ROOF INTEGRATED PHOTOVOLTAIC SYSTEM
20230018614 · 2023-01-19
Inventors
- Brian Edward Atchley (Petaluma, CA, US)
- Peter Clemente (Warren, NJ, US)
- Nazar Dzoba (Edison, NJ, US)
- Anthony Folk (Whitehouse Station, NJ, US)
- Amy Ochsenrieter (Morristown, NJ, US)
- Daniel East (Petaluma, CA, US)
Cpc classification
E04D3/38
FIXED CONSTRUCTIONS
E04D3/3605
FIXED CONSTRUCTIONS
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04D1/12
FIXED CONSTRUCTIONS
F24S2025/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2020/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S30/00
ELECTRICITY
Y02B10/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S25/613
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A roof integrated photovoltaic system includes a starter bar having a foot base and configured to be installed to a roof deck, a plurality of water shedding layers, and a photovoltaic module. One of the plurality of water shedding layers is configured to be installed over the foot base of the starter bar, and one of another of which is configured to overlap and be installed over the one of the plurality of water shedding layers. The system further includes a foot module configured to be attached to an upper portion of the photovoltaic module. A lower portion of the photovoltaic module is configured to align with the foot base of the starter bar, and the foot module is configured to be affixed on a last overlapping layer of the plurality of water shedding layers to the roof deck.
Claims
1. A method, comprising: installing at least one starter bar to a roof deck, wherein the at least one starter bar includes a foot base; installing one of a first plurality of water shedding layers over the foot base of the at least one starter bar; overlapping at least one of another of the first plurality of water shedding layers over the one of the first plurality of water shedding layers; and installing at least one first photovoltaic module, each of the at least one first photovoltaic module having a top surface, a bottom surface, an upper portion, a lower portion, a pair of side portions, each of which extends from the upper portion to the lower portion, and at least one first foot module attached to the upper portion, wherein the lower portion of each of the least one first photovoltaic module is aligned with the foot base of the at least one starter bar, and the at least one first foot module is affixed on a last overlapping layer of the at least one of another of the first plurality of water shedding layers to the roof deck.
2. The method of claim 1, wherein the last overlapping layer of the at least one of another of the first plurality of water shedding layers includes a second water shedding layer.
3. The method of claim 1, wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, and a third water shedding layer overlapping the second water shedding layer, the third water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.
4. The method of claim 1, wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer overlapping the one of the first plurality of water shedding layers, a third water shedding layer overlapping the second water shedding layer, and a fourth water shedding layer overlapping the third water shedding layer, the fourth water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.
5. The method of claim 2, further comprising the step of affixing the one of the first plurality of water shedding layers and the second water shedding layer to the roof deck.
6. The method of claim 3, further comprising the step of affixing the one of the first plurality of water shedding layers and the second and third water shedding layers to the roof deck.
7. The method of claim 4, further comprising the step of affixing the one of the first plurality of water shedding layers and the second, third and fourth water shedding layers to the roof deck.
8. The method of claim 3, wherein the second water shedding layer includes a first edge that is positioned offset from the foot base of the starter bar, and the third water shedding layer includes a first edge that is positioned offset from the first edge of the second water shedding layer.
9. The method of claim 4, wherein the second water shedding layer includes a first edge that is positioned offset from the foot base of the starter bar, the third water shedding layer includes a first edge that is positioned offset from the first edge of the second water shedding layer, and the fourth water shedding layer includes a first edge that is positioned offset from the first edge of the third water shedding layer.
10. The method of claim 1, further comprising the steps of installing one of a second plurality of water shedding layers over the at least one first module foot, and overlapping at least one of another of the second plurality of water shedding layers over the one of the second plurality of water shedding layers.
11. The method of claim 4, further comprising the step of installing at least one second photovoltaic module, the at least one second photovoltaic module having a top surface, a bottom surface, an upper portion, a lower portion, a pair of side portions, each of which extends from the upper portion of the at least one second photovoltaic module to the lower portion of the at least one second photovoltaic module, and at least one second foot module attached to the upper portion of the at least one second photovoltaic module, wherein the lower portion of the at least one second photovoltaic module is aligned with the at least one first foot module of the at least one first photovoltaic module, and the at least one second foot module is affixed on a last overlapping layer of the at least one of another of the second plurality of water shedding layers to the roof deck.
12. A system, comprising: at least one starter bar configured to be installed to a roof deck, wherein the at least one starter bar includes a foot base; a first plurality of water shedding layers, one of which is configured to be installed over the foot base of the at least one starter bar, and at least one of another of which is configured to overlap and be installed over the one of the first plurality of water shedding layers; at least one first photovoltaic module having a top surface, a bottom surface, an upper portion, a lower portion, and a pair of side portions, each of which extends from the upper portion to the lower portion; and at least one first foot module configured to be attached to the upper portion of the at least one first photovoltaic module, wherein the lower portion of each of the least one first photovoltaic module is configured to align with the foot base of the at least one starter bar, and the at least one first foot module is configured to be affixed on a last overlapping layer of the at least one of another of the first plurality of water shedding layers to the roof deck.
13. The system of claim 12, wherein the last overlapping layer of the at least one of another of the first plurality of water shedding layers includes a second water shedding layer.
14. The system of claim 12, wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer configured to overlap the one of the first plurality of water shedding layers, and a third water shedding layer configured to overlap the second water shedding layer, the third water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.
15. The system of claim 12, wherein the at least one of another of the first plurality of water shedding layers includes a second water shedding layer configured to overlap the one of the first plurality of water shedding layers, a third water shedding layer configured to overlap the second water shedding layer, and a fourth water shedding layer configured to overlap the third water shedding layer, the fourth water shedding layer being the last overlapping layer of the at least one of another of the first plurality of water shedding layers.
16. The system of claim 12, wherein the at least one starter bar includes a plurality of starter bars, and wherein the at least one first photovoltaic module includes a plurality of first photovoltaic modules, and wherein each of the lower portions of each of the plurality of first photovoltaic modules is configured to align with a corresponding one of the foot base of the plurality of starter bars.
17. The system of claim 16, further comprising a second plurality of water shedding layers, one of which is configured to be installed over the at least one first module foot, and at least one of another of which is configured to overlap and be installed over the one of the second plurality of water shedding layers.
18. The system of claim 17, further comprising at least one second photovoltaic module, the at least one second photovoltaic module having a top surface, a bottom surface, an upper portion, a lower portion, and a pair of side portions, each of which extends from the upper portion of the at least one second photovoltaic module to the lower portion of the at least one second photovoltaic module; and at least one second foot module configured to be attached to the upper portion of the at least one second photovoltaic module, wherein the lower portion of the at least one second photovoltaic module is configured to align with the at least one first foot module of the at least one first photovoltaic module, and the at least one second foot module is configured to be affixed on a last overlapping layer of the at least one of another of the second plurality of water shedding layers to the roof deck.
19. The system of claim 12, further comprising a bracket for at least one module-level power electronic, wherein the bracket is configured to be attached to the at least one first photovoltaic module and position the at least one module-level power electronic under the bottom surface of the at least one first photovoltaic module.
20. The system of claim 19, wherein the bracket includes at least one hook member configured to be removably attached to at least one of the top portion, the lower portion and either of the side portions of the at least one first photovoltaic module.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0035] Referring to
[0036] In an embodiment, one layer 24 of the first plurality of water shedding layers 16 is configured to be installed over the at least one foot base 14 of the at least one starter bar 12, and at least one of another layer 26 of the plurality of water shedding layers 16 is configured to overlap and be installed over the one layer 24 of the first plurality of water shedding layers 16. In an embodiment, each of the first plurality of water shedding layers 16 includes water shedding properties and acts a moisture barrier for the roof deck 20. In an embodiment, each of the first plurality of water shedding layers 16 includes fire retardant properties.
[0037] Referring to
[0038] In an embodiment, the at least one of another layer 26 of the first plurality of water shedding layers 16 overlaps the at least one layer 24 of the first plurality of water shedding layers 16 over a first portion 40 of the one layer 24 of the first plurality of water shedding layers 16 to create a second, revealed portion 42. In an embodiment, the second, revealed portion 42 of the one layer 24 of the first plurality of water shedding layers 16 includes a width that is approximately equal to a length of the at least one photovoltaic module 28. In an embodiment, the length of the at least one photovoltaic module 28 extends from the upper portion 34 of the at least one photovoltaic module 28 to the lower portion 36 of the at least one photovoltaic module 28. In an embodiment, the one layer 24 of the first plurality of water shedding layers 16 includes a width, and wherein the width of the second, revealed portion 42 of the one layer 24 of the first plurality of water shedding layers 16 is approximately equal to half of the width of the one layer 24 of the first plurality of water shedding layers 16.
[0039] In another embodiment, the at least one of another layer 26 of the first plurality of water shedding layers 16 includes a second water shedding layer 26 configured to overlap the one layer 24 of the first plurality of water shedding layers 16, and a third water shedding layer 44 configured to overlap the second water shedding layer 26, the third water shedding layer 44 being the last overlapping layer of the at least one of another layer 26 of the first plurality of water shedding layers 16. In an embodiment, the one layer 24 of the first plurality of water shedding layers 16 and the second and third water shedding layers 26, 44 are configured to be affixed to the roof deck 20. In an embodiment, the one layer 24 of the first plurality of water shedding layers 16 and the second and third water shedding layers 26, 44 are configured to be affixed to the roof deck 20 by a plurality of nails. In an embodiment, the one layer 24 of the first plurality of water shedding layers 16 and the second and third water shedding layers 26, 44 are configured to be affixed to the roof deck 20 by an adhesive.
[0040] Referring to
[0041] In an embodiment, the at least one first foot module 18 includes a plurality of first foot modules 18. In an embodiment, the at least one starter bar 12 includes a plurality of starter bars 12. In an embodiment, the at least one first photovoltaic module 28 includes a plurality of first photovoltaic modules 28, and each of the lower portions 36 of each of the plurality of first photovoltaic modules 28 is configured to align with a corresponding one of the at least one foot base 14 of the plurality of starter bars 12.
[0042] Referring back to
[0043] In an embodiment, the system 10 includes at least one second photovoltaic module 28, the lower portion 36 of the at least one second photovoltaic module 28 is configured to align with the at least one first foot module 18 of the at least one first photovoltaic module 28, and at least one second foot module 18 is configured to be affixed on a last overlapping layer of the at least one of another of the second plurality of water shedding layers 48 to the roof deck 20. In an embodiment, each of the second plurality of water shedding layers 48 consists of MINERAL GUARD® roof rolling material manufactured and sold by GAF.
[0044] In an embodiment, the last overlapping layer of the at least one of another layer 52 of the second plurality of water shedding layers 48 is a fifth water shedding layer 52. In an embodiment, the one layer 50 of the second plurality of water shedding layers 48 and the fifth water shedding layer 52 are configured to be affixed to the roof deck 20. In an embodiment, the one layer 50 of the second plurality of water shedding layers 48 and the fifth water shedding layer 52 are configured to be affixed to the roof deck 20 by a plurality of nails. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and the fifth water shedding layer 52 are configured to be affixed to the roof deck 20 by an adhesive.
[0045] In an embodiment, the at least one of another layer 52 of the second plurality of water shedding layers 48 includes a fifth water shedding layer 52 configured to overlap the one 50 of the second plurality of water shedding layers 48, and a sixth water shedding layer 54 configured to overlap the fifth water shedding layer 52, the sixth water shedding layer 54 being configured to be the last overlapping layer of the at least one of another layer 52 of the second plurality of water shedding layers 48. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and the fifth and sixth water shedding layers 52, 54 are configured to be affixed to the roof deck 20. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and fifth and sixth water shedding layers 52, 54 are configured to be affixed to the roof deck 20 by a plurality of nails. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and fifth and sixth water shedding layers 52, 54 are configured to be affixed to the roof deck 20 by an adhesive.
[0046] Referring back to
[0047] In an embodiment, the second plurality of water shedding layers 48 and the fifth, sixth and seventh water shedding layers 52, 54, 56 are configured to be affixed to the roof deck 20. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and the fifth, sixth and seventh water shedding layers 52, 54, 56 are configured to be affixed to the roof deck 20 by a plurality of nails. In an embodiment, the one 50 of the second plurality of water shedding layers 48 and the fifth, sixth and seventh water shedding layers 52, 54, 56 are configured to be affixed to the roof deck 20 by an adhesive.
[0048] In an embodiment, the at least one second foot module 18 includes a plurality of second foot modules 18. In an embodiment, the at least one first photovoltaic module 28 includes a plurality of first photovoltaic modules 28, and the at least one second photovoltaic module 28 includes a plurality of second photovoltaic modules 28, wherein each of the lower portions 36 of each of the plurality of second photovoltaic modules 28 is configured to align with a corresponding one of the at least one first foot module 18 of each of the plurality of first photovoltaic modules 28.
[0049] Referring to
[0050] Referring to
[0051] Referring to
[0052] In an embodiment, the flashing member 108 is made from metal. In an embodiment, the flashing member 108 is made from aluminum. In another embodiment, the flashing member 108 is made from stainless steel. In another embodiment, the flashing member 108 is made from galvalume. In another embodiment, the flashing member 108 is made from a polymer. In an embodiment, the flashing member 108 is made from a composite material. In another embodiment, the flashing member 108 is made from fiberglass.
[0053] Referring to
[0054] Referring to
[0055] In an embodiment, the system 10 creates a solar plane that is different than the shingle plane comprised of the roofing system surrounding the photovoltaic modules 28. The transition between shingle plane and the solar plane is compatible with the system 10 and the application of flashing between the planes assures water shedding at the surface covered with the shingles 22. In an alternate embodiment, sealant materials are used for sealing the boundary area between the solar plane and the shingle plane.
[0056] Referring to
[0057] Referring to
[0058] Referring to
[0059] Referring to
[0060] In another embodiment, a method for installing a roof integrated photovoltaic system includes the following steps: [0061] Installing a base layer to a roof deck, the base layer having a first side and a second side opposite the first side, the first side including an adhesive with a first width and the second side including an adhesive with a second width that is narrower than the first width. In an embodiment, the base layer consists of QUICKSTART® peel and stick starter roll roofing material manufactured and sold by GAF. [0062] Installing a starter bar on the base layer and to the roof deck, the starter bar including a foot base. In an embodiment, the foot base is affixed to the roof deck by fasteners. [0063] Installing a first water shedding layer over the foot base of the starter bar and affixing the first water shedding layer to the roof deck. In an embodiment, the width of the first water shedding layer will be about half of the width of the subsequently installed water shedding layers. In an embodiment, the first water shedding layer is affixed to the roof deck by a plurality of fasteners. In an embodiment, the first water shedding layer covers the fasteners affixing the starter bar to protect them from moisture penetration. [0064] Installing a second water shedding layer over the first water shedding layer. In an embodiment, the second water shedding layer includes a width that is twice the width of the first water shedding layer. In an embodiment, the second water shedding layer fully covers the first water shedding layer. In an embodiment, the second water shedding layers is affixed to the roof deck by a plurality of fasteners. In an embodiment, from this point forward, each full-width of the water shedding layers is shifted by half of the width. [0065] Installing foot modules on the second water shedding layer. [0066] Installing a third water shedding layer over the foot modules. This method ensures every point on the roof deck is covered by two layers of the water shedding layers. In an embodiment, each fastener is sandwiched between a water shedding layer underneath the fastener and a water shedding layer below the fastener. In another alternate embodiment, if only one water shedding layer is required, the overlap between the water shedding layers will be characterized to the fastener zones to cover the fasteners. In this regard, the shift between the water shedding layers will be more than half of the width of the water shedding layers. In an embodiment, the water shedding layers include a width equal to width of the photovoltaic module width divided evenly, thereby foregoing the need for pre-measuring and enabling self-templating.
[0067] While a number of embodiments of the present invention have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. Further still, the various steps may be carried out in any desired order (and any desired steps may be added and/or any desired steps may be eliminated). All such variations and modifications are intended to be included within the scope of the invention as defined in the appended claims.