Textured Superstrate Shingle-Mimicking PV Module
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Solution Overview
Problem
The mass-market adoption of solar roofing is hindered by poor aesthetics, as standard rack-mounted photovoltaic systems do not match the appearance of traditional roofing materials, leading to unwanted attention and negative consumer feedback.
Innovation Solution
The development of roof-integrated photovoltaic modules with a textured superstrate that mimics the appearance of shingles, featuring a pattern of indentations on the superstrate layer to create a randomized appearance, thereby blending in with traditional roofing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard rack-mounted photovoltaic systems are used, then electricity generation function is achieved, but aesthetic appearance deteriorates compared to traditional roofing materials
Solution Approach 1:
The patent merges the photovoltaic module structure with traditional roofing materials by integrating solar cells directly into shingle-like components. The module combines roofing functions (water shedding, structural integrity) with electricity generation in a single integrated assembly, eliminating the need for separate rack mounting hardware and achieving both aesthetic compatibility and functional performance.
Solution Approach 2:
The photovoltaic module is designed to serve multiple functions simultaneously: it acts as both a roofing material (providing weather protection and structural support) and an electricity generation device. The shingle-integrated design allows the same component to fulfill aesthetic, protective, and energy-producing roles, replacing the need for separate traditional roofing and solar installation systems.
2Use of energy by moving object
If photovoltaic modules are installed on roof decks, then electricity generation is achieved, but aesthetic compatibility with traditional roofing materials deteriorates
Solution Approach 1:
The photovoltaic module copies the visual characteristics and structural form of traditional roofing shingles. The front surface is designed to replicate the appearance, texture, and dimensional features of conventional asphalt or wooden shingles, making the solar installation visually indistinguishable from traditional roofing materials while maintaining full electricity generation capability.
Solution Approach 2:
The module incorporates color-matching technologies and surface treatments that allow it to assume various colors and finishes compatible with different traditional roofing styles. This enables the photovoltaic installation to blend aesthetically with existing roof designs while preserving its light-absorbing properties for electricity generation.
3Shape
If textured superstrate with indentations is applied, then aesthetic appearance matching traditional roofing is improved, but manufacturing precision requirements increase
Solution Approach 1:
The manufacturing process utilizes parameter optimization within acceptable tolerances to achieve the desired textured appearance. By establishing appropriate ranges for indentation depth, spacing, and pattern variability rather than requiring exact precise values, the system achieves aesthetic compatibility with traditional roofing while maintaining manufacturability through standard production capabilities.
Data Source
AI summary
A system including a solar module installed on a roof deck, including a superstrate layer, an encapsulant having an upper layer and a lower layer, and a photovoltaic layer intermediate the upper layer and the lower layer of the encapsulant. An upper surface of the superstrate layer includes an indentation pattern. The indentation pattern includes a mesh of indentations indented into the upper surface of the superstrate layer and a plurality of openings defined by the mesh of indentations.