U.S. patent application number 12/134049 was filed with the patent office on 2008-12-11 for integrated solar roofing tile connection system.
This patent application is currently assigned to SOLAR ROOFING SYSTEMS, INC.. Invention is credited to Peter Bressler, Abby Nessa Feinstein, Seth Galewyrick, Martin Low, Edward Siahaan, David Wachob.
Application Number | 20080302031 12/134049 |
Document ID | / |
Family ID | 40094566 |
Filed Date | 2008-12-11 |
United States Patent
Application |
20080302031 |
Kind Code |
A1 |
Bressler; Peter ; et
al. |
December 11, 2008 |
INTEGRATED SOLAR ROOFING TILE CONNECTION SYSTEM
Abstract
An integrated solar roofing tile connection system for
installing on a roof surface for converting solar energy into
electrical energy includes a plurality of battens that each have a
length and are mounted to the roof surface. The plurality of
battens are generally parallel to and spaced from one another. A
plurality of electrically connected female connectors mounted to
each batten and spaced along the length of each batten. A plurality
of photovoltaic roofing tiles are mounted to each batten. Each
photovoltaic roofing tile has a tile base that has a first side
surface, a second side surface and a top edge and a photovoltaic
circuit. The photovoltaic circuit includes a plurality of
electrically interconnected photovoltaic cells and first and second
terminal ends. Each photovoltaic roofing tile includes a male
connector that extends from the tile base. Each male connector at
least partially exposes the first and second terminal ends. Each
male connector is removably mountable to and in electrical
engagement with a corresponding female connector.
Inventors: |
Bressler; Peter;
(Philadelphia, PA) ; Galewyrick; Seth;
(Philadelphia, PA) ; Siahaan; Edward;
(Philadelphia, PA) ; Feinstein; Abby Nessa;
(Philadelphia, PA) ; Wachob; David; (New Hope,
PA) ; Low; Martin; (Collegeville, PA) |
Correspondence
Address: |
PANITCH SCHWARZE BELISARIO & NADEL LLP
ONE COMMERCE SQUARE, 2005 MARKET STREET, SUITE 2200
PHILADELPHIA
PA
19103
US
|
Assignee: |
SOLAR ROOFING SYSTEMS,
INC.,
Philadelphia
PA
|
Family ID: |
40094566 |
Appl. No.: |
12/134049 |
Filed: |
June 5, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60942112 |
Jun 5, 2007 |
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60942124 |
Jun 5, 2007 |
|
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60942151 |
Jun 5, 2007 |
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Current U.S.
Class: |
52/173.3 |
Current CPC
Class: |
H01R 12/721 20130101;
H02S 20/25 20141201; Y02E 10/50 20130101; H01R 13/112 20130101;
Y02B 10/10 20130101; H02S 40/34 20141201 |
Class at
Publication: |
52/173.3 |
International
Class: |
E04D 13/18 20060101
E04D013/18 |
Claims
1. An integrated solar roofing tile connection system for
installing on a roof surface and converting solar energy into
electrical energy, the integrated solar roofing tile connection
system comprising: a plurality of battens each having a length and
being mounted to the roof surface, the plurality of battens being
generally parallel to and spaced from one another; a plurality of
electrically connected female connectors mounted to each batten and
spaced along the length of each batten; and a plurality of
photovoltaic roofing tiles mounted to each batten, each
photovoltaic roofing tile having a tile base having a first side
surface, a second side surface and a top edge and a photovoltaic
circuit, the photovoltaic circuit including a plurality of
electrically interconnected photovoltaic cells and first and second
terminal ends, each photovoltaic roofing tile further including a
male connector extending from the tile base, each male connector at
least partially exposing the first and second terminal ends, each
male connector being removably mountable to and in electrical
engagement with a corresponding female connector.
2. The integrated solar roofing tile connection system of claim 1,
wherein the photovoltaic cells and photovoltaic circuit are
contained within a laminate that is mounted to each tile base.
3. The integrated solar roofing tile connection system of claim 2,
wherein the laminate is spaced a first predetermined tile overlap
distance from the top edge of the base and substantially covers the
remainder of the first side surface of the tile base.
4. The integrated solar roofing tile connection system of claim 1,
wherein each male connector has an outwardly extending flange that
extends around an outer periphery of the male connector proximate
the top edge of the tile base.
5. The integrated solar roofing tile connection system of claim 4,
wherein the flange includes a sealing elastomeric o-ring.
6. The integrated solar roofing tile connection system of claim 1,
wherein the male connector extends from the top edge of the tile
base.
7. The integrated solar roofing tile connection system of claim 1
wherein each batten includes a pivot extension extending from a top
edge of the batten, each female connector being pivotably mounted
to a respective pivot extension.
8. The integrated solar roofing tile connection system of claim 1
wherein each female connector is electrically connected through
wiring, the wiring at least partially mounted to each batten and
extending between each of the female connectors.
9. The integrated solar roofing tile connection system of claim 1,
wherein each female connector is mounted to the respective
batten.
10. The integrated solar roofing tile connection system of claim 1,
wherein each female connector includes first and second contacts
electrically coupling with the first and second terminal ends
respectively.
11. The integrated solar roofing tile connection system of claim 1,
wherein each photovoltaic roofing tile partially overlaps three
adjacent photovoltaic roofing tiles.
12. The integrated solar roofing tile connection system of claim 1,
wherein each female connector includes a bypass diode electrically
connected between the first and second terminal ends.
13. The integrated solar roofing tile connection system of claim 1,
wherein the male connectors are rigid.
14. The integrated solar roofing tile connection system of claim 1,
wherein the first and second terminal ends are exposed on a bottom
surface of the male connector facing toward the second side surface
of the tile base.
15. The integrated solar roofing tile connection system of claim 1,
wherein each tile base includes at least one batten latch flexibly
extending from the second side surface, each batten latch
releasably engaging a top edge of the corresponding batten at least
partially securing the roofing tile to the respective batten.
16. The integrated solar roofing tile connection system of claim 1
further comprising a plurality of non-photovoltaic roofing tiles
mounted to the battens.
17. An integrated solar roofing tile connection system for
installing on a roof surface and converting solar energy into
electrical energy, the integrated solar roofing tile connection
system comprising: a plurality of battens each having a length and
a top edge and being mounted to the roof surface, the plurality of
battens being generally parallel to one another; and a plurality of
electrically connected female connectors pivotably mounted to the
top edge of each batten and spaced along the length of each batten;
a plurality of photovoltaic roofing tiles mounted to each batten,
each photovoltaic roofing tile having: a tile base having a first
side surface, a second side surface, a top edge and a lateral edge,
a photovoltaic laminate including a plurality of electrically
interconnected photovoltaic cells, the photovoltaic laminate being
fixedly mounted to the first side surface of the tile base and
being spaced a second tile overlap distance from the top edge, the
photovoltaic laminate substantially covering the remainder of the
first side of the tile base, the photovoltaic laminate including a
contact tab extending outwardly from the top edge of the tile base,
a photovoltaic circuit electrically connecting the photovoltaic
cells and having first and second terminal ends extending along the
contact tab, the first and second terminal ends being at least
partially exposed on a surface of the contact tab facing toward the
second side surface of the tile base, a rigid contact support
mounted partially over the contact tab and being generally parallel
to the photovoltaic laminate, a flange mounted around the contact
tab and the contact support proximate the top edge of the tile base
forming a male connector, wherein each male connector is removably
mounted to and in electrical engagement with the corresponding
female connector, and wherein a central photovoltaic roofing tile
overlaps a laterally adjacent photovoltaic roofing tile by an
amount equal to a first predetermined tile overlap distance and two
photovoltaic roofing tiles adjacent the top edge of the central
photovoltaic roofing tile each overlap the central photovoltaic
roofing tile an amount equal to the second tile overlap
distance.
18. The integrated solar roofing tile connection system of claim 17
further comprising a plurality of non-photovoltaic roofing tiles
generally covering the remainder of the roof surface.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/942,151 filed Jun. 5, 2007 entitled
"Solar Roofing Connector System", U.S. Provisional Patent
Application No. 60/942,112 filed Jun. 5, 2007 entitled "Solar
Roofing Tile Connection System" and U.S. Provisional Patent
Application No. 60/942,124 filed Jun. 5, 2007 entitled "Solar
Roofing Tile".
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a solar roofing tile
connection system, specifically a solar roofing tile connection
system that includes solar roofing tiles, custom battens and female
connectors that facilitate an electrical connection between
adjacent solar roofing tiles in an integrated solar roofing
system.
[0003] Photovoltaic cells formed of single crystal and/or thin film
sub-modules convert solar energy into electrical energy. Various
systems have been introduced to adapt photovoltaic cells for
installation on to commercial and residential roofs.
Conventionally, photovoltaic modules were provided as separate
devices on top of an existing roof. However, roofing products have
recently been developed that integrate the photovoltaic cells
directly into individual roofing tiles or shingles which are
assembled to form an integrated solar roofing system. The
integrated solar roofing system is installed like a typical pitched
roof. Any area of the roof that is undesirable for solar energy
generation is covered with visually consistent inactive tiles,
removing the obstacle of seamlessly blending photovoltaic cells
with an existing roofing product. Together they create a
functionally and visually integrated roofing membrane.
[0004] The flow of electricity travels from one photovoltaic
roofing tile to another and is used or transmitted to a grid.
Alternatively, the electricity may be stored. The photovoltaic
roofing tiles must be easy to install and easily removable to allow
for repairs and replacement. The electrical interconnection from
one photovoltaic roofing tile to the next, or from one photovoltaic
module to another photovoltaic module, has been typically formed
either through direct interconnection of photovoltaic module or
roofing tiles or through wiring which electrically connects the
photovoltaic roofing tiles or modules. Such a configuration
however, often requires special installation steps, instructions,
and special training to prepare and establish the electrical
connections. Therefore, a different installation method is required
for the photovoltaic roofing tiles than that used for installing
the inactive or conventional tiles. In some instances an
electrician is required, further increasing expense and
installation time. Additionally, removal and replacement of a
defective photovoltaic roofing tile without damaging or disturbing
adjacent tiles is often difficult.
[0005] There it is desirable to provide a solar roofing connection
system that allows for simplified installation such that
installation and replacement of the photovoltaic roofing tiles is
similar to that of non-photovoltaic or conventional roofing tiles.
Ultimately, there is a need to provide a solar roofing connection
system that requires minimal installation deviation from that of a
typical roof installation.
BRIEF SUMMARY OF THE INVENTION
[0006] Briefly stated, the present invention is directed to an
integrated solar roofing tile connection system for installing on a
roof surface and converting solar energy into electrical energy.
The integrated solar roofing tile connection system includes a
plurality of battens that each have a length and are mounted to the
roof surface. The plurality of battens are generally parallel to
and spaced from one another. A plurality of electrically connected
female connectors mounted to each batten and spaced along the
length of each batten. A plurality of photovoltaic roofing tiles
are mounted to each batten. Each photovoltaic roofing tile has a
tile base that has a first side surface, a second side surface and
a top edge and a photovoltaic circuit. The photovoltaic circuit
includes a plurality of electrically interconnected photovoltaic
cells and first and second terminal ends. Each photovoltaic roofing
tile further includes a male connector that extends from the tile
base. Each male connector at least partially exposes the first and
second terminal ends. Each male connector is removably mountable to
and in electrical engagement with a corresponding female
connector.
[0007] In another aspect, the invention is directed to an
integrated solar roofing tile connection system for installing on a
roof surface and converting solar energy into electrical energy.
The integrated solar roofing tile connection system includes a
plurality of battens that each have a length and a top edge and are
mounted to the roof surface. The plurality of battens are generally
parallel to and spaced from one another. A plurality of
electrically connected female connectors are pivotably mounted to
the top edge of each batten and are spaced along the length of each
batten. A plurality of photovoltaic roofing tiles are mounted to
each batten. Each photovoltaic roofing tile has a tile base that
has a first side surface, a second side surface, a top edge and a
lateral edge. Each photovoltaic roofing tile includes a
photovoltaic laminate that includes a plurality of electrically
interconnected photovoltaic cells. The photovoltaic laminate is
fixedly mounted to the first side surface of the tile base and is
spaced a second tile overlap distance from the top edge. The
laminate substantially covers the remainder of the first side of
the tile base. The laminate includes a contact tab that extends
outwardly from the top edge of the tile base. A photovoltaic
circuit electrically connects the photovoltaic cells and has first
and second terminal ends that extend along the contact tab. The
first and second terminal ends are at least partially exposed on a
surface of the contact tab facing toward the second side surface of
the tile base. Each photovoltaic roofing tile includes a rigid
contact support that is mounted partially over the contact tab and
is generally parallel to the photovoltaic laminate. Each
photovoltaic roofing tile includes a flange that is mounted around
a periphery of the contact tab and the contact support proximate
the top edge of the tile base forming a male connector. Each male
connector is removably mounted to and in electrical engagement with
the corresponding female connector. A central photovoltaic roofing
tile overlaps a laterally adjacent photovoltaic roofing tile by an
amount equal to a first predetermined tile overlap distance and two
photovoltaic roofing tiles adjacent the top edge of the central
photovoltaic roofing tile each overlap the central photovoltaic
roofing tile an amount equal to the second tile overlap
distance.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The foregoing summary, as well as the following detailed
description of a preferred embodiment of the invention, will be
better understood when read in conjunction with the appended
drawings. For the purpose of illustrating the invention, there is
shown in the drawings an embodiment which is presently preferred.
It should be understood, however, that the invention is not limited
to the precise arrangements and instrumentalities shown.
[0009] In the drawings:
[0010] FIG. 1 is a top perspective view of an installed integrated
solar roofing system in accordance with the preferred embodiment of
the present invention partially cut away to show the underlying
battens and female connectors;
[0011] FIG. 2 is a top perspective view of a photovoltaic roofing
tile of the integrated solar roofing system shown in FIG. 1;
[0012] FIG. 3 is an exploded perspective view of a photovoltaic
laminate of the photovoltaic roofing tile shown in FIG. 2;
[0013] FIG. 4 is a perspective view of a mold for manufacturing the
photovoltaic roofing tile shown in FIG. 2;
[0014] FIG. 5 is a perspective view of a non-photovoltaic roofing
tile of the integrated solar roofing system shown in FIG. 1;
[0015] FIG. 6 is an exploded perspective view of the
non-photovoltaic roofing tile shown in FIG. 5;
[0016] FIG. 7 is an exploded perspective view of the female
connectors and battens shown in FIG. 1;
[0017] FIG. 8 is a top perspective view of the assembled female
connectors and battens shown in FIG. 1 with the photovoltaic and
non-photovoltaic tiles removed;
[0018] FIG. 9 is a top perspective view of female connectors and
solar roofing battens shown in FIG. 1 during installation using a
batten sheet;
[0019] FIG. 10 is an enlarged top perspective view of a female
connector extending from a batten shown in FIG. 1;
[0020] FIG. 11 is a bottom perspective view of the female connector
and batten shown in FIG. 10;
[0021] FIG. 12 is a rear cross-sectional perspective view of the
female connector and batten shown in FIG. 10 taken along line 12-12
in FIG. 10;
[0022] FIG. 13 is a side cross-sectional perspective view of the
female connector shown in FIG. 10 taken along line 13-13 in FIG.
10;
[0023] FIG. 14 is a side elevational partial cross section view of
a photovoltaic roofing tile, batten and female connector shown in
FIG. 1 just prior to installation of the photovoltaic roofing tile;
and
[0024] FIG. 15 is a side elevational partial cross section view of
the photovoltaic tile, batten and female connector shown in FIG. 14
after installation of the photovoltaic tile.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Certain terminology is used in the following description for
convenience only and is not limiting. The words "right", "left",
"lower" and "upper" designate directions in the drawings to which
reference is made. The words "inwardly" and "outwardly" refer to
directions toward and away from, respectively, the geometric center
of an integrated solar roofing connection system in accordance with
the present invention, and designated parts thereof. Unless
specifically set forth herein, the terms "a", "an" and "the" are
not limited to one element but instead should be read as meaning
"at least one". The terminology includes the words noted above,
derivatives thereof and words of similar import.
[0026] Referring to FIG. 1, the integrated solar roofing system,
generally designated 10, is used to generate electricity from solar
energy on a roof or roof surface 20 of a residential or a
commercial building 22. The integrated solar roofing system 10 is
comprised of active or photovoltaic roofing tiles 12 and inactive
or non-photovoltaic roofing tiles 14. In FIG. 1, the photovoltaic
roofing tiles 12 are shown having a phantom interior outline
designating a photovoltaic layer 42. However, the photovoltaic
roofing tiles 12 preferably have the same or a similar appearance
to the non-photovoltaic roofing tiles 14 and the variation in
appearance in the drawings is for demonstrative purposes only. The
photovoltaic roofing tiles 12 have the same or a similar appearance
and configuration to the non-photovoltaic roofing tiles 14 but the
photovoltaic roofing tiles 12 include at least one photovoltaic
cell 16 (FIG. 3) for generating electricity. The photovoltaic
roofing tiles 12 are grouped in an area on the roof 20 that is a
desired area for generating electricity. The area could be small,
involving only a few photovoltaic roofing tiles 12 or the entire
roof 20 depending on cost, location of the roof 20 relative to the
sun and obstacles such as trees or a neighboring building blocking
the sun. For example, most users in North America may choose to
place the photovoltaic roofing tiles 12 only on the south facing
side of a roof 20 because of the extended exposure from the south
due to the earth's tilt relative to the sun. The photovoltaic
roofing tiles 12 and the non-photovoltaic roofing tiles 14
preferably have an oscillating or curved shape to resemble
conventional ceramic roof tiles. However, the photovoltaic roofing
tiles 12 and the non-photovoltaic roofing tiles 14 may be formed in
any shape such as a flat slate-like tile for example.
[0027] Referring to FIGS. 2-4, each photovoltaic roofing tile 12 is
preferably comprised of a tile base 18 which is constructed of
building code approved material. The tile base 18 has a sun or
first side 18a, a roof or second side 18b, an upper or top edge
18c, a lower or bottom edge 18d, a first lateral side 18e and a
second lateral side 18f. The tile base 18 is preferably constructed
of an inserted molded polypropylene material, as discussed further
below but the tile base 18 may be constructed of any suitable
roofing material such as authentic slate, authentic ceramic tile,
authentic cement tile, metal roofing, asphalt roofing, Elastocast
(BASF), Bayflex (Bayer Material Science), Zytrel and/or Hytrel
(Dupont). The tile base 18 may also be metallic, mineral, organic,
polymeric, or a nondisclosed composite material.
[0028] The tile base 18 preferably includes at least one and
preferably a pair of recessed space apart nail targets 24 located
toward the top edge 18c of the tile base 18. Each nail target 24
preferably has a flat base 24a to provide a large surface in direct
contact with a batten 26 (FIG. 1) and helps to prevent the
photovoltaic roofing tile 18 from lifting from the roof surface 20
in heavy winds. The nail target 24 preferably also includes a
raised nail hole 24b. The nail hole 24b is raised to help prevent
any water that may have entered the recessed nail target 24 from
entering the nail hole 24. The tile base 18 further preferably
includes at least one and preferably a pair of spaced apart, spring
biased batten latches 28 proximate the top edge 18c and preferably
spaced alternately between the nail targets 24 for temporarily and
releasably engaging with a batten 26 during installation to hold
the photovoltaic roofing tile 12 in place until the photovoltaic
roofing tile 12 is more permanently secured to the batten 26 as
described in further detail below. The batten latches 28 preferably
each have a general Z-shape (in side view, see FIG. 14) with a
longer proximal end 28a that is attached to the tile base 18 (see
FIGS. 14 and 15). The batten latches 28 are each preferably
upwardly angled at least at the distal end 28b of each batten latch
28. The distal end 28b at least partially extends away from the
tile base 18 further than the lowest point of the tile base 18. The
batten latches 28 are each spring biased such that the distal end
28b is capable of being urged upwardly and into a batten latch
recess 28c (See FIG. 2) within the tile base 18 such that the
batten latch 28 does not extend past the tile base 18. The batten
latch 28 is preferably molded of the same or similar material as
the tile base 18 and has a relatively thin proximal end 28a such
that the batten latch 28 may be broken free from the tile base 18
as described further below. Though it is preferred that the batten
latches 28 are molded of the same or similar material as the tile
base 18, the batten latches 28 may be molded of a different
material such as metal and either insert molded or otherwise later
installed or assembled to the tile base 18. The batten latches 28
and the recessed nail targets 24 are preferably configured such
that when the photovoltaic roofing tiles 12 are stacked on top of
one another during shipping and storage, the downwardly projecting
portions of the recessed nail targets 24 and the batten latches 28
are received within the recessed nail targets 24 and the batten
latches 28 respectively of the photovoltaic roofing tile 12
directly below such that the photovoltaic roofing tiles 12 are
nestable and form a compact stack. The compactness of the stacked
photovoltaic roofing tiles 12 allows for more photovoltaic roofing
tiles 12 to be shipped and/or stored on a palette (not shown) and
occupy a space similar in size to what a stack of conventional roof
tiles (not shown) would occupy.
[0029] A first ridge 30 preferably extends away from the first side
18a of the tile base 18 proximate the top edge 18c. A second ridge
32 preferably extends away from the second side 18b of the tile
base 18 proximate the bottom edge 18d. The first and second ridges
30, 32, act as dams or barriers when the photovoltaic roofing tiles
12 are installed to prevent wind driven rain or moisture from
extending beyond and eventually underneath the overlapping
photovoltaic roofing tiles 12. The tile base 18 also preferably
includes an upwardly facing grove 34 on the first side 18a of the
tile base 18 proximate the first lateral side 18e and a
correspondingly shaped downwardly facing groove 36 on the second
side 18b proximate the second lateral side 18f. The upwardly facing
grooves 34 mate with the downwardly facing grooves 36 during
installation such that the downwardly facing grooves 36 overlap the
upwardly facing grooves 34 allowing an overlap of the second
lateral side 18f a first overlap distance D.sub.1 to overlap the
first lateral side 18e of an adjacent photovoltaic roofing tile 12
as the photovoltaic roofing tiles 12 are installed from left to
right along the roof surface 20. The orientation of the upwardly
facing grooves 34 may be switched with the downwardly facing
grooves 36 such that the first lateral side 18e of the photovoltaic
roofing tile 12 overlaps the second lateral side 18f of an adjacent
photovoltaic roofing tile 12.
[0030] Referring to FIGS. 2, 3 and 4, each photovoltaic roofing
tile 12 includes a thin generally flexible photovoltaic laminate 38
fixedly mounted to the first side 18a of the tile base 18. The
laminate 38 is comprised of several encapsulated layers sandwiching
the thin film photovoltaic cell(s) 16 and connected circuitry 40.
The circuitry 40 is preferably comprised of a tin/silver copper or
simply copper bus (not shown) with various solder/flux
combinations. The circuitry 40 includes first and second terminal
ends 40a, 40b that extend from the laminate 38 along a contact tab
56. The photovoltaic cells 16 and circuitry form a photovoltaic
layer 42. The photovoltaic layer 42 is sandwiched between a first
laminate sheet 44 and a second laminate sheet 46. The first and
second laminate sheets 44, 46 are preferably constructed from but
not limited to ETFE fluorinated polymer Tefzel, Aklar, silicone
oxide or any other water vapor barrier layers such as glass. The
first laminate sheet 44 allows light into the photovoltaic cells 16
while providing a protective cover for the photovoltaic layer 42.
The first laminate sheet 44 is preferably textured or otherwise
treated to avoid an overly shiny or reflective surface and to
better conceal the appearance of the photovoltaic layer 42. The
first and second laminate sheets 44, 46 are preferably laminated to
opposing sides of the photovoltaic layer 42 by first and second EVA
laminate adhesive layers 48, 50. The bottommost layer of the
photovoltaic laminate 38 is preferably an applique layer or back
sheet 52 constructed of a polypropylene material or any suitable
material such as EPE (ethyl vinyl acetate (EVA)/polyester/EVA). The
back sheet 52 may be mounted to the second laminate sheet 44 by a
third adhesive layer 54. The back sheet 52 prevents the hot
material injected during molding of the tile base 18 from damaging
the photovoltaic laminate 38. The first laminate sheet 44 and the
first adhesive layer 48 preferably include a first laminate tab 44a
and a first adhesive tab 48a respectively which each extend over
the entire length of the contact tab 56. The second and third
adhesive layers 50, 54, the second laminate sheet 46 and the back
sheet 52 have a second adhesive tab 50a, a third adhesive tab 54a,
a second laminate tab 46a and a back sheet tab 52a respectively
that preferably extend only partially along the contact tab 56
until the contact tab 56 reaches the top edge 18c of the tile base
18 such that a distal end of the first and second terminal ends
40a, 40b is exposed toward the second side 18b of the tile base 18
or toward the roof surface 20. However, the first and second
terminal ends 40a, 40b may be left uncovered in any direction on
the contact tab 56 or in any manner such as cutting slots or holes
to leave at least a portion of the first and second terminal ends
40a, 40b following the lamination process without the need for
further manufacturing steps and is sufficient to allow for an
electrical connection with the photovoltaic layer 42 as described
further below.
[0031] The laminate 38 is preferably manufactured via a vacuum
lamination process where a specific cycle of heat, vacuum, and
pressure is applied to produce a flexible but durable laminate that
provides outdoor and mechanical and environmental protection to the
photovoltaic cell(s) 16. The photovoltaic laminate 38 is formed by
assembling the photovoltaic layer 42 between the first and second
laminate sheets 44, 46, with or without the first and second
adhesive layers 48, 50 and then placing the stack in a vacuum
laminator (not shown). Preferably, but not limiting, a platen (not
shown) is set at 150.degree. C. For approximately three minutes,
both chambers then pull a vacuum for about seven minutes the upper
chamber is released to atmosphere for a total cycle of about 10
minutes. Aluminum sheets (not shown) are preferably used as carrier
sheets to carry the laminate 38 into and out of the laminator. A
gritted surface such as sandpaper (not shown), is preferably
provided on one of the carrier sheets to provide a textured surface
to the first laminate sheet 44. Alternatively, the aluminum of the
carrier sheets or the platen of the laminator themselves could be
textured to provide the textured surface to the first laminate
sheet 44. The back sheet 52 is then attached to the second laminate
layer 46, preferably using the third adhesive layer 54. While a
preferred series of layers for the photovoltaic laminate 38 has
been described above, other arrangements of layers and other
materials for the individual layers could be used to achieve the
same result of securing photovoltaic cells 16 to the tile base
18.
[0032] Referring to FIG. 4, once the photovoltaic laminate 38 has
been assembled, the photovoltaic laminate 38 is inserted into a
mold 58. The laminate 38 is preferably preheated to a predetermined
temperature to prevent the photovoltaic laminate 38 from being
subjected to two different heats, one on each side of the
photovoltaic laminate 38, that could cause the photovoltaic
laminate 38 to warp during cooling. Preheating the laminate 38
allows the laminate 38 and tile bale 18 to cool and shrink
generally at a similar rate and amount. Once in place in the mold
58, the photovoltaic laminate 38 is preferably held toward a first
side 58a of the mold 58 by a vacuum 58c or other means. Because the
photovoltaic laminate 38 is flexible, the photovoltaic laminate 38
conforms to the shape 58d of the mold 58 (the generally shape 58d
of the mold 58 is shown in phantom). A rigid contact support 62 is
preferably inserted over the contact tab 56 during the molding
process as well forming a male connector 64 such that the contact
support 62 is positioned between the contact tab 56 and the first
side 58a of the mold 58 during molding. However, the contact
support 62 may be integrally formed with the tile base 18. When
cooled, the contact support 62 adds stiffness to the contact tab 56
extending from the top edge 18c of the tile base 18. A molten
polymeric material is then injected into the mold 58 through an
injection port 60 on a second side 58b of the mold 58 to form the
tile base 18 underneath the laminate 38. The back sheet 52 protects
the photovoltaic layer 42 and the second laminate sheet 46 from
being damaged proximate the injection port 60 where the injected
material for the tile base 18 is at its highest temperature. An
outwardly extending flange 66 (FIG. 2), is preferably molded around
a portion the contact support 62 and the contact tab 56 proximate
the top edge 18c forming a rigid male connector 64. The flange 66
preferably includes an elastomeric o-ring 66a that is assembled
onto the flange 66 after the molding process (See FIG. 13). Though
it is preferred that the flange 66 be integrally molded with the
tile base 18, the flange 66 may be separately assembled or may be
part of the contact support 62. The photovoltaic roofing tile 12 is
preferably molded in a generally vertical orientation to enable
gravity to assist in maintaining the proper positioning of the
photovoltaic laminate 38 and the contact support 62 during the
molding process. Though it is preferred that the photovoltaic
laminate 38 be fixed to the tile base 18 using the insert molding
process described above, the photovoltaic laminate 38 may be
mounted to the tile base 18 in any suitable manner such as using an
adhesive or fasteners. Once the photovoltaic roofing tile 12 has
sufficiently cooled, the photovoltaic roofing tile 12 is removed
from the mold 58. Once removed from the mold, it is preferred that
the first and second terminal ends 40a, 40b are exposed on a bottom
surface of the male connector 64 as a result of the molding process
to form a rigid, integral male electrical plug or connector 64
right out of the mold 58 without the need for further steps or
attachments. The first and second terminal ends 40a, 40b may be
exposed through the laminate 38 in any direction on the male
connector 64 so long as there is no need to perform additional
steps once the photovoltaic roofing tile 12 is removed from the
mold 58 such as removing material from the male connector 64 or
attaching additional components.
[0033] Referring to FIG. 2, though the photovoltaic laminate 38 is
generally thin, it is preferred that the photovoltaic laminate 38
be generally flush with the remainder of the first side 18a of the
tile base 18. The photovoltaic laminate 38, except for the contact
tab 56, is preferably spaced from the top edge 18c by a second tile
overlap distance D.sub.2. During installation, a subsequent upper
row of photovoltaic roofing tiles the previous lower row of
photovoltaic roofing tiles 12 by the overlap distance D.sub.2
preferably such that only the photovoltaic laminate 38 is exposed
and any portion of the first side surface 18a not covered by the
photovoltaic laminate 38 is covered by an adjacent overlying
photovoltaic roofing tile 12 or adjacent non-photovoltaic roofing
tile 14. Spacing the photovoltaic laminate 38 from the top edge 18c
allows for the nail targets 24 and batten latches 28 to extend
through the base tile 18 without damaging or otherwise impacting
the photovoltaic laminate 38. The photovoltaic laminate 38
preferably extends from the first lateral side 18e to the second
lateral side 18f of the tile base with the photovoltaic layer 42
being spaced from the first lateral side 18e by the first overlap
distance D.sub.1. However, the photovoltaic laminate 38 need not
necessarily extend from the first lateral side 18e to the second
lateral side 18f and may be cover any suitable amount of the first
side surface 18a such as being spaced from the first lateral side
18e by the first overlap distance D.sub.1 to prevent being
contacted by an adjacent photovoltaic roofing tile 12.
[0034] Referring to FIGS. 5 and 6, the non-photovoltaic roofing
tiles 14 are configured and manufactured in a similar manner as the
photovoltaic roofing tiles 12 except that the non-photovoltaic
roofing tiles 14 do not include the male connector 64 and the
photovoltaic laminate 38 is replaced with a cover 68. The
components of the non-photovoltaic roofing tile 14 that are similar
to photovoltaic roofing tile 12 have been labeled with similar
numbering as the photovoltaic roofing tile 12 with the addition of
a trailing prime symbol. The cover 68 is comprised of an upper
layer 70, a fourth adhesive layer 72 and a back sheet 52'. The
upper layer 70 is preferably a glossy layer of weatherproof paint
such as the type used on automobiles. However, any suitable
material may be used so long as the upper layer 70 has a similar
appearance as the photovoltaic laminate 38 to help create a
visually consistent roof 20 where it is not readily discernable
which roofing tiles 12, 14 are the photovoltaic roofing tiles 12
and which roofing tiles 12, 14 are the non-photovoltaic roofing
tiles 14. The cover 68 is preferably molded to the tile base 18' in
a similar manner as described above for the laminate 38 of the
photovoltaic roofing tile 12.
[0035] Referring to FIGS. 7-9, photovoltaic roofing tiles 12 are
electrically connected to each other through a plurality of
corresponding female connectors 74 and battens 26. The battens 26
are preferably custom made and replace the use of conventional
battens (not shown). However, the battens 26 may alternatively be
comprised of a cover (not shown) that extends over the conventional
battens. The battens 26 are preferably molded of a polymeric
material and are mounted to a batten sheet 76. The batten sheet 76
is preferably a flexible sheeting material similar to conventional
roofing underlayments 78 (FIG. 9). The batten sheet 76 preferably
includes nail markings (not shown) to indicate where the battens 26
and or photovoltaic roofing tiles 12 are to be installed. The
batten sheet 76 may be used in place of the conventional
underlayment 78 or the batten sheet 76 may be installed in addition
to and on top of the conventional underlayment 78 (see FIG. 9). The
batten sheet 76, battens 26 and female connectors 74 are preferably
used only under the photovoltaic roofing tiles 12 while only
conventional battens are used under the non-photovoltaic roofing
tiles 14. However, the batten sheet 76 and battens 26 may extend
under or be used under the non-photovoltaic roofing tiles 14 as
well.
[0036] The batten sheet 76 is preferably installed with the battens
26 and female connectors 74 already attached prior to installation.
Pre-installation of the battens 26 and the female connectors 74
facilitates simplified installation of the integrated solar roofing
system 10 and allows for automated and precise assembly in a
factory setting. However, the battens 26 and female connectors 74
may be assembled on the roof surface 20 as well. The female
connectors 74 are preferably pre-installed on the respective batten
26 and the battens 26 are attached to the roof surface 20 or batten
sheet 76 at the appropriate locations by the manufacturer or
distributor. However, the female connectors 74 may be attached to
the battens 26 during roof installation, with the spacing being
measured or dictated by the location of the corresponding male
connector 64. If the batten sheet 76 is installed first without
pre-connected battens 26, the batten sheet 76 is installed in the
same manner that the conventional underlayment 78 is installed
except that the batten sheet 76 preferably includes nail markings
for positioning of the battens 26. Once the batten sheet 76 is
installed in an area where the photovoltaic roofing tiles 12 are to
be installed, the battens 26 are nailed or otherwise secured into
place and the female connectors 74 are positioned on the battens 26
where it is projected that a male connector 64 will extend from the
top of the photovoltaic roofing tiles 12. The male connector 64
allows for mechanical and electrical connection of the photovoltaic
cells 16 and the female connectors 74 such that adjacent
photovoltaic roofing tiles 12 may be electrically connected to
combine the resulting electrical energy.
[0037] Referring to FIG. 10, each female connector 74 is preferably
pivotably attached to the respective batten 26. The battens 26 each
include a C-shaped pivot extension 80 extending from the upper edge
of the batten 26. A nail extension 82 preferably extends from the
lower edge of the batten 26 in the opposite direction from the
pivot extension 80. The nail extension 82 preferably has a smaller
thickness than the remainder of the batten 26 and is preferably
used for receiving nails (not shown) or other fasteners for
securing the batten 26 to the roof surface 20. The nail extensions
82 may include nail markings (not shown) to indicate where a nail
or fastener should be inserted. The female connectors 74 preferably
each include a pair of generally cylindrical pivot arms 84. The
pivot arms 84 extend laterally from the remainder of the female
connector 74 and are pivotably disposed within the pivot extension
80. The pivot arms 84 are preferably snap fit into the pivot
extension 80 such that the female connector 74 may be easily
installed and removed from the batten 26. If the female connectors
74 and battens 26 are pre-installed or temporarily secured to the
batten sheet 76, the batten sheet 76 may be directly rolled,
vertically upwardly rather than from left to right, onto the roof
structure 20 with the battens 26 and female connectors 74 already
in the appropriate positions (see FIG. 9). The pivotal connection
of the female connector 74 to the batten 26 not only allows for a
slight tilt of the female connector 74 during installation as
described further below but the pivotal connection of the female
connectors 74 with respect to the battens 26 also allows for the
female connectors 74 to be at least partially folded on top of the
batten 26 such that the batten sheet 76 may be rolled up with the
battens 26 and female connectors 74 already in place. Once the
batten sheet 76 is unrolled, the female connectors 74 pivot to lay
against the batten sheet 76 due to gravity or are manually flipped
down onto the batten sheet 76 by the installer prior to
installation of the photovoltaic roofing tiles 12.
[0038] Referring to FIGS. 10-13, each female connector 74 includes
a pair of first and second contacts 90, 92 preferably in the form
of two U-shaped clips that receive and tightly engage the distal
end of the male connector 64 such that the first and second
terminal ends 40a, 40b are in direct and positive electrical
contact with the first and second contacts 90, 92 respectively. The
first and second contacts 90, 92 may have any shape capable of
allowing a good electrical connection between the first and second
terminal ends 40a, 40b and the first and second contacts 90, 92 and
need not extend over the contact support 62. A first electrical
wire 94 is connected to the first contact 90 and a second
electrical wire 96 is connected to the second contact 92. The first
and second electrical wires 94, 96 each include an insulating cover
94a, 96a respectively.
[0039] Referring to FIGS. 11 and 13, the first and second
electrical wires 94, 96 are preferably contained, or at least
partially contained, within the battens 26. A wire groove 98
extending into and along the pivot extension 80 is preferably
provided for example for receiving and retaining the first and
second electrical wires 94, 96 as they runs from one female
connector 74 to the next female connector 74 along the batten 26.
Though it is preferred that the first and second wires 94, 96 be
contained within the pivot extension 80, the first and second
electrical wires may be at least partially contained within the
batten 26, within the batten sheet 76 or not restrained at all. The
first and second electrical wires 94, 96 may also be integrally
provided within the batten 26 and the contact between the pivot
arms 84 or the like between the female connector 74 and the batten
26 could also establish an electrical connection with internal
electrical wiring or electrically conductive elements (not shown).
The first electrical wire 94 extends in one lateral direction along
the batten 26 and the second electrical wire 96 extends in the
opposite lateral direction along the batten 26 such that there is
an electrical input and an electrical output to the female
connector 74. The first and second electrical wires 94, 96 may
extend to an adjacent or other photovoltaic roofing tile 12, off of
the roof surface 20, or to any other electrical component.
[0040] A bypass diode 100 preferably extends between the first and
second contacts 90, 92 such that the first and second contacts 90,
92 and the circuitry 40 in the photovoltaic layer 42 may be
electrically bypassed allowing electricity to run from the first
electrical wire 94 to the second electrical wire 96 without
interruption in the event that the photovoltaic roofing tile 12
fails or the connection between the female connector 74 and the
male connector 64 is interrupted. A first crimp sleeve 102
preferably secures the first electrical wire 94 to the first
contact 90 and a second crimp sleeve 104 preferably secures the
second electrical wire 96 to the second contact 92. The first and
second crimp sleeves 102, 104 also preferably hold the bypass diode
100 in connection with the first and second electrical wires 94,
96.
[0041] The female connector 74 is preferably comprised of a back
cover 74a and receiving window 74b. The receiving window 74b is at
least partially open toward the batten 26 for receiving the male
connector 64 from a photovoltaic roofing tile 12, preferably
allowing the only access to the first and second contacts 90, 92.
The receiving window 74b preferably includes sealing ribs 106
extending toward the center of the receiving window 74b and slanted
back toward the back cover 74a (FIG. 13). The back cover 74a and
the receiving window 74b are preferably held together with screws
74c extending through the back cover 74a (FIG. 11) and into screw
supports 74d in the receiving window 74b (FIG. 12). The back cover
74a and receiving window 74b are preferably sealed together with an
elastomeric gasket 108. Though the two piece female connector 74 is
preferred for assembly purposes, the female connector 74 may be
comprised of one or more sections and is not limited to having a
separate back cover 74a and receiving window 74b.
[0042] Referring to FIG. 13, the o-ring 66a on the flange 66
extends slightly further than the width and length of the opening
of the receiving window 74b. When the male connector 64 is inserted
into the female connector 74, the o-ring 66a is compressed and the
flange 66 preferably engages the ribs 106 to seal the male
connector 64 to the female connector 74 and prevent over insertion
of the male connector 64. The flange 66 may also snap fit or be
otherwise temporarily retained within the receiving window 74b.
When the flange 66 is inserted into the receiving window 74b, the
exposed first and second terminal ends 40a, 40b contact lower arms
90a, 92a of the first and second contacts 90, 92, respectively
(FIG. 13). The contact tab 56 and the contact support 62 spread
apart the first and second contacts 90, 92 to spring bias the first
and second contacts 90, 92 into good electrical contact with the
first and second terminal ends 40a, 40b respectively. The receiving
window 74b may include a pierceable covering (not shown) or
alternatively the ribs 106 may be held in compressive contact to
seal the female connector 74 during assembly to further prevent a
human finger (not shown) from touching the first and second
contacts 90, 92 but may separate with sufficient force caused by
the insertion of the male connector 64.
[0043] The female connectors 74 along a batten 26 are electrically
connected by the first and second electrical wires 94, 96. The
battens 26 may be configured either in parallel or series. For
example, when the photovoltaic roofing tiles 12 are arranged in
series, the first and second electrical wires 94, 96 runs from a
female connector 74 to the next adjacent female connector 74 along
one row from left to right such that the electrical wires 94, 96 do
not cross (FIGS. 11 and 12). In the next row, the ends of the first
and second electrical wires 94, 96 from right to left cross (not
shown) such that first and second wires 94, 96 alternates between
the inner most and outmost entry point of the adjacent female
connector 74. Such a configuration allows for a series connection
with the same photovoltaic roofing tiles 12 used throughout and
prevents the installer from confusing photovoltaic roofing tiles 12
that have reversed positive and negative terminal ends 40a, 40b.
Alternatively, each photovoltaic roofing tile 12, or more likely,
each row of photovoltaic roofing tiles 12, may be connected in
parallel. The first and second electrical wires 94, 96 may also
extend to a different batten 26 or off of the roof surface 20.
Regardless of the preferred configuration, the electrical schematic
may be determined and assembled in a factory setting, allowing the
installer to simply install the photovoltaic roofing tiles 12
similarly to the non-photovoltaic roofing tiles 14 without worrying
about the electrical schematic and arrangement of the photovoltaic
roofing tiles 12 other than to connect the male connector 64 of
each of the photovoltaic roofing tiles 12 to the corresponding
female connector 74.
[0044] Referring to FIGS. 1, 14 and 15, the photovoltaic roofing
tiles 12 and the non-photovoltaic roofing tiles 14 are preferably
installed in a conventional overlapping fashion. For example, a
first row of tiles 110 is installed from left to right overlapping
the previous photovoltaic or non-photovoltaic tile 12, 14 by a
first overlap distance D.sub.1 (FIG. 2) and then similarly
installing a second row of tiles 112 from left to right that
overlap the first row of tiles 110 by the second overlap distance
D.sub.2 (FIG. 2). The photovoltaic roofing tiles 12 and the
non-photovoltaic roofing tiles 14 are preferably installed in a
similar manner to one another in that the photovoltaic roofing
tiles 12 and the non-photovoltaic roofing tiles 14 are slid
upwardly on a plane spaced from and generally parallel to the roof
surface 20 such that each photovoltaic and non-photovoltaic roofing
tile 14 is slid across the batten 26 (see FIGS. 14 and 15). The
photovoltaic roofing tiles 12 preferably differ in installation in
only that the male connector 64 must be aligned with the
corresponding female connector 74. The horizontal receiving port
74b of the female connector 74 allows the male connector 64 to be
inserted within the female connector 74 without vertical
displacement (perpendicular to the roof surface 20) of the
photovoltaic roofing tile 12. As the photovoltaic roofing tile 12
is slid across the batten 26 a distal end 28b of the batten latch
28 contacts the front top edge of the batten 26 and deflects the
batten latch 28 upwardly into the batten recess 28c such that the
batten latch 28 is deflected out of the way and does not prohibit
or limit the photovoltaic roofing tile 12 from being slid across
the batten 26. Once the distal end 28b of the batten latch 28
passes the upper edge of the batten 26, the batten latch 28 returns
to its initial position under its own bias such that the distal end
28b engages or latches on to the upper rear edge of the batten 26.
The batten latch 28 engages with the batten 26 such that the
photovoltaic roofing tile 12 is temporarily held in place and
prevents the photovoltaic roofing tile 12 from sliding off of the
batten 26 during installation. Simultaneously with the engagement
of the batten latch 28 with the batten 26, the male connector 64
slides into the female connector 74 such that an electrical
connection is established. Because the mechanical connection to the
female connector 74 may not be sufficient to hold the photovoltaic
tile 12 in place, the batten latch 28 ensures that the photovoltaic
roofing tile 12 remains in place until a nail 114 (FIG. 15) or
other fastener more is driven through the recessed nail targets 24
to more permanently secure the photovoltaic roofing tile 12 to the
batten 26 and/or roof surface 20.
[0045] The horizontal installation of the photovoltaic roofing tile
12 also allows for easier removal and replacement of a defective
photovoltaic roofing tile 12 without disturbing adjacent tiles 12,
14. During removal or replacement of the photovoltaic roofing tile
12, the nail 114 is removed and the batten latch 28 is either
disengaged by the use of a tool (not shown) or may be broken off to
allow the photovoltaic roofing tile 12 to be removed in a generally
planar fashion as similar to insertion. A replacement photovoltaic
roofing tile 12 is then installed similarly to the initial
installation such that the photovoltaic roofing tile 12 is slid in
a plane generally parallel to the roof surface 20 and the male
connector 64 is inserted into the female connector 74.
[0046] Installation of the photovoltaic tiles 12 concludes by
dropping two leads, positive and negative (not shown), that extend
from the batten sheet 76 or the upward most solar roofing batten 26
connected to the electrical wires with "quick-connect" terminals
(not shown) into the roof ridge line or through a hole drilled
through the roof surface 20. The leads allow an electrician to
connect one batten sheet 76 to another batten sheet 76.
[0047] It will be appreciated by those skilled in the art that
changes could be made to the embodiment described above without
departing from the broad inventive concepts thereof. It is
understood, therefore, that this invention is not limited to the
particular embodiment disclosed, but it is intended to cover
modifications within the spirit and scope of the present invention
as defined by the appended claims.
[0048] Further, to the extent that the assembly methods do not rely
on the particular order of steps set forth herein, the particular
order of the steps in the steps set forth in the preferred methods
should not be construed as limitation on the claims. The claims
directed to the method of the present invention should not be
limited to the performance of their steps in the order written, and
one skilled in the art can readily appreciate that the steps may be
varied and still remain within the spirit and scope of the present
invention.
* * * * *