structural stability is maintained, but installation flexibility around obstacles is reduced

Engineering Contradiction:

Improveroofing module stabilityVSAvoidinstallation flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The roofing module incorporates flexible polymer layers, particularly in the frontsheet and backsheet components. These flexible thin films allow the roofing module to be cut and shaped to fit around obstacles on the roof surface while maintaining structural integrity and stability during installation and service.

Inventive Principle:

Principle #30Flexible shells and thin films

3Use of energy by moving object

If photovoltaic modules are installed covering entire roof surface, then energy generation is maximized, but aesthetic uniformity is compromised

Engineering Contradiction:

Improveenergy generationVSAvoidvisual appearance uniformity

Core Design Contradiction:

Use of energy by moving objectVSShape

Solution Approach 1:

The roofing system is segmented into distinct functional zones: photovoltaic modules for energy generation and aesthetically matched roofing modules for coverage areas where solar cells are not installed. This segmentation allows the roof to maintain visual uniformity while still maximizing energy generation in appropriate areas.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20230203815A1Roofing module system

Publication Date: 2023.06.29 GAF ENERGY LLC

AI summary

A system includes a plurality of roofing modules and a plurality of photovoltaic modules. The roofing modules include a first layer and a second layer. The first layer has a first surface that is textured. The roofing modules are configured to be installed on the roof deck of a structure proximate to the photovoltaic modules. An appearance of the roofing modules aesthetically matches an appearance of the photovoltaic modules when viewed from a vantage point located at a ground level of the structure.