U.S. patent application number 15/399712 was filed with the patent office on 2018-04-26 for building integrated photovoltaic system for tile roofs.
The applicant listed for this patent is SolarCity Corporation. Invention is credited to Daniel Preston Flanigan, Jack Raymond West.
Application Number | 20180115275 15/399712 |
Document ID | / |
Family ID | 61970010 |
Filed Date | 2018-04-26 |
United States Patent
Application |
20180115275 |
Kind Code |
A1 |
Flanigan; Daniel Preston ;
et al. |
April 26, 2018 |
BUILDING INTEGRATED PHOTOVOLTAIC SYSTEM FOR TILE ROOFS
Abstract
Building integrated photovoltaic (BIPV) systems provide for
solar panel arrays that can be aesthetically pleasing to an
observer, with minimal visible difference between photovoltaic and
non-photovoltaic areas of the BIPV system. BIPV systems can be
incorporated as part of roof surfaces as built into the structure
of the roof, particularly as roofing tiles that have photovoltaic
elements embedded or incorporated into the body of the roofing
tiles. BIPV systems can also include mimic or dummy tiles that
appear similar to tiles with photovoltaic elements, but do not
collect solar energy. In some configurations, the appearance of
BIPV tile roof systems can be generally uniform to an observer at
ground level, where the blending and distribution of photovoltaic
and non-photovoltaic elements generate a consistent and elegant
appearance that camouflages any differences between photovoltaic
tile or non-photovoltaic tiles.
Inventors: |
Flanigan; Daniel Preston;
(Petaluma, CA) ; West; Jack Raymond; (San Rafael,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SolarCity Corporation |
San Mateo |
CA |
US |
|
|
Family ID: |
61970010 |
Appl. No.: |
15/399712 |
Filed: |
January 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62413298 |
Oct 26, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02S 40/34 20141201;
H01L 31/048 20130101; Y02B 10/10 20130101; H02S 20/25 20141201;
H02S 40/36 20141201; E04D 1/12 20130101; Y02E 10/50 20130101; Y02A
30/60 20180101 |
International
Class: |
H02S 20/25 20060101
H02S020/25; H02S 40/36 20060101 H02S040/36 |
Claims
1-2. (canceled)
3. The roofing system of claim 4, wherein the plurality of full PV
mimic tiles, left-half PV mimic tiles, right-half PV mimic tiles
are disposed over other sections of the roof.
4. A building integrated photovoltaic (BIPV) roofing system
comprising: at least one full PV tile; at least one left-half PV
tile; at least one right-half PV tile; at least one blank non-PV
roof tile; at least one full PV mimic tile; at least one left-half
PV mimic tile; and at least one right-half PV mimic tile; wherein a
plurality of full PV tiles, left-half PV tiles, right-half PV
tiles, and blank non-PV roof tiles are arranged together in a
non-regular pattern over a first section of a roof that receives
incident solar energy at a specific power production rating per
unit of roof area resulting in a first pattern density and
corresponding to an aggregate power production capability ranging
from 3,000 kW to 12,600 kW; wherein a plurality of full PV mimic
tiles, left-half PV mimic tiles, right-half PV mimic tiles, and
blank roof tiles are arranged on a second section of the roof in a
non-regular pattern at the first pattern density and are not
electrically coupled thereby providing a consistent visual
aesthetic to the first and second sections of the roof.
5. The roofing system of claim 4, wherein the plurality of full PV
roof tiles, left-half PV roof tiles, and right-half PV roof tiles
are electrically coupled via wiring positioned underneath the
plurality of full PV tiles, left-half PV tiles, right-half PV
tiles, and blank roof tiles.
6. The roofing system of claim 4, wherein the plurality of full PV
roof tiles, left-half PV roof tiles, and right-half PV roof tiles
are electrically coupled via power bus bars positioned underneath
the plurality of full PV tiles, left-half PV tiles, right-half PV
tiles, and blank roof tiles.
7. (canceled)
8. The roofing system of claim 4, wherein the plurality of full PV
tiles, left-half PV tiles, right-half PV tiles, and blank roof
tiles having the first pattern density are randomly distributed
over the first section of the roof.
9. The roofing system of claim 8, wherein the plurality of full PV
mimic tiles, left-half PV mimic tiles, right-half PV mimic tiles,
and blank roof tiles having the first pattern density are randomly
distributed over the second section of the roof.
10. The solar roof of claim 11, wherein the a plurality of first
photovoltaic roof tiles, second photovoltaic roof tiles, third
photovoltaic roof tiles carry an energy production load ranging
from 3,000 kW to 12,600 kW.
11. A solar roof comprising: a first photovoltaic roof tile, having
two solar cell modules; a second photovoltaic roof tile, having
only one solar cell module biased toward a left side of the second
photovoltaic roof tile; a third photovoltaic roof tile, having only
one solar cell module biased toward a right side of the third
photovoltaic roof tile; a non-photovoltaic roof tile; a series of
electrical connectors electrically coupling the first photovoltaic
roof tile, the second photovoltaic roof tile, and the third
photovoltaic roof tile on a common string via a wire harness; a
first photovoltaic dummy tile, having two silicon members; a second
photovoltaic dummy tile, having one silicon member biased toward a
left side of the second photovoltaic dummy tile; and a third
photovoltaic dummy tile, having one silicon member biased toward a
right side of the third photovoltaic dummy tile, wherein the first
photovoltaic roof tile, the second photovoltaic roof tile, the
third photovoltaic roof tile, and the non-photovoltaic roof tile
are adjacent one another and coupled to a common support surface to
form a first section of a solar roof surface and distributed on the
roof surface in at a solar cell density to provide a desired load
of power production capability, wherein the solar cell modules
cover from 70% to 80% of the first section of the roof surface, and
wherein the first photovoltaic dummy tile, the second photovoltaic
dummy tile, the third photovoltaic dummy tile, and the
non-photovoltaic roof tile are mechanically coupled to each other
to form a second section of the roof surface.
12. (canceled)
13. The solar roof of claim 11, wherein a plurality of the first
photovoltaic roof tile, the second photovoltaic roof tile, the
third photovoltaic roof tile, and the non-photovoltaic roof tile
are arranged in horizontal courses, where vertically adjacent
horizontal courses are offset from each other by about half a
photovoltaic tile width.
14. (canceled)
15. The solar roof of claim 11, wherein the electrically connected
solar cell modules build up to have a voltage at the end of the
wire harness of about from 50 V to about 80 V.
16. The solar roof of claim 11, wherein the electrically connected
solar cell modules build up to have a voltage at the end of the
wire harness of about 300 V.
17. The solar roof of claim 11, wherein one or more
non-photovoltaic roof tiles are cut to fit around an obstacle in
the roof surface.
18. The solar roof of claim 11, wherein the distribution and
arrangement of the first photovoltaic roof tile, the second
photovoltaic roof tile, the third photovoltaic roof tile, and the
non-photovoltaic roof tile provide for a consistent visual
aesthetic of the roof surface.
19. The solar roof of claim 11, wherein the distribution and
arrangement of the first photovoltaic dummy tile, the second
photovoltaic dummy tile, the third photovoltaic dummy tile, the
first photovoltaic roof tile, the second photovoltaic roof tile,
the third photovoltaic roof tile, and the non-photovoltaic roof
tile provide for a consistent visual aesthetic of the roof
surface.
20. The solar roof of claim 11, wherein: the first photovoltaic
roof tile, the second photovoltaic roof tile, the third
photovoltaic roof tile, and the non-photovoltaic roof tile are
assembled as a string of structural elements for an energy
production region of the roof surface; and wherein the first
photovoltaic dummy tile, the second photovoltaic dummy tile, the
third photovoltaic dummy tile and a further non-photovoltaic roof
tile are assembled as a string of structural elements for an
non-production region of the roof surface.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This claims the benefit of priority to U.S. Provisional
Application No. 62/413,298, entitled "BUILDING INTEGRATED
PHOTOVOLTAIC SYSTEM FOR TILE ROOFS" and filed on Oct. 26, 2016,
which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This generally relates to photovoltaic arrays.
BACKGROUND
[0003] Solar is becoming increasingly popular in the United States
and abroad, but penetration remains relatively low versus the
number of homes that could benefit from solar. The price per
kilowatt for solar is now competitive with or below that of utility
power in most areas, however, solar largely remains a niche product
for those who value saving money, reducing CO.sub.2 emissions, or
both.
[0004] One factor that may limit the adoption of solar technology
is aesthetics. Most residential solar systems are installed as
modules on an existing tile or composition shingle roof. The solar
array, which often only covers a portion of the roof, or even a
portion of one mounting plane on the roof, stands out as separate
and distinct from the existing roof, both in height and material.
This structure is therefore visible even from the street level and
over large distances.
[0005] Another obstacle to solar adoption in existing homes is the
dissonance between the age of the existing roof and the solar
system, particularly where the existing roof is made from
composition shingles. The expected life of a solar system can be
about 25 years, and the expected life of a composition shingle roof
is also about 50 years, depending on the local climate and specific
tile materials. At the time a customer is considering going solar,
their existing roof may be several years, if not decades, into that
lifespan. So the customer may be presented with the dilemma of
getting a new roof first, increasing the cost of going solar, or
installing a 25-year solar system on a roof which may have a
relatively shorter remaining operational lifespan.
[0006] Accordingly, there is a need to resolve the dissonance
between the expected life of the solar system and the remaining
life of the roof, that also blends in more aesthetically with the
complete roof surface or at least the mounting plane, and that does
not require the prospective customer to pay for a new roof and a
new solar system over that roof.
BRIEF SUMMARY
[0007] Various embodiments provide a new and improved approach to
installing solar on existing roofs, and in particular, existing
tile roofs. Some aspects fit over an existing tile roof and/or
other suitable roof surfaces (e.g., a metal roof, composite
shingle, roof deck, underlayment or insulation layer). Some aspects
have improved aesthetics that reduce the visual differences between
solar and non-solar portions of the roof. Some aspects are more
modular and/or simplify the replacement capability of individual
photovoltaic modules of the system. In addition, some aspects cost
less to make and install compared to conventional solar systems.
Further, some arrangements of solar and non-solar portions of the
roof, or of photovoltaic and non-photovoltaic portions of modules
or roof tiles, can generate a visual pattern and aesthetic that
appear irregular, random, or made from traditional roofing
materials. Some solar systems can be installed as a new roof rather
than a re-roof or mounted to an existing roof. These and other
embodiments are discussed in greater detail in the detailed
description and drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Illustrative aspects of the present disclosure are described
in detail below with reference to the following drawing figures. It
is intended that that embodiments and figures disclosed herein are
to be considered illustrative rather than restrictive
[0009] FIG. 1A shows an example of a prior art photovoltaic array
installed on a roof.
[0010] FIG. 1B shows an exemplary prior art photovoltaic
module.
[0011] FIG. 2A shows a schematic of a portion of a building
integrated photovoltaic system having photovoltaic tiles, in
accordance with embodiments of the disclosure.
[0012] FIG. 2B shows an exemplary photovoltaic tile having two
solar cells in the reveal portion of the tile, in accordance with
aspects of the disclosure.
[0013] FIG. 2C shows an exemplary photovoltaic tile having one
solar cell in the reveal portion of the tile, biased toward the
right side of the tile, in accordance with aspects of the
disclosure.
[0014] FIG. 2D shows an exemplary photovoltaic tile having one
solar cell in the reveal portion of the tile, biased toward the
left side of the tile, in accordance with aspects of the
disclosure.
[0015] FIG. 2E shows an exemplary non-photovoltaic tile having no
solar cells on the upper surface of the tile, in accordance with
aspects of the disclosure.
[0016] FIG. 2F shows an exemplary photovoltaic tile having two
non-photovoltaic silicon elements in the reveal portion of the
tile, in accordance with aspects of the disclosure.
[0017] FIG. 2G shows an exemplary photovoltaic tile having one
non-photovoltaic silicon element in the reveal portion of the tile,
biased toward the right side of the tile, in accordance with
aspects of the disclosure.
[0018] FIG. 2H shows an exemplary photovoltaic tile having one
non-photovoltaic silicon element in the reveal portion of the tile,
biased toward the left side of the tile, in accordance with aspects
of the disclosure.
[0019] FIGS. 2I and 2J show exploded cross-sectional views of solar
cells of photovoltaic modules, showing the different layers of the
photovoltaic module, in accordance with embodiments of the
disclosure.
[0020] FIG. 2K shows a schematic of a portion of a building
integrated photovoltaic system having non-photovoltaic tiles, in
accordance with embodiments of the disclosure.
[0021] FIG. 3 shows a perspective view of a photovoltaic tile,
having a solar cell on the left side of the reveal region, in
accordance with embodiments of the disclosure.
[0022] FIG. 4 shows an exemplary set of roof tiles including one
non-photovoltaic tile and three photovoltaic tiles with solar cells
in portions of the reveal region, in accordance with embodiments of
the disclosure.
[0023] FIG. 5 shows a set of roof tiles in three overlapping
courses, including both non-photovoltaic and photovoltaic tiles, in
accordance with embodiments of the disclosure.
[0024] FIG. 6 shows an exemplary residential building having a roof
constructed from both non-photovoltaic and photovoltaic tiles and
having an aesthetically pleasing appearance, in accordance with
embodiments of the disclosure.
[0025] FIG. 7A shows a schematic illustration of solar cell density
on a roof surface formed from photovoltaic tiles, having a
relatively light energy production layout, in accordance with
embodiments of the disclosure.
[0026] FIG. 7B shows a schematic illustration of solar cell density
on a roof surface formed from photovoltaic tiles, having a
relatively heavy energy production layout, in accordance with
embodiments of the disclosure.
[0027] FIG. 8 is a schematic of an exemplary BIPV array forming a
roof surface, with roof tiles arranged in multiple courses, in
accordance with embodiments of the disclosure.
[0028] FIG. 9 is a schematic of an exemplary BIPV array forming a
roof surface, with roof tiles arranged in multiple courses, where
roof surface has various obstacles to work around when laying down
roof tiles, in accordance with embodiments of the disclosure.
[0029] FIG. 10 is a schematic of roof surface showing electrical
connections beneath tiles of a BIPV system, in accordance with
embodiments of the disclosure.
[0030] FIG. 11 is a schematic of roof surface showing other various
electrical connections for tiles of a BIPV system, in accordance
with embodiments of the disclosure.
DETAILED DESCRIPTION
[0031] The present disclosure describes various embodiments of
photovoltaic roofing systems and associated systems and methods.
Some embodiments relate to building integrated photovoltaic module
assemblies and associated systems and methods. In various
embodiments, the systems described herein lower costs of
conventional systems in which a photovoltaic ("PV") system is
installed over a roof, and at the same time can provide an improved
aesthetic for a PV roof system, and particularly a building
integrated PV system.
[0032] Certain details are set forth in the following description
and in the Figures to provide a thorough understanding of various
embodiments of the present technology. Other details describing
well-known structures and systems often associated with PV systems,
roofs, etc., however, are not set forth below to avoid
unnecessarily obscuring the description of the various embodiments
of the present technology.
[0033] Many of the details, dimensions, angles and other features
shown in the Figures are merely illustrative of particular
embodiments. Accordingly, other embodiments can include other
details, dimensions, angles and features without departing from the
spirit or scope of the present invention. Various embodiments of
the present technology can also include structures other than those
shown in the Figures and are expressly not limited to the
structures shown in the Figures. Moreover, the various elements and
features shown in the Figures may not be drawn to scale. In the
Figures, identical reference numbers identify identical or at least
generally similar elements.
[0034] As used herein, the term "substantially" refers to the
complete or nearly complete extent or degree of an action,
characteristic, property, state, structure, item, or result. For
example, an object that is "substantially" uniform in height to
another object would mean that the objects are either completely or
nearly completely uniform in height. The exact allowable degree of
deviation from absolute completeness may in some cases depend on
the specific context, however, generally speaking, the nearness of
completion will be so as to have the same overall result as if
absolute and total completion were obtained.
[0035] As used herein, the term "about" is used to provide
flexibility to a numerical range endpoint by providing that a given
value may be "above" or "below" the value. For example, the given
value modified by about may be, for example, by .+-.5%, .+-.10%,
.+-.15%, .+-.20%.
[0036] Wherever used throughout the disclosure and claims, the term
"generally" has the meaning of "approximately" or "closely" or
"within the vicinity or range of". The term "generally" as used
herein is not intended as a vague or imprecise expansion on the
term it is selected to modify, but rather as a clarification and
potential stop gap directed at those who wish to otherwise practice
the appended claims, but seek to avoid them by insignificant, or
immaterial or small variations. All such insignificant, or
immaterial or small variations should be covered as part of the
appended claims by use of the term "generally".
[0037] As used herein, the term "building integrated photovoltaic
system" or "BIPV" generally refers to photovoltaic systems
integrated with building materials to form at least a portion of a
building envelope. For example, the BIPV system can form the roof
or roofing membrane of a building. The BIPV systems described
herein can be retrofitted, can be a part of a new construction
roof, or a combination of both. Such building integrated
photovoltaic structures can be alternatively referred to as
building integrable photovoltaic ("BIP") or building applied
photovoltaics ("BAPV"). Components of a BIPV system used, in part,
as the actual building envelope (e.g., roofing membrane), can
provide a watertight or substantially watertight seal for the roof
surface.
[0038] For the sake of distinguishing between structural elements
of the present BIPV system, as used herein, the terms "photovoltaic
module", "PV module", and "solar cell" refer to the structures of
the system with solar energy collecting elements, while the term
"PV tile" refers to such solar collecting elements as mounted or
adhered to a structural roof tile. Accordingly, as use herein, a
"roof tile" refers to a structural element of a roof, which may or
may not have PV elements attached thereto, depending on the context
of the description.
[0039] As used herein, the terms "up-roof" and "down-roof" are used
to provide orientation, direction, position, or a reference point
relative to or in context of a roof or roofing surface upon which
the systems described herein are installed on and/or form a portion
of. Up-roof generally refers to an orientation that is relatively
closer to the roof ridge while down-roof refers to an orientation
that is relatively closer to the roof eave.
[0040] As used herein, the singular forms "a", "an", and "the" are
intended to include the plural forms as well, unless the context
clearly indicates otherwise. It will be further understood that the
terms "includes" and/or "including", when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
[0041] Spatially relative terms, such as "beneath", "below",
"lower", "above", "upper", and the like, may be used herein for
ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as shown in the
figures. It will be understood that the spatially relative terms
are intended to encompass different orientations of the device in
use or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, term such as "below" can encompass both an
orientation of above and below, depending on the context of its
use. The device may be otherwise oriented (rotated 90 degrees or at
other orientations) and the spatially relative descriptors used
herein are interpreted accordingly.
[0042] Although the terms "first", "second", etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, it should be understood that they should not be
limited by these terms. These terms are used only to distinguish
one element, component, region, layer, or section from another
region, layer, or section. Thus, a first element, component,
region, layer, or section discussed below could be termed a second
element, component, region, layer, or section without departing
from the teachings of the present invention.
[0043] As used herein, the terms "and/or" and "at least one of"
include any and all combinations of one or more of the associated
listed items.
[0044] Rapid shutdown devices ("RSD") for PV systems can be applied
to the systems described herein, and can be located or positioned
in various locations. In some embodiments, a recess or other
opening can be made in structural support pans (e.g. a transition
pan or a non-PV pan) through insulation such that RSD can be inset
or positioned inside recessed opening. Vents can be positioned on
top of opening to conceal or cover opening. Structural support pans
can be elements of roofing frames or array systems that provide
stability or integrity to the overall structures, as described in
further detail below. RSD can be positioned within a box or other
suitable container prior to positioning within recess. In other
embodiments, RSD can be positioned under eaves, or eave flashings
or gutters. In yet other embodiments, RSD can be positioned within
attic portions of a building.
[0045] Generally, PV modules are crystalline-based solar panels,
which can be either or both of monocrystalline solar panels or
polycrystalline (multi-crystalline) solar panels. The laminate or
wafer forming the solar energy-collecting surface of such PV
modules can be mechanically coupled, adhered, or bonded to
structurally supporting tiles. In some embodiments, PV modules can
include layers of amorphous silicon or thin film variations of
solar energy-collecting laminates, or thin-film solar materials
directly applied as continuous sheets. Generally, PV tiles as
considered herein, which can include PV modules, solar cells and
laminates, have individual structures that can be used in
combination to form larger solar arrays and/or building structures,
as set forth below. Alternatively, thin-film PV modules, such as
cadmium telluride, copper-indium-gallium-diselenide ("CIGS"), or
amorphous thin-film silicon may be used. In still further
embodiments, cells based on perovskite or other as of yet
non-commercialized materials may be used. The particular type of
cell technology used for any given installation can be selected
both for solar energy collecting functionality and for aesthetic
qualities, as related to the present disclosure.
[0046] For any given solar panel installation on the roof of a
residential, commercial, or industrial building, there is a balance
obtained between the power generation of the solar panel array, the
visual appearance and aesthetic of the solar panel array, and the
structural requirements for mounting or constructing the solar
panel array. For BIPV installations as considered herein, the
materials for forming the roof and the PV elements for collecting
solar radiation are combined into a single unit, where the
aesthetic of the solar panel array can be optimized while still
maintaining a desired level of power collection and generation.
However, not every surface, slope, or region of a roof may be
amenable to, or need to be used for, solar energy generation. Thus,
BIPV systems can also include "dummy" or "mimic" roof tiles that
can include patterning or silicon elements that appear similar to
the PV tiles, but do not collect solar radiation and are not
electrically connected to a centralized power transformer.
[0047] PV elements that are distributed over all roof surfaces can
have a visual uniformity that is neat, generally continuous, and
elegant. Adjusting the density of PV element on a roof surface
changes both the appearance of the overall roof and the energy
production of the solar array on the roof, typically measured in
kilowatts (kW) or kilowatt-hours (kWh). Accordingly, the density of
PV elements can be adjusted to achieve a desired kilowatt-hour
production goal while maintaining an even distribution of the PV
elements with a consistent visual aesthetic. In some aspects, PV
elements can be distributed on the surface of a roof in a
randomized, semi-randomized, or non-regular pattern to achieve the
aesthetically pleasing neat, generally continuous, and elegant
appearance.
[0048] In contrast with embodiments of the present disclosure, FIG.
1A shows a prior art PV array installed on roof 100. The exemplary
PV array of FIG. 1A includes six solar panels 101 or modules which
(though not shown in detail) are mounted on roof 100 using one of
various known rail-based or rail-free mounting systems, as are
currently employed by solar installers, such as San Mateo,
Calif.-based SolarCity Corporation.
[0049] FIG. 1B shows one type of conventional solar panel 101 in
more detail. Solar panel 101 includes PV laminate 102, which in
conventional silicon-based cells, consists of a silicon sandwich of
p-doped and n-doped silicon layers, a top glass sheet protecting
the laminate, and a back sheet that can include a plurality of
layers--and rigid metal frame 103, supporting PV laminate 102.
Although shown as a unitary structure, laminate 102 may include a
plurality of individual solar cells that are wired together to form
a single unit under the top glass sheet. In the example shown in
FIG. 1B, frame 103 is a grooved frame with groove 104 surrounding
the outer face of frame 103 on all sides. Grooved frame modules
such as module 101 are manufactured and sold by SolarCity
Corporation of San Mateo, Calif. In such a module, groove 104
serves as mechanism for attaching other mounting hardware (e.g., a
leveling foot, an interlock) to join modules together and to
support the modules over a roof surface. Those of ordinary skill in
the art will appreciate that panel 101 may also have a plain,
non-grooved frame. Non-grooved frames are typically interconnected
to one another and connected to the roof using connectors that
clamp down between the top and bottom edges of the frame.
[0050] Although these types of framed PV modules achieve their
structural function, they are aesthetically suboptimal and have
material usage inefficiencies. First, conventional PV systems, such
as that shown in FIG. 1A, are typically installed over an existing
roof, and not as part of the existing roof, essentially requiring
redundant structure since the PV array will shield most of the
portion of the roof that it is installed over. Second, conventional
systems are deemed by some people to be unappealing, having a
choppy, discontinuous, and/or extraneous aesthetic. Conventional PV
modules usually come in one of two colors: blue, signifying a
poly-crystalline silicon structure, and black, signifying a
mono-crystalline silicon or thin-film structure. The metal frame
portion can be painted black to help it blend in with the roof
surface, or it can simply be raw aluminum. Regardless of whether
blue or black modules are used, the difference between the look of
the portion of the roof that is covered with solar panels and the
remainder of the roof is generally quite dramatic. This contrast
can be particularly jarring with a conventional PV system and array
mounted on a tile roof. As a result, roofs that are partially
covered with solar panels have an aesthetic contrast that can be
seen from very far distances due to the difference in reflectivity,
elevation, height, and/or color between these two very different
surfaces.
[0051] Tile Roof Building Integrated Photovoltaic Array
[0052] As discussed herein, solar cells that are integrated as part
of roof tiles can be connected together as and laid down so that
they make up the main surface of a roof, and in particular, a tile
roof. By having the PV tiles individually carry solar cells,
because the PV tiles are part of the roof, advantages can be
obtained in comparison to more traditional "on-roof" arrays that
are slightly elevated from the surface of a roof. For example, roof
surfaces formed of PV tiles are directly built onto the framing
structure of a roof can be lighter than on-roof installations, at
least because the built-in BIPV solar array does not require a
second structure above an existing roof. Further, a roof that is
being replaced in a re-roofing installation can replace older or
traditional roof tiles or with PV tiles, which can be more
efficient in reducing the amount of materials needed for a
re-roofing installation. Also, electrical connections, junction
boxes, and wiring can be generally housed underneath PV tiles of
BIPV assemblies, protecting such components from precipitation,
wind, and excess heat, and further hiding such components from an
observer so as to make the overall BIPV system visually attractive
or uniform.
[0053] BIPV solar arrays generally aspire to provide for an
advantage over traditional on-roof PV systems by having a less
drastic topological difference, thereby reducing visually
noticeable differences in height on regions of the roof. However,
previous implementations of BIPV systems do not necessarily provide
for further visual qualities or design that effectively minimize
noticeable differences between solar materials and standard roofing
materials that form the overall PV system. Embodiments of the
present disclosure provide for a BIPV system, with solar cells
applied onto individual roofing tiles and electrically connected in
strings or other circuits, which is visually appealing at least in
that the solar elements and roofing materials are combined and
assembled in a layout that minimizes or camouflages the differences
between the solar components and the standard construction
materials.
[0054] A part of the advantage of the present system is that the
process of laying a tile roof is straightforward, where accounting
for PV elements on tiles, and making electrical connections between
the solar cells on tiles, requires only minimal additional work and
training. A BIPV tile roof as considered herein is mounted in
generally the same manner as a standard tile roof, for example:
securing and sealing underlayment or other sheathing to frame
elements of the roof, adding battens as needed to portions of the
roof frame, installing tiles to form the main surface of the roof,
working around obstacles (e.g., chimneys, skylights, vents, etc.)
as needed, and installing ridge and edge tiles in combination with
flashing or other trim structures of the roof. In the present
system, the roof tiles must have a structural integrity capable of
accommodating and supporting PV elements on the tiles, in terms of
weight, heat generated, ability to connect electronics, and
retaining strength to serve as a portion of a roof surface. The
tiles used can be of standard sizes as known in the industry.
Further, tiles used for systems considered herein can have a wide
range of colors to match or blend with PV elements, including, but
not limited to, blue, blacks, grays, browns, and natural clay
colorations.
[0055] FIG. 2A shows exemplary BIPV system 200 installed in a plane
as part of roof surface 202. BIPV system 200 is arranged from roof
tiles 204 in horizontal rows or courses along the length of roof
surface 202. Vertically adjacent courses of roof tiles 204 are
offset from each other by about half the width of each roof tile
204, such that seams or breaks between two vertically adjacent rows
of roof tiles 204 do not form a single seam or break along the full
slope of roof surface 202, but rather form an alternating pattern
of seams, where breaks between adjacent roof tiles 204 are
relatively equidistant from each other. Roof surface 202 further
includes ridge flashing 208 at the top of roof surface 202 and eave
flashing 210 at the bottom of roof surface 202.
[0056] Several different types of roof tiles 204 can be used for
roof surfaces 202 as considered herein. Roof tiles 204 can be made
of materials including, but not limited to: stone, quartz, slate,
granite, ceramics, concrete, porcelain, rigid shingle, clay, glass,
onyx, or replica materials for the same. Roof tiles 204 can have
shapes including, but not limited to: rectangular, square, club,
step, bullnose, fishtail, arrow, curved, or irregular. Roof tiles
204 having one side longer than another side can be oriented either
with the longer edge of roof tile 204 generally parallel to the
width dimension roof surface 202 or with the shorter edge of roof
tile 204 generally parallel to the width dimension roof surface
202. Generally, roof tiles 204 considered for use herein are flat
tiles for forming roofing structures, but in other embodiments roof
tiles can include, but are not limited to: curved tiles, barrel
tiles, s-shaped tiles, Spanish tiles, tiles shaped to be used on
the edges of a roof, or tiles shaped to interlock with adjacent
tiles. In further alternative embodiments, roof tiles can be
stamped tiles, having a size and weight similar to roof shingles,
which can have a striated or contoured top surface, where the top
surface can be formed of glass. All roof tiles 204 considered
herein can have be formed with lapping tabs or features extending
past the perimeter of the top surface, or without excess trim or
material extending from a bottom plane or surface of roof tile
204.
[0057] Each roof tile 204 as shown in BIPV system 200 can have one
solar cell 206, two solar cells 206, or no solar cells on the upper
surface of roof tile 204. FIG. 2B shows roof tile 204 having two
solar cells 206 in the reveal portion of the tile, effectively
spanning the complete width of roof tile 204, which can be referred
to as full PV tile 212. FIG. 2C shows roof tile 204 having one
solar cell 206 in the reveal portion of the tile, biased toward the
right side of roof tile 204, which can be referred to as right-half
PV tile 214. FIG. 2D shows roof tile 204 having one solar cell 206
in the reveal portion of the tile, biased toward the left side of
roof tile 204, which can be referred to as left-half PV tile 216.
FIG. 2E shows non-photovoltaic roof tile 204 having no solar cells
on the upper surface of roof tile 204, and can be referred to as a
non-photovoltaic, blank, or simply roof tile 204. It can be
appreciated that while right-half PV tiles 214 and left-half PV
tiles 216 components of BIPV system 200 refer to "halves" of PV
tiles, each individual solar cell 206 in fact covers about
one-quarter or less of a top surface of roof tile 204 in the reveal
portion of roof tile 204. Generally, an upper portion of the top
surface of roof tile 204 in BIPV system is a "lapped" or "overlap"
region and, as part of a roofing installation, will be physically
covered or underneath bottom surfaces of roof tiles 204 of the next
adjacent, up-roof row of roof tiles 204.
[0058] Solar cells 206, embedded or adhered to roof tiles 204, can
be frameless or have a minimized frame structure. Practically, for
PV tiles, roof tiles 204 are both the structural substrate and
frame for solar cells 206. In some aspects, solar cells 206 can
have electrical contacts in a frame section, but this is optional.
In other words, solar cells 206 can be constructed without a rigid
frame (e.g., made of metal, plastic) surrounding or enclosing the
edges of the PV material, or in some embodiments, surrounding only
a portion of the bottom and sides but not the top of solar cell
206.
[0059] Accordingly, BIPV system 200 shown in FIG. 2A includes a
mixture of full PV tiles 212, right-half PV tiles 214, left-half PV
tiles 216, and blank roof tiles 204. Unlike on-roof mounted PV
arrays or other BIPV systems where only some regions of a roof
surface are covered with photovoltaic elements, the set of full PV
tiles 212, right-half PV tiles 214, left-half PV tiles 216, and
blank roof tiles 204 completely form a structural envelope for roof
surface 202. Further, viewed together, these PV tiles and blank
tiles form BIPV system 200 that reduces the redundancy inherent in
conventional PV systems while providing a uniform look and
appearance. BIPV system 200 achieves a combined function of forming
structurally sound roof surface 202 as well as a solar energy
collecting circuit.
[0060] The particular PV tiles chosen for any given BIPV system 200
layout can be generally randomized, or semi-randomized, while
accounting for unique structural limitations of roof surface 202
for specific installations. For sections or regions of roof surface
202 that require cutting or trimming to fit around obstacles or
elements in roof surface 202, or to form edges of roof surface,
blank roof tiles 204 can be cut for fitting around obstacles or
contours. The randomized or semi-randomized assortment of PV tiles
and blank roof tiles 204 can thus allocate solar cells 206, via the
underlying PV tiles, to sections of roof surface 202 that do not
have obstacles, sections that do not form upper, lower, lateral, or
other edges and sides of roof surface 202.
[0061] Other aspects of roof surface 202 can interface with BIPV
system 200 to form a satisfactory roof. For example, ridge flashing
208 can include a ridge cap at the top of the resultant BIPV array,
and may be used for venting, heat dissipation, wire management, and
to generally conceal and protect wires (e.g., conduits or cables)
or other equipment (e.g., fans, vents, connectors, inverters,
jumpers, home-run connections). Waterproofing components, such as
liners or trim, can be set underneath or between PV tiles such that
roof surface 202 properly functions as a roof to prevent water from
entering the structure of the building. BIPV system 200 can also
include other roofing components (e.g., flashings, gutters, vents,
caps, covers, trims), for example, at eave flashing 210, hips,
valleys, or sides of the roof (not shown).
[0062] Roof tiles 204, both PV tiles and non-photovoltaic tiles,
can mounted as part of roof surface 202 with other structural
components to form a roof envelope of a building. Moreover, as
discussed in greater detail herein, PV tiles supporting or embedded
with solar cells 206 can be specifically configured to accommodate
electrical junction boxes or micro-inverters on each individual PV
tile, located on the bottom surface (underside) of relevant roof
tiles 204. Wiring, cables, and/or power buses to electrically
connect PV tiles, and by extension solar cells 206 on PV tiles, can
string together a plurality of PV tiles. To avoid physical
conflicts with underlying studs, rafters, joints, battens,
buttresses, or other infrastructure of a roof, such electrical
components can be attached to the underside of PV tiles in
locations to avoid physical conflicts. In combination or
alternatively, blank roof tiles 204 that do not include electrical
connectors or components can be used where such that there is no
structure on the underside of blank roof tiles 204 that would
otherwise physically conflict with underlying roof
infrastructure.
[0063] A string of PV tiles can be electrically connected together
as a subset circuit of roof surface 202 to have a specific or
desired number of solar cells as part of the subset. Such subset
circuits can have a specific number of solar cells to build to a
desired voltage or kilowatt production. For example, a subset
circuit of electrically connected PV tiles can have four (4) solar
cells, six (6) solar cells 206, eight (8) solar cells 206, ten (10)
solar cells 206, twelve (12) solar cells 206, or any number of
solar cells 206 within or around that numerical range. By
extension, subset circuits can alternatively have more solar cells
206 to build to higher voltage and kilowatt levels, for example
having 20-cell, 24-cell, 30-cell, 36-cell, 40-cell, 42-cell,
48-cell, 54-cell, 56-cell, 60-cell, 70-cell, 80-cell, or 92-cell
embodiments. Further embodiments can have PV tiles with other
number-of-solar-cell embodiments above, below, or within the
above-considered increments. The various embodiments of strings
with different numbers of solar cells allows for flexibility in
selecting solar panels appropriate for any given system
installation.
[0064] FIG. 2F shows roof tile 204 having two silicon elements 216
in the reveal portion of the tile, which can be referred to as full
PV mimic tile 218. In an installation, full PV mimic tile 218 will
have effectively the same appearance as full PV tile 212 shown in
FIG. 2B. FIG. 2G shows roof tile 204 having one silicon element 216
in the reveal portion of the tile, biased toward the right side of
roof tile 204, which can be referred to as right-half PV mimic tile
220. In an installation, right-half PV mimic tile 220 will have
effectively the same appearance as right-half PV tile 214 shown in
FIG. 2C. FIG. 2H shows roof tile 204 having one silicon element 216
in the reveal portion of the tile, biased toward the left side of
roof tile 204, which can be referred to as left-half PV mimic tile
222. In an installation, left-half PV mimic tile 222 will have
effectively the same appearance as left-half PV tile 216 shown in
FIG. 2D. In some contexts, full PV mimic tile 218, right-half PV
mimic tile 220, or left-half PV mimic tile 222 can be collectively
referred to as dummy tiles. Further, as none of full PV mimic tile
218, right-half PV mimic tile 220, left-half PV mimic tile 222, and
blank roof tiles 204 include any photovoltaic elements, in
aggregate these can be referred to as non-photovoltaic roof
tiles.
[0065] FIG. 2I shows a schematic of non-production region 201 of a
BIPV 200 system using non-photovoltaic tiles, particularly full PV
mimic tiles 218, right-half PV mimic tiles 220, left-half PV mimics
tile 222, and blank roof tiles 204. The pattern and arrangement of
the non-photovoltaic tiles, is similar to the PV tiles as seen in
FIG. 2A, with roof tiles 204 in horizontal rows or courses along
the length of roof surface 202. Vertically adjacent courses of
non-PV tiles are offset from each other by about half the width of
each roof tile 204, such that seams or breaks between two
vertically adjacent rows of non-PV tiles do not form a single seam
or break along the full slope of roof surface 202, but rather form
an alternating pattern of seams, where breaks between adjacent roof
tiles 204 are relatively equidistant from each other. Again, roof
surface 202 further includes ridge flashing 208 at the top of roof
surface 202 and eave flashing 210 at the bottom of roof surface
202.
[0066] Accordingly, BIPV system 200 can be constructed using seven
(7) stock keeping units (SKUs): full PV tiles 212, right-half PV
tiles 214, left-half PV tiles 216, blank roof tiles 204, full PV
mimic tiles 218, right-half PV mimic tiles 220, and left-half PV
mimic tiles 222. While there can be seven SKUs, only four of the
seven types of tiles will be needed for any given section of an
installation, depending on whether the section of BIPV system 200
is desired to be an energy collecting region or non-production
region 201. For example, on a given building, the South face of a
roof may receive the most incident solar energy, while the North
face of the roof of the building may not receive sufficient
sunlight to be worth having PV tiles. To optimize the use of PV
elements, full PV tiles 212, left-half PV tiles 216, right-half PV
tiles 214, and blank tiles 204 can be laid on the South face of
roof surface in a randomized arrangement, while full PV mimic tiles
218, left-half PV mimic tiles 222, right-half PV mimic tiles 220,
and blank roof tiles 204 can be placed also in a randomized
arrangement on the North face of roof surface. Thus, both the South
and North sides of roof surface 202 can appear similar, while
having slightly different functional effects, e.g. both solar
collection and an attractive aesthetic appearance versus only an
attractive aesthetic appearance, respectively.
[0067] For some roof surfaces 202, regions of roof surface may be
occluded from consistent incident sunlight (e.g. due to shade from
a tree), and accordingly, an occluded portion of roof surface 202
can be laid with dummy, mimic PV tiles, in order to avoid wasting
energy collecting PV tiles in that occluded portion of roof
surface. It can be understood that BIPV system 200 maximizes the
amount of solar energy collected where full PV tiles 212,
right-half PV tiles 214, and left-half PV tiles 216 are located in
portions of roof surface 202 that receive a significant amount of
incident solar energy, being, for example, on a portion of roof
surface 202 that receives sunlight from about 8 to about 16 hours a
day, regardless of the azimuth position of the sun relative to that
portion of the roof surface. In other words, full PV tiles 212,
right-half PV tiles 214, and left-half PV tiles 216 can be placed
where solar cells 206 can collect sufficient solar energy to meet
the designed or desired energy production goal of BIPV system.
Conversely, full PV mimic tiles 218, right-half PV mimic tiles 220,
and left-half PV mimic tiles 222 can be used on portions of roof
surface 202 that do not receive enough incident solar energy to
merit use of PV tiles, for example a portion of roof surface 202
that receives incident solar energy for less than about 8 hours per
day, or where use of PV tiles would be relatively inefficient and a
greater cost than benefit for BIPV system 200.
[0068] The combination of these elements above for BIPV system 200,
both in PV tiles and non-PV tiles, can provide for an overall roof
appearance that is visually pleasing, with minimal points of
contrast or sharp edges to distract the eye of an observer. The
clear aesthetic advantage includes the fact that roof surface 202
does not look choppy or discontinuous, with distinctive PV sections
and non-PV sections.
[0069] In some aspects, PV tiles and non-PV tiles can be deployed
or arranged on a roof surface at the same density, which can
thereby minimize points of distinction between different types of
roof tiles. In further aspects, PV tiles and non-PV tiles can be
deployed or arranged on a roof surface in a non-regular pattern,
either at an equal density of PV tiles and non-PV tiles or at a
density biased toward either more PV tiles or more non-PV tiles. In
other words, production layouts of PV tiles and non-PV tiles can be
set and arranged at a desired density for any given installation of
a solar roof surface.
[0070] FIGS. 2J and 2K show exploded cross-sectional views of
exemplary solar cells 206, showing in further detail layers of
solar cells 206 used, for example, in FIGS. 2B, 2C, and 2D. In some
embodiments, solar cells 206 described herein refer to
crystalline-type solar modules. However, solar cells 206 are not
limited to crystalline-type solar cell technology. For example, in
other embodiments, thin-film or amorphous solar (e.g., amorphous
silicon) can be used as laminate layers with certain embodiments of
solar cells 206 described herein. In yet further embodiments,
hybrid crystalline and amorphous solar modules can be used with
solar cells 206 systems described herein. In other embodiments,
other types of solar cells (e.g., non-silicon based semiconductors,
partial silicon, non-crystalline, partial crystalline, organic,
carbon-based, perovskite, cadmium-telluride, CIGS, dye sensitized,
transparent luminescent solar concentrator, polymer, transparent
cells) can be provided as part of solar cells 206. Both FIGS. 2J
and 2K show solar cell 206 in exploded cross-section above roof
tile 204, however, it is understood that solar cell 206 forms a
single unit with roof tile 204, by being embedded within, adhered
to, integrated with, closely mounted on, or otherwise secured to
the upper surface of roof tile 204.
[0071] As shown in FIG. 2J and noted above, in some embodiments,
solar cells 206 can include PV layers 224 (e.g., solar cells,
semiconductor layers, bussing, insulation, laminate) sandwiched
between encapsulation layers 226 (e.g., ethylene-vinyl acetate).
Solar cells 206 can further include one or more backsheets 228
(e.g., polyvinyl fluoride film) and/or glass layers 230. As shown
in FIG. 2K, solar cells 206 can include first and second glass
layers 230 (e.g., "glass on glass") sandwiching encapsulation
layers 226. The glass on glass solar cells 230 can also eliminate
or reduce the need for additional intermediate material layers
(e.g., underlayment, felt paper) between a bottom of solar cell 206
and tile roofing material, which may otherwise be used for fire
protection or other purposes. In certain embodiments, solar cells
206 can include both glass layer 230 and one or more backsheet
layers 228.
[0072] Although backsheet layers 228 can have a light color, such
as white, solar cells 206 can include non-white (e.g., black, blue,
transparent) backsheet layers 228. Non-white backsheet layers 228
can improve aesthetics by reducing glare or reflection off or
through glass layers 230 or underlying roof tile 204 as compared to
white backsheet layers 228. Additionally, black or blue backsheets
tend to be closer in color to conventional solar cells or PV
modules. Thus, non-white backsheets can create a more uniform
appearance with the rest of the system. Backsheet layers 228 (or
other layers) may be cut at an angle, such that the cut, exposed
portion of backsheet layer 228 faces an underlying roof 202 or roof
tile 204, or is oriented in a substantially downward direction
(e.g., toward the roof tile) when solar cells are assembled,
embedded in, or adhered to a surface of roof tile 204.
[0073] The arrangement of backsheet layers 228 above or below PV
layers 224 and encapsulation layers 226 can provide for added
thermal control and/or directed light reflection within solar cells
206. In some embodiments, solar cells 206 may include first and
second backsheet layers 228 (e.g., non-white or white) sandwiching
encapsulation layers 226 (e.g., on both air and cell sides of PV
module stack). Further, backsheet layers 228 can be integrated with
encapsulation layers 226 or adhesive layers in certain embodiments.
Certain backsheets 228 can also provide solar cells 206 with
improved thermal dissipation or heat reflective properties,
electrical insulation, or protection from damage, moisture, or UV
degradation. Such backsheets can include dyMat.TM.,
DuraShield.RTM., or PowerShield.RTM..
[0074] It should be understood that in these embodiments, roof
pitches where such systems are installed are non-zero, and that the
systems are installed to account for the angle or slope of
(non-flat) roofs. The distances or gaps between various tiles,
rows, courses, or assemblies thereof, and the degree to which such
gaps are concealed will be dependent on roof pitch, the distance a
viewer is from the roof, and the height of the viewer.
[0075] FIG. 3 shows a perspective view of PV tile 300, having a
solar cell on the left side of PV tile 300 reveal region. The solar
cell is located in the portion of PV tile 300 that will be the,
relatively down-roof, reveal region, because when laid down with
other roof tiles to form a roofing system, the, relatively up-roof,
lapping region, of the roof tile will be covered by a roof tile
from the next vertically adjacent row of roof tiles. For any
individual roof tile, the lower/down-roof portion can be referred
to as the "reveal". It is understood that other PV tiles can have
the solar cell located in the left-half, down-roof region of the
supporting roof tile, while yet other PV tiles can have solar cells
across the full span (right and left halves) of the underlying,
supporting roof tile. PV tile 300 shows a version of tiles for BIPV
systems as considered herein where the solar cell(s) of PV tile 300
is located along the longer length dimension (e.g. the long edge)
of PV tile 300; accordingly, both the reveal portion and lapped
portion of PV tile 300 also track long the longer length dimension
of PV tile 300. It can be appreciated that a non-PV, mimic or dummy
tile can have an identical, or near-identical appearance to PV tile
300, with a structure similar to solar cells in the same respective
location of the roof tile.
[0076] The size of a solar cell in the reveal portion of PV tile
300 can leave a buffer region and distance around each solar cell.
In some aspects, a buffer distance of about five millimeters (5 mm)
can be present around each solar cell. The buffer zone can provide
for a region where an operator can handle PV tile 300 without
touching solar cells on the upper surface of PV tile 300. The
buffer zone between two solar cells on the same PV tile 300 can be
from between about five to about ten millimeters (5-10 mm), or
greater, depending on the underlying roof tile used. In further
aspects, solar cells can be positioned on PV tile 300 at a position
within the reveal region that is a sufficient distance away from
the portion of PV tile 300 that will be overlapped by an adjacent
up-roof row, to thereby avoid shading concerns.
[0077] FIG. 4 shows an exemplary set of roof tiles including one
non-photovoltaic tile and three photovoltaic tiles with solar cells
in portions of the reveal region. Specifically shown are blank tile
400, full PV tile 402, left-half PV tile 404, and right-half PV
tile 406. Full PV tile 402, left-half PV tile 404, and right-half
PV tile 406 shown versions of tiles for BIPV systems as considered
herein where the solar cells of full PV tile 402, left-half PV tile
404, and right-half PV tile 406 are located along the shorter
length dimension (e.g. the short edge) of each respective PV tile.
Accordingly, both the reveal portion and lapped portion in each of
full PV tile 402, left-half PV tile 404, and right-half PV tile 406
also track long the shorter length dimension of these PV tiles. It
can be appreciated that non-PV, mimic or dummy tiles can have an
identical, or near-identical appearance to each of full PV tile
402, left-half PV tile 404, and right-half PV tile 406, with
structures similar to solar cells in the same respective locations
of the roof tiles.
[0078] FIG. 5 shows an exemplary set of PV tiles from FIG. 4 in
three overlapping courses 500, including both non-photovoltaic and
photovoltaic tiles, in an exemplary arrangement for a BIPV roofing
system. The top course of overlapping courses 500 includes (from
left to right) left-half PV tile 404, right-half PV tile 406, and
blank tile 400. The bottom course of overlapping courses 500
includes full PV tile 402 in the center of the three PV tiles,
while the remainder of PV tiles in overlapping courses 500 happen
to be right-half PV tiles 406. Again, it can be understood that
non-PV, mimic or dummy tiles, can have an identical or
near-identical appearance as these PV tiles, and thereby have a
similar overall appearance when arranged as overlapping courses
500.
[0079] FIG. 6 shows an exemplary residential building having a roof
constructed from both non-photovoltaic and photovoltaic tiles and
having an aesthetically pleasing appearance. The subtle and elegant
distribution of PV elements across the roof surface is
intentionally similar to and near indistinguishable from a standard
tile roof. The attractive implementation of solar cells as
construction elements of a roof surface addresses a generally unmet
and underserved need in the field, in that the appearance of the PV
tile roof surpasses the quality and other attempts at visual
integration of many other BIPV systems.
[0080] FIG. 7A shows a schematic illustration of solar cell density
on a roof surface formed from photovoltaic tiles, having a
relatively light energy production layout. In particular, light
production layout 700 is an exemplary embodiment of a roof surface
forty feet (40 ft.) in length and twenty feet (20 ft.) in height
covered with about 1,400 solar cells, each producing 4.5 W per
solar cell, for an energy production load of 6,300 kW. FIG. 7B
shows a schematic illustration of solar cell density on a roof
surface formed from photovoltaic tiles, having a relatively heavy
energy production layout. In particular, heavy production layout
702 is an exemplary embodiment of a roof surface forty feet (40
ft.) in length and twenty feet (20 ft.) in height covered with
about 2,800 solar cells, each producing 4.5 W per solar cell, for
an energy production load of about 12,600 kW.
[0081] In both light production layout 700 and heavy production
layout 702, blank tiles can be distributed throughout the section
of the roof to control density of PV elements. Such blank tiles can
also be used around obstructions and roof edges by cutting blank
tiles as required to accommodate other structures on the roof.
Further, blank tiles can be used and cut-as-needed at the edges,
ridges, and eaves of a roof to define the boundaries of the roofing
installation. The density of PV elements and solar cells on a roof
surface can also be controlled for by installing a calculated or
determined number of full PV tiles and half PV tiles in combination
with (or alternatively to) and blank tiles. A specific density of
PV elements or solar cells on a roof surface can be adjusted to
obtain a desired Kilowatt-hour (kWh) production goal, while still
having a visual uniformity. Moreover, randomized or semi-randomized
placement of PV tiles on a roof surface will lead to a generally
even distribution of PV elements, thus providing for both an even
aesthetic appearance of the roof and an even amount of solar energy
collection from the roof.
[0082] It can be appreciated that the terms and scale of light
production layout 700 and heavy production layout 702 as shown in
FIGS. 7A and 7B are relative to each other, with heavy production
layout 702 simply having double the solar cell density of light
production layout 700. The range of PV tile layouts and energy
production can vary depending on the individual requirements of any
given roof or installation location and the ranges for the number
of solar cells on a roof surface can scale up or down in
density--where the more blank tiles (or dummy tiles) there are
relative to PV tiles, or the more half-PV tiles there are relative
to full PV tiles, the lower the power collected and produced by the
roof.
Indeed, the exemplary embodiments of FIG. 7A and FIG. 7B should not
be considered limiting or exclusive, as various combinations,
arrangements, and configurations of various PV tiles and non-PV
tiles can provide for a wide range of production loads. In some
implementations, a roofing system can have a production layout that
generates an energy production load from about 3,000 kW to about
12,600 kW. In other implementations, a roofing system can have a
production layout that generates an energy production load from
about 1,000 kW to about 20,000 kW, or an energy production load
bounded at any increment, gradient, or range therein.
[0083] Various layouts of solar cells can be implemented in any
given BIPV system installation, with the density of solar cells on
the roof determined to build to desired voltages or power outputs.
For example, a BIPV system having a low-density of solar cells can
have a sufficient number of solar cells to build up to an
electrically connected string of PV elements producing around fifty
volts (50 V) of electric potential. In another embodiment, a BIPV
system having a low-density of solar cells can have a sufficient
number of solar cells to build up to an electrically connected
string of PV elements producing around eighty volts (80 V) of
electric potential. Alternative embodiments of a low-density
configuration BIPV system can produce from about 50 V to about 80 V
of electric potential, or a voltage at any gradient or increment of
voltage within that range.
[0084] Conversely, high-density configurations of BIPV systems can
have the surface area of the relevant roof section be saturated
with solar cells to a point where about 70%-80% of the roof section
is covered with solar cells or other PV elements. Even with such
high-density implementations, the section of roof surface can be
filled with solar cells to the point where the roof maintains an
aesthetic such that the appearance is natural, and not
discontinuous or off-putting.
[0085] Determining the appropriate or desired density of solar
cells on a roof surface is driven by three factors: (1) the
geometry of the roof plane, (2) the desired or necessary kilowatt
(kW) power output for the roof surface, and (3) the visual
aesthetic of the roof. Determining the appropriate solar cell
density for any given BIPV system, balancing both aesthetic and
power generation requirements, can be considered to be a balancing
of two ratios, which can be independently varied. The first is the
ratio of tile-to-silicon for a given roof area and the second is
the ratio of PV-to-non-PV for a given roof area.
[0086] In some embodiments, the arrangement of the solar cells and
PV tiles in a BIPV system can be allocated or designed manually to
appear randomized and generally uniform to the human eye. In other
embodiments, the arrangement of solar cells in a BIPV system can be
determined by a computer-executed algorithm, using factors such as
roof plane geometry and desired power output to set the arrangement
in a manner that is, again randomized and generally uniform to the
human eye. In further embodiments, a combination of both
automated/software driven design and human/holistic placement can
be applied to set the arrangement of solar cells for any given BIPV
system. In further aspects, predetermined arrangements or
configurations of solar cells and PV tiles can be used to account
for and work around obstacles in a roof surface, or to form edges
along the roof surface.
[0087] Tile and Wiring Layouts
[0088] FIG. 8 is a schematic of an exemplary BIPV array 802 forming
roof surface 800, with roof tiles 804 arranged in multiple rows or
courses. Solar cells 806 are present on some roof tiles 804 on the
right side, left side, or both sides of the reveal portion of roof
tiles 804. Some members of BIPV array 802 are blank roof tiles.
Ridge flashing 808 and eave flashing 810, in combination with BIPV
array 802, complete roof surface 800.
[0089] Various courses of PV tiles are shown, with specific
variation between the courses. First course 818 is formed with full
PV tiles 812, right-half PV tiles 814, and left-half PV tiles 816;
there are no blank roof tiles 804 in first course 818. Second
course 820 is formed with full PV tiles 812 and blank roof tiles
804; there are no right-half PV tiles 814 or left-half PV tiles 816
in second course 820. Third course 822 is formed with blank roof
tiles 804, right-half PV tiles 814, and left-half PV tiles 816;
there are no full PV tiles 812 in third course 822. Fourth course
824 is formed with full PV tiles 812, right-half PV tiles 814, and
blank roof tiles 804; there are no left-half PV tiles 816 in fourth
course 824. Fifth course 826 is formed with full PV tiles 812,
left-half PV tiles 816, and blank roof tiles 804; there are no
right-half PV tiles 814 in fifth course 826. Of course, any given
course for BIPV array 802 can have any variation of PV tiles and
blank tiles, where the number and type of tiles can be selected to
achieve a desired power output and aesthetic appearance.
[0090] FIG. 9 is a schematic of an exemplary BIPV array 802 forming
roof surface 801, with roof tiles 804 arranged in multiple rows or
courses, where roof surface has various obstacles to work around
when laying down roof tiles 804. In particular, roof surface 801
includes skylight 828, chimney 830, and vent 832. Each of skylight
828, chimney 830, and vent 832 can have different sizes, shapes,
and positions on roof surface 801. Some roof surfaces 801 can have
one or more skylights 828, chimneys 830, or vents 832. Blank roof
tiles 804 can be cut and positioned around such obstacles or
interruptions in roof surface 801. Further, roof surface 801 has an
angled side edge 803, for which blank roof tiles 804 can also be
cut or trimmed to terminating at angled side edges 803. In
alternative aspects, a half-sized blank may be used as a pre-cut
part (e.g., a half-SKU) to make fitting tiles on the roof easier
with higher consistency and reliability, or to make cutting and
trimming parts onsite easier and more efficient.
[0091] FIG. 10 is a schematic of roof surface 800 showing
electrical connections beneath tiles of BIPV array 802. In
particular, FIG. 10 shows potential wiring connections using
individual electrical connectors, harness connection system, and
power bus track schemes. It can be understood that schematically,
for clarity, electrical connectors are shown in locations
overlapping with solar cells 806. For actual construction and
installation, electrical connections can be physically located
under regions of PV tiles that are more efficient both for the
manufacture of individual tiles and minimize potential physical
conflicts when assembling a roof (e.g. in or under a top or up-roof
lapped portion of a PV tile).
[0092] In BIPV system 802, the PV tiles are necessarily
electrically connected, such as with junction boxes 834,
micro-inverters, DC optimizers, power bus bars 842, or other
local/module-level electronics. In some embodiments, as shown in
third course 822 and fourth course 824, solar cells 806 of the PV
tiles can be electrically connected via wiring 836, coupling
junction boxes 834 (or some other form of electrical connectors) on
the back side of PV tiles, where the electrical connectors are
located proximate to solar cells 806, on the opposite side of each
PV tile. Accordingly, full PV tiles 812 can have two junction boxes
834, while right-half PV tiles 814 and left-half PV tiles 816 can
each have one junction box 834. In some embodiments, dual junction
box 835 can electrically connect two solar cells 806 on full PV
tile 812. Blank roof tiles 804 do not need an electrical
connection, but can further include mounting guide 838 to support
and route wiring 836 on the underside of BIPV array 802. One or
more rows or courses of electrically coupled PV tiles can connect
to combination boxes 840, where combination boxes 840 can be
voltage or current inverters, power meters, electrical drops,
optimizers, transformers, or the like, which can then route
electricity into the electrical main 844 of the building or toward
the electrical grid. In some aspects, combination boxes 840 can be
referred to as minor electrical boxes or terminal boxes. The
electrical connection between wiring 836 and combination box 840
can pass through diode 839, where diode 839 can serve as a one-way
gate to prevent electrical surges, reverse flow, and regulate
current within BIPV array 802. Wiring 836 can be run underneath
flashing or other roof construction components to a transformer or
other central electrical main 844 of a building. Electrical
connections between the PV tiles and combination boxes 840 or
electrical main 844 can be made with an MC4 connector (a
Multi-Contact 4 mm electrical connector), or other such direct
current (DC) positive-locking electrical connector.
[0093] In other embodiments, as seen in first course 818 and second
course 820, power bus bars 842 can also be used to electrically
connect solar cells of the PV tiles. Individual power bus bars 842
can electrically connect PV tiles along part of a row, or an entire
course of, PV tiles. Two or more power bus bars 842 can connect to
combination boxes 840. All of the wiring schematics considered may
further include a home run to connect BIPV array 802, via
combination boxes 840 to a respective electrical main 844, or
ultimately to a public or external electrical grid. In some
aspects, power bus bars 842 can replace and serve as cross-battens,
thereby also providing structure to roof surface 800, and
maximizing use of space beneath roof tiles 804 of BIPV system 802.
In other aspects, power bus bars 842 can have two tracks of
electrical contacts (each of which can be continuous or
discontinuous), such that PV tiles placed in between the two tracks
can make electrical connections once arranged in a functional
position (e.g. twisted into place such that electrical contacts on
the PV tile touch the electrical tracks).
[0094] In other embodiments, as seen in fifth course 826, harness
couplings 846 can electrically connect to junction boxes 834
(and/or dual junction boxes 835) on PV tiles. As shown,
standardized electrical contacts can extend from PV tiles to which
harness couplings 846 can quickly and easily attach to. Harness
coupling 846 are wired together, providing an advantage in that
wiring 836 does not need to be individually connected to every
junction box 834 of a set of PV tiles, but rather the wiring 836 is
securely and consistently connected to harness couplings 846 which
simply plug into junction boxes 834.
[0095] Such strings of PV tiles, connected by wiring 836, harness
couplings 846, or by power bus bars 840, can be a string of low
voltage, high voltage, or intermediate voltage, depending on the
specific building and desired power production. A low voltage
architecture can be a string that builds to 50 V or a string that
builds to 80 V. In other implementations, a string of PV tiles can
build to a high voltage architecture of about 300 V-600 V. In some
installations, it may be necessary to further include a rapid
shutdown device (RSD) as part of the string, to ensure that the
BIPV array 802 is code compliant as needed.
[0096] FIG. 11 is a schematic of roof surface 800 showing
alternative possible electrical connections for tiles of BIPV array
802. In particular, FIG. 11 shows potential wiring connections
using strands of PV tiles electrically connected as a subset of
elements (e.g. like a string of Christmas lights) and in-tile
bussing connections. Again, it can be understood that for a clear
schematic illustration, electrical connectors are shown in
locations overlapping with solar cells 806, whereas the actual
physical location of such electrical connections can be centered or
anchored in other regions of a PV tile.
[0097] In some embodiments, as seen in first course 818, second
course 820, and third course 822, various sets of the full PV roof
tiles, left-half PV roof tiles, right-half PV roof tiles, and
optionally the blank tiles can be electrically strung together in
sets (e.g. like a string of Christmas lights) at the time of
manufacture, and then installed as a set at a worksite.
Preassembling such strands of PV tiles can provide for greater
accuracy and consistency in assembly. In some aspects, such strands
of PV tiles can include eight (8) to twelve (12) PV tiles, and thus
up to from about sixteen (16) to twenty-four (24) solar cells 806;
of course, in other implementations, PV tiles strands can have a
greater or lesser number of PV tiles and/or solar cells 806. As
shown, each strand of PV tiles can have diodes 839 terminating the
strand, where each strand of PV tiles can have variable numbers of
PV tiles and/or solar cells. In some aspects, a strand of PV tiles
can have twenty (20) PV tiles, ten (10) PV tiles, five (5) PV
tiles, or two (2) PV tiles. PV tile strands of various lengths can
be used to lay roof tiles 804 over roof surface 800, mixing,
matching, and fitting PV tile strands as appropriate for the unique
contours of any given installation. In further aspects, single PV
tiles may be used to fill in short or narrow regions of roof
surface 800 where a longer PV tile strand would be inappropriate to
use.
[0098] In some embodiments, as seen in fourth course 824 and fifth
course 826, the PV tiles can have built-in power bussing, where the
electrical connections are embedded wiring 848 within each
individual PV tile, with tile connectors 850 on the sides of PV
tiles capable of electrically connecting to adjacent PV tiles.
Embedded wiring 848 in each PV tile, electrically connected to
solar cells 806, allows for modular assembly of PV tiles with
minimal need for additional wiring or external components. Indeed,
PV tiles with embedded wiring 848 can also include embedded diodes
849 in some or all PV tiles of a built-in power bussing
implementation of BIPV array 802, thereby providing for the
protection and advantages of the one-way electrical gate without an
additional element. Tile connectors 850 can be closely mounted or
otherwise embedded within PV tiles, and arranged such that tile
connectors 850 on adjacent PV tiles can directly electrically
connect to each other or be connected with a minimal length of
additional wiring. Alternatively, tile connectors 850 can include
an amount of wiring slack such that tile connectors 850 can extend
a short distance to couple with adjacent or proximate tile
connectors. In such embodiments, some blank tiles can be direct
bypass tiles, with embedded wiring 848 simply passing through PV
tile. In other implementations a bypass whip (e.g., a short length
of wiring 836) can connect tile connectors 850 on PV tiles
separated by one or more blank roof tiles 804, without any
electrical connection through blank roof tiles 804. Bypass whips
may also be used to run from the end of course to the beginning of
the next up-roof course of tiles.
[0099] In some embodiments, as seen in fourth course 824, built-in
bussing embodiments can have embedded wiring 848 passing through PV
tiles and always connecting to solar cells 806 in the respective PV
tiles. In some embodiments, as seen in fifth course 826, built-in
bussing embodiments can have more than one embedded wiring 848 path
passing through PV tiles and connecting to solar cells 806 and also
passing a home run line in the respective PV tiles. In further
aspects, built-in power bussing embodiments can include end cap 852
connections, completing a circuit for a given region of PV tiles
with embedded wiring 848. In other embodiments, jumper 854 can
electrically connect two lines of embedded wiring 848 within one PV
tile, or alternatively, between two PV tiles in vertically adjacent
courses. In further variations, tile connectors 850 can be located
either on opposite sides of PV tiles as shown, or on perpendicular
edges of PV tiles (not shown) to allow for electrical coupling
between vertically adjacent rows.
[0100] In both FIG. 10 and FIG. 11, while diodes 839 are shown
connected in relation to one or more courses of PV tiles, or
partial courses of PV tiles, diodes 839 can be allocated throughout
BIPV array 802 based on power generated by a section or region of
BIPV array, such that individual combination boxes 840 can
appropriately handle subsets of PV tiles. In particular,
combination boxes 840 rated to handle 300 W of power can be
electrically coupled with three diodes 839, where each diode 839 is
rated to handle 100 W of power. The number of PV tiles and
correlated solar cells 806 that add together to generate 100 W of
power can span one, two, or three or more courses of roof surface
800. In alternative aspects, combination box 840 can be an
optimizer, and in particular an optimizer configured to handle
lower power inputs. In further alternative aspects, diodes 839 can
be replaced with micro-inverters or micro-optimizers, removing the
need for combination boxes 840 as part of BIPV array 802. In
various embodiments, if a currently available optimizer is
utilized, it may be necessary to limit the string voltage of any
particular string of tiles to be less than 300 volts--the limit on
input voltage for such products.
[0101] In some aspects, optionally applicable to all embodiments of
wiring layouts for BIPV arrays as considered herein, tiles that are
electrically connected to each other can be so connected as wired
on a common string, via a wire harness. In other aspects,
photovoltaic tiles, non-photovoltaic tiles, or combinations thereof
can be arranged adjacent to each other and coupled to a common
support surface to form one or more sections of a solar roof
surface.
[0102] In further alternative embodiments, PV tiles as discussed
herein may be inductively coupled with an underlying power mat(s)
or lattice. Such an induction-based system would eliminate the need
for most wiring and physical connectors. The underlying power
mat(s) or lattice would be disposed on a roof deck or battens of a
roof structure, and electrically coupled with minor electrical
boxes or optimizers that further connect with an electrical main
box. PV tiles would be arranged and secured over corresponding
sections of the power mat(s) or lattice, such that the underlying
power mat(s) or lattice would receive electricity collected by
solar cells through induction, and subsequently convey that
electricity to the minor electrical boxes and/or electrical main
box.
[0103] At combination boxes 840, a specific power point electrical
load management can be implements to in order to control the
overall BIPV array 802 and distribution of power. One or more
channels or pathways can be tunneled or cut through portions of
insulation or insulation layers in the underlying roof to run PV
wires. In various embodiments, micro-inverters, DC optimizers, or
other module-level electronics can optionally be electrically
connected to one or more of PV tiles as part of overall array and
BIPV system.
[0104] From the foregoing, it will be appreciated that specific
embodiments of the invention have been described herein for
purposes of illustration, but that various modifications may be
made without deviating from the spirit and scope of the various
embodiments of the invention. Further, while various advantages
associated with certain embodiments of the invention have been
described above in the context of those embodiments, other
embodiments may also exhibit such advantages, and not all
embodiments need necessarily exhibit such advantages to fall within
the scope of the invention. Accordingly, the invention is not
limited, except as by the appended claims.
[0105] While the above description describes various embodiments of
the invention and the best mode contemplated, regardless how
detailed the above text, the invention can be practiced in many
ways. Details of the system may vary considerably in its specific
implementation, while still being encompassed by the present
disclosure. As noted above, particular terminology used when
describing certain features or aspects of the invention should not
be taken to imply that the terminology is being redefined herein to
be restricted to any specific characteristics, features, or aspects
of the invention with which that terminology is associated. In
general, the terms used in the following claims should not be
construed to limit the invention to the specific examples disclosed
in the specification, unless the above Detailed Description section
explicitly defines such terms. Accordingly, the actual scope of the
invention encompasses not only the disclosed examples, but also all
equivalent ways of practicing or implementing the invention under
the claims.
[0106] The teachings of the invention provided herein can be
applied to other systems, not necessarily the system described
above. The elements and acts of the various examples described
above can be combined to provide further implementations of the
invention. Some alternative implementations of the invention may
include not only additional elements to those implementations noted
above, but also may include fewer elements. Further any specific
numbers noted herein are only examples; alternative implementations
may employ differing values or ranges, and can accommodate various
increments and gradients of values within and at the boundaries of
such ranges.
[0107] References throughout the foregoing description to features,
advantages, or similar language do not imply that all of the
features and advantages that may be realized with the present
technology should be or are in any single embodiment of the
invention. Rather, language referring to the features and
advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment of the present
technology. Thus, discussion of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0108] Furthermore, the described features, advantages, and
characteristics of the present technology may be combined in any
suitable manner in one or more embodiments. One skilled in the
relevant art will recognize that the present technology can be
practiced without one or more of the specific features or
advantages of a particular embodiment. In other instances,
additional features and advantages may be recognized in certain
embodiments that may not be present in all embodiments of the
present technology.
[0109] Any patents and applications and other references noted
above, including any that may be listed in accompanying filing
papers, are incorporated herein by reference. Aspects of the
invention can be modified, if necessary, to employ the systems,
functions, and concepts of the various references described above
to provide yet further implementations of the invention.
[0110] Unless the context clearly requires otherwise, throughout
the description and the claims, the words "comprise," "comprising,"
and the like are to be construed in an inclusive sense, as opposed
to an exclusive or exhaustive sense; that is to say, in the sense
of "including, but not limited to." As used herein, the terms
"connected," "coupled," or any variant thereof means any connection
or coupling, either direct or indirect, between two or more
elements; the coupling or connection between the elements can be
physical, logical, or a combination thereof. Additionally, the
words "herein," "above," "below," and words of similar import, when
used in this application, refer to this application as a whole and
not to any particular portions of this application. Where the
context permits, words in the above Detailed Description using the
singular or plural number may also include the plural or singular
number respectively. The word "or," in reference to a list of two
or more items, covers all of the following interpretations of the
word: any of the items in the list, all of the items in the list,
and any combination of the items in the list.
[0111] Although certain aspects of the invention are presented
below in certain claim forms, the applicant contemplates the
various aspects of the invention in any number of claim forms.
Accordingly, the applicant reserves the right to pursue additional
claims after filing this application to pursue such additional
claim forms, in either this application or in a continuing
application.
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