Labor Saving Solar Roofing Shingle

Abstract

Embodiments relate to an enhanced method for installing solar roofs by primarily reducing the installation time. The design is for a roofing shingle with an embedded solar module that installs intuitively like normal roofing shingles without special tools, fasteners or alignment. The shingle structure is molded out of low thermal expansion plastic composite and is compatible with commercial photovoltaic modules as well as solar infrared radiation absorbing devices.

Claims

1. A roofing shingle comprising: a) a headlap and exposure with headlap width greater than the exposure width, b) a solar module embedded in the exposure, c) a shingle structure molded out of bulk molding compound.

2. The shingle in claim 1 wherein the sides of the shingle have an overhanging structure.

3. The shingle in claim 1 wherein the bulk molding compound is comprised of a) between 23 and 30% polyester resin b) between 0.15 and 0.35% of an organic peroxide catalyst c) up to about 0.7% zinc stearate d) up to about 30% fiberglass e) up to about 60% calcium hydroxide f) up to about 70% rice hull g) up to about 50% hemp fiber h) up to about 3% carbon black i) up to about 30% magnesium hydroxide.

4. The shingle in claim 1 wherein the composite material has a CTE less than 1.8×10.sup.−5 C.sup.−1.

5. The shingle in claim 1 wherein the solar module is comprised of a monocrystalline or polycrystalline PV cells.

6. The shingle in claim 1 wherein a tapered shingle is used in the 1st course to set the angle of shingle installation.

7. The shingle in claim 5 wherein a parallel wire junction in the headlap overhang is used to connect shingles in series.

8. The shingle in claim 5 wherein Underwriters Laboratories specification 3135 wire is routed through the ribs on the underside of a shingle to connect adjacent shingles in series to the module junction box.

9. The shingle in claim 1 wherein the solar module is comprised of a solar IR absorbing module comprised of an array of tubes containing heat-transfer fluid covered by an IR transmitting glass plate.

10. The shingle in claim 9 wherein flexible corrugated tubing is used to transfer heat containing between adjoining shingles.

11. The shingle in claim 9 wherein a parallel tubing union is used to connect the heat transfer fluid to adjoining shingles.

12. The shingle in claim 9 wherein a tapered shingle is used in the 1.sup.st course to set the angle of shingle installation.

13. A device comprising an insulated body with male and female receptacles in a parallel orientation that are connected inside the body and capable of conducting current between the male and female connectors.

14. The device in claim 12 wherein male and female bullet connectors carry electrical current.

15. The device in claim 12 wherein male and female connectors carry hydraulic current.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0057] FIG. 1 shows an exemplary embodiment of a PV shingle with headlap (101), nailing or fastening strip (102) and PV module fixed to the exposure (103)

[0058] FIG. 2 shows an exemplary embodiment of an electricity generating PV shingle with a typical PV module (201) fixed to the structure of the exposure (202) and with a cutout (203) to accommodate the PV module junction box.

[0059] FIG. 3 shows an exemplary embodiment of a how a PV module (301) is fixed to the composite PV shingle structure (303) with a gap for adhesive (302).

[0060] FIG. 4 shows an exemplary embodiment of a spring-loaded clip (401) used to fasten a PV module (402) to the composite shingle structure (403).

[0061] FIG. 5 shows an exemplary embodiment of insets in the nailing strip (501) to accommodate typical roofing screws with washers as well as the inset (502) in the exposure to accommodate a PV module so that it is flush with the exposure frame, nailing strip and headlap.

[0062] FIG. 6 shows an exemplary embodiment of the structure on the underside of a PV shingle with headlap ribs (601), nailing strip ribs (602) and exposure ribs (603).

[0063] FIG. 7 shows an exemplary embodiment of features for routing PV module wiring with cutouts to allow wires to pass to the headlap through the nailing strip (701), cutouts to allow wires to pass laterally to the sides of the shingle (702) and an overhang (703) in the headlap to facilitate series wiring of adjacent panels

[0064] FIG. 8 shows an exemplary embodiment of shingle wiring with wires exiting the junction box (801), transiting to the headlap and routing laterally (802) to a series connection under the overlap in the headlap (803).

[0065] FIG. 9 shows an exemplary embodiment of a parallel wire series connector used to connect adjacent shingles with a female bullet connector receptacle (901), a male bullet connector (902) and an insulated housing (903) containing a conductor joining the male and female bullet connectors.

[0066] FIG. 10 shows an exemplary embodiment of starting shingle with taper (1001) and nailing strip (1002).

[0067] FIG. 11 shows an exemplary embodiment of the layup of a PV shingle installation with the roofing deck (1101), starting shingle (1102) and PV shingle (1103).

[0068] FIG. 12 shows an exemplary embodiment of the layup of a PV shingle installation with the roofing deck (1201), PV shingle (1202), top course shingle (1203) and flashing (1204).

[0069] FIG. 13 shows an exemplary embodiment of the layout of two adjacent installed shingles with a waterproofing sheet (1301) sealing the headlap of the joint between them.

[0070] FIG. 14 shows an exemplary embodiment of a PV shingle installation with a waterproofing sheet (1401) sealing the headlap joint between two adjacent panels.

[0071] FIG. 15 shows an exemplary embodiment of thermal energy generating solar module with IR transmitting glass (1501), a support (1502) for the glass and/or solar absorbing tubes and tubes (1503) that absorb heat and carry heat-transfer fluid.

[0072] FIG. 16 shows an exemplary embodiment of the underside thermal energy generating solar shingle with a composite frame (1601), IR absorbing tubes (1602), a manifold for collecting heat transfer fluid from the array of tubes (1603), and a corrugated tube (1604) to transport fluid from the manifold to a series connection with an adjoining panel or to pass through the roof surface for storage and distribution.