ROOF INTEGRATED SOLAR POWER SYSTEM WITH TOP MOUNTED ELECTRICAL COMPONENTS AND CABLES
A roof integrated solar power system includes a plurality of solar modules. Each solar module carries a photovoltaic or solar panel with solar cells. Edge regions of the solar module are disposed to the sides of the solar panel and are devoid of solar cells. An electrical component such as a junction box or micro-inverter, or DC optimizer is mounted on top of the solar module within at least one of the edge regions. Cabling for interconnecting the electrical component to electrical components of others of the plurality of solar modules also is located within the side regions. In one embodiment, the electrical component and cabling is disposed within a recess within a side region and covered by a flat access panel. In another embodiment, the electrical component and cabling is located atop the side region and is covered by an access panel in the form of a protective cover strip. The solar modules are installable on a roof in aligned or staggered courses to form the solar power system, and with the installed courses of modules together forming a water barrier protecting the roof.
This application is a continuation of U.S. patent application Ser. No. 16/171,819 filed Oct. 26, 2018 and entitled “Roof Integrated Solar Power System With Top Mounted Electrical Components And Cables,” which is a continuation-in-part of U.S. patent application Ser. No. 14/044,196 filed on Oct. 2, 2013 and entitled “Roof Integrated Solar Panel System with Side Mounted Micro Inverters” now U.S. Pat. No. 10,115,850, which claims the benefit of U.S. Provisional Patent Application No. 61/708,822, filed on Oct. 2, 2012, and entitled “Roof Integrated Solar Panel System with Side Mounted Micro Inverters.” The disclosures of these prior applications are hereby incorporated by reference in their entireties.
TECHNICAL FIELDThis disclosure relates generally to photovoltaic energy production and more specifically to solar panels and associated solar power systems configured to be mounted on the roof of a building for producing electrical energy when exposed to sunlight.
BACKGROUNDCollecting energy directly from the sun has drawn more and more interest in the past several years as people and industries turn to more sustainable forms of energy production. One way to collect energy from the sun is through the use of photovoltaic panels that generate electrical energy when the panels are exposed to sunlight. Large numbers of such panels can be erected in an array and electrically interconnected to generate correspondingly large volumes of electrical energy. Such photovoltaic arrays have been used to supply electrical power for commercial manufacturing plants, wineries, commercial buildings, and even domestic buildings. Such systems unfortunately tend to be large, bulky, unsightly, and generally not aesthetically desirable for installation on the roof of one's home.
More recently, photovoltaic systems have been developed that are designed to be installed on the roof of a residential home and, when installed, to present a more pleasing and acceptable appearance. One example is the Powerhouse® brand solar shingle from Dow Solar, which is relatively flat, installed in a manner similar to normal asphalt shingles, and at least to some degree resembles ordinary shingles. These more recent systems, while a step in the right direction, have generally been less acceptable than expected for a number of reasons including their tendency to leak, their susceptibility to large reductions in efficiency when one or a few panels of the system are shaded, and the difficulty of detecting and replacing defective panels and/or defective electrical connections beneath the panels. These systems generally also require large inverters in a garage or other location that convert the direct current (DC) electrical energy generated by the panels to alternating current (AC) electrical energy for connection to the public grid.
A need persists for a roof integrated solar power system that addresses the above and other problems and shortcomings, that is suitable in appearance and function for use on the roofs of residential homes, and that is easily installed and easily serviced when necessary. It is to the provision of such a system that the present invention is primarily directed.
SUMMARYBriefly described, a roof integrated solar power system is disclosed for installation on the roof of a residential home to produce electrical energy when exposed to the sun. By “roof integrated” it is meant that the system also functions as the roofing membrane or water barrier of the building to shed water and protect the roof deck. The system comprises a plurality of solar modules that may or may not include a frame, a photovoltaic or solar panel comprising a plurality of solar cells on the module, and an electronics compartment or region located to one side of the solar panel. The electronics compartment or region is generally formed in or accessible from the top surface of the solar module.
In one embodiment, a micro-inverter is mounted in the electronics compartment and is electrically connected to the solar panel of the module to convert the DC energy produced by the solar panel to AC energy for distribution. Also located in the electronics compartment or region and accessible from the top surface of the solar module is an electrical connection block for coupling the AC energy from the micro-inverter of the module to AC energy generated by others of the plurality of modules in the solar power system. The aggregated AC electrical energy generated by the plurality of solar modules can then be delivered to the public electrical grid, used directly to power appliances, or stored in a battery bank for later use.
In another embodiment, the solar modules are frameless and are attached directly to the roof deck with appropriate fasteners. Each module of this embodiment has a top surface that faces away from a roof on which it is mounted. A solar panel comprising an array of solar cells is disposed on the upper surface of the module and edge portions to the sides of the solar panel that are devoid of solar cells. One or more electrical components, such as a junction box, DC optimizer, smart junction box, and/or a micro-inverter, are disposed within the edge portions on top of the module.
Cables also are located within the edge portions on top of the module for interconnecting the electrical components of one module to those of adjacent modules in the solar power system. An access panel in the form of a protective cover strip is configured to be attached to adjacent modules extending along their edge portions. The protective cover strip covers, protects, and provides access to the electrical components and cables within the edge portions atop the solar modules.
These and other features, aspects, and advantages of the system of this disclosure will become more apparent upon review of the detailed description set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
Referring now in more detail to the drawing figures, wherein like reference numerals, where appropriate, indicate like parts throughout the several views,
The frame 12 of this embodiment is further formed to define a recessed electronics compartment 19 spaced from one end of the photovoltaic panel, and that is formed in or accessible from the top surface of the frame. A micro-inverter 21 or other electrical component such as a junction box, smart junction box, or DC optimizer is contained within the electronics compartment 19 and is connected through a wire 20 to the photovoltaic panel 18 of the module. The micro-inverter, which is a commercially available product available from a number of suppliers such as, for example, Enphase Energy of Petaluma, Calif., functions to convert DC energy produced by the photovoltaic panel 18 to AC energy, preferably at a common frequency such as 60 cycles per second (Hz). Doing the DC-AC conversion on the module itself has been found to be more efficient than directing aggregated DC electrical energy from a plurality of solar panels to a remotely located large capacity inverter somewhere else in a home.
The AC output of the micro-inverter is directed through wire 22 to AC connection block 24, also located within the electronics compartment 19 and accessible from the top surface of the frame. The AC connection block 24 is configured to allow the AC output of other modules of the system to be interconnected so that the AC outputs of all the modules is can be aggregated into a single AC output that can be connected to the electrical grid, power appliances, or otherwise used. For example, wire 33 may connect to the AC connection block 24 from the micro-inverter of the next adjacent module of the system while wire 34 may connect to the AC connection block of a module in a next higher course of modules in a system. In this way, the AC output of each module is aggregated and can be applied through a trunk line to its eventual use.
A removable access panel 32 is sized and configured to be mounted to the top of the module covering the electronics compartment to provide aesthetic appeal and to protect components in the electronics compartment. The access panel 32 is accessible from the top surface of the frame. The access panel 32 can be made to match the frame 12 or the photovoltaic panel 18 in appearance if desired, or it may be configured to contrast with the frame or photovoltaic panel. In one aspect, the top surface of the access panel 32 can be substantially flush with the top surface of the photovoltaic panel 18, and both the top surface of the access panel 32 and the top surface of the photovoltaic panel 18 may or may not be substantially flush with the top surface of the frame 12.
The right end portion 16 of the frame 12 in this embodiment is formed with a laterally extending overlap 27 having channels 29 formed on its underside. Similarly, the left end portion 17 of the frame 12 is formed with a laterally extending underlap 28 also having channels 31 formed therealong. The channels 31 are configured to engage and mesh with the channels 27 when two modules of the system are connected end-to-end as described in more detail below. A tapered recess 26 is formed along the underside of the front edge portion 14 of the frame 12. As detailed below, the recess 26 is sized and configured to receive rear edge portion 13 of a like module 11 in a next lower course of modules of a system. As a result, the modules can form a water barrier when assembled together on a roof deck that also provides water shedding during rain that protects the roof.
It will be appreciated that when a plurality of modules 11 are installed on a roof, the thickness of each module can be minimized to improve aesthetics since the micro-inverters are not mounted on the backs of the photovoltaic panels but rather to their sides and are accessible from the top of the frame. Further, if a micro-inverter of a module should fail or an AC connection block should require access, it is a simple matter to remove the corresponding access panel 32, make the needed repairs, and replace the access panel. An entire module also can be replaced if defective simply by removing the access panel disconnecting the module at the connection block, moving it, replacing it with a new module, and rewiring the new module within the electronics compartment. This is in stark contrast to traditional solar shingles, which must be removed from the roof deck to effect repairs and are not easily replaced when defective.
As may be appreciated by one of skill in the art, the process of converting the DC electrical energy to AC electrical energy can produce significant heat. Consequently, positioning the micro-inverter 21 to one side of the photovoltaic panel 18, rather than on the back or below the photovoltaic panel, can be advantageous by relocating the heat source out from under photovoltaic components that may be affected by higher ambient temperatures. As a result, the modules 11 can be installed directly to the deck 43 of the roof rather than elevated on a frame above the deck, as with some prior art systems, to provide ventilation for electrical modules that are mounted on the backs or below the photovoltaic panels.
The upper edge or headlap portion of the module 11 in the lower course is shown received within the recess 26 of the upper course of modules. In this way, the lower edge portions of the upper course of modules overlaps the headlap portions of a lower course of shingles to facilitate water shedding. A starter strip 47 is affixed to the roof deck along the forward edges of a lowermost course of modules and fills the recesses 26 of these modules. The starter strip may be formed of any appropriate material such as plastic, wood, a composite, or other material and extends along the lower edges of the lowermost course of modules to provide a substrate to which the lowermost course of modules may be affixed along their forward edges. Sealant may be applied between the starter strip 47 and the modules to inhibit windblown water from penetrating beneath the lowermost course of modules. The wiring 20, 33, and 34 as well as any additional wiring may easily be routed through the frames 13 of the modules and all electrical connections are made within the electronics compartments 19 during installation of a system of modules.
The roof integrated solar power system of this invention is installed on a roof deck as illustrated in
As each module is installed on a roof deck, or after installation of the entire system, the modules are electrically connected together. This is done using connector blocks 24 located within the electrical compartment 19. The connector blocks electrically connect the micro-inverters of each module in a course to the micro-inverters in other modules of the course through wires 33 that are hidden beneath the modules. Likewise, the micro-inverters of each course are connected to those of a next higher (or lower) course through wires 34 that also are hidden beneath the modules. In the preferred embodiment, the micro-inverters are electrically connected in parallel so that the total voltage of the system is substantially the same as the voltage of one of the micro-inverters while the electrical current capacity of the system is substantially the sum of the current capacities of all of the micro-inverters. The total electrical energy developed by the system can then be connected through a trunk wire, buss, or otherwise to the public electrical grid, to appliances in the home, or other destinations.
With the modules installed and wired, the electrical compartments of the modules are covered by their access panels 32 to complete the installation. The interface between the access panels and the top of the frame 12 can be made water tight if desired, so that the micro-inverter is positioned below the water barrier and water shedding is accomplished across the tops of the access panels during rain. Alternatively, water may be allowed to leak into the electrical compartments which may be provided with appropriate drainage systems or weep holes so that the micro-inverter is positioned above the water barrier and the water shedding is accomplished from within the electrical compartments. In the later case, vents may be formed in the access panels to vent heated air from within the electrical compartments to ambience to help maintain the temperature of the micro-inverters within acceptable ranges.
It will be appreciated, moreover, that with either configuration the primary water barrier provided by the frames 12 of the assembled solar power modules 11 may not be breached or interrupted during repairs, adjustments, or upgrades to the electrical components located with the electronics compartments 19, and that are accessible from the top of the modules 11.
The solar modules in this embodiment are attached directly to the roof deck with appropriate fasteners. The modules may be framed or frameless solar modules or more preferably may be lightweight flexible solar modules such as those available from Rich Solar of Derrimut, Australia and others. In either case, the solar modules are mounted directly to the roof deck so that mounting rails and associated mounting hardware are not necessary. This greatly reduces the cost of the system. The illustrated embodiment shows the use of lightweight flexible solar modules 53 having grommets 58 for use in securing the modules to the roof. Of course, any other means for securing the solar modules directly to the roof are possible and all should be considered to be within the scope of the invention. Access panels 56 in the form of removable protective cover strips 56 cover the edges of side-by-side abutting solar modules for purposes detailed below.
The protective cover strips 56 are sized and configured to overlie, cover, and protect the electrical components 59 and cables 61 but to be easily removable if needed for service or replacement of a solar module or its electrical components. In the illustrated embodiment, each protective cover strip 56 comprises multiple strip sections 56a, 56b, and 56c with the bottom ends of upper sections overlapping top ends of lower sections. This provides water shedding properties and makes it easier to handle, install, and remove the protective cover strips when necessary. End caps 57 may be used to cover and seal open ends of the cover strips. It will be seen that the cover strips 56 are mounted on the solar modules to the sides of the solar panels and covering the edge portions of the modules. The cover strips 56 also are raised above the upper surfaces of the solar modules to accommodate the electrical components and cabling below.
Each electrically aggregated column can then be electrically coupled together to aggregate all of the electrical energy produced by the solar modules of the solar power system. This can be done at the top or bottom of the installation or somewhere in-between. For example, the electrical components of two side-by-side modules can be configured to couple together across the width of the installation. Once electrical connections and cable routing is complete, the protective cover strips 56 are installed over the electrical components, cabling, and connectors to protect them from the elements and to prevent rainwater from seeping through the junctions 65 between side-by-side solar modules. The protective cover strips can be secured with snaps, screws, spring clips, or any other technique for securing them removably to the solar modules. The top and bottom ends of the protective cover strips can be sealed with appropriate end caps 57.
Flashing 62 may be installed across the top of the installed solar power system to integrate it with surrounding shingles 54 and direct cascading water onto the tops of the solar modules. Flashing also may be used along the sides and the bottom edge of the installed system if desired.
The invention has been described herein in terms of preferred embodiments and methodologies considered by the inventor to represent the best modes of carrying out the invention. It will be understood by the skilled artisan; however, that a wide range of additions, deletions, and modifications, both subtle and gross, may be made to the illustrated and exemplary embodiments without departing from the spirit and scope of the invention disclosed herein.
Claims
1. A system, comprising:
- a sloped roof deck;
- a plurality of photovoltaic modules installed on the roof deck, wherein the plurality of photovoltaic modules is arranged in an array, wherein the array includes an upper side extending along the roof deck, a lower side extending along the roof deck, and at least a first side extending between the upper side and the lower side;
- a plurality of roofing shingles installed on the roof deck, wherein the plurality of roofing shingles is proximate to at least the first side of the array, wherein the plurality of roofing shingles includes a first roofing shingle; and
- at least one flashing installed on the roof deck, wherein the at least one flashing includes a first flashing, wherein the first flashing includes a first side and a second side, wherein the first side of the first flashing overlays at least a portion of the first side of the array.
2. The system of claim 1, wherein the first roofing shingle overlays the second side of the first flashing,
- wherein the first flashing does not overlay the first roofing shingle, and
- wherein the first side of the array does not overlay the first flashing.
3. The system of claim 1, wherein the array includes a second side opposite the first side of the array and extending between the upper side and the lower side of the array,
- wherein the at least one flashing includes a second flashing, and
- wherein the second flashing is located along the second side of the array.
4. The system of claim 3, wherein the plurality of roofing shingles includes a second roofing shingle, and
- wherein the second flashing is between the second roofing shingle and the second side of the array.
5. The system of claim 4, wherein each of the plurality of roofing shingles is an asphalt roofing shingle.
6. The system of claim 1, wherein each of the plurality of roofing shingles is an asphalt roofing shingle.
7. The system of claim 1, wherein the at least one flashing includes a second flashing, and
- wherein the second flashing is located along the lower side of the array.
8. The system of claim 1, wherein the first flashing includes at least one channel.
9. The system of claim 8, wherein the at least one channel includes a plurality of channels.
10. The system of claim 1, wherein the plurality of photovoltaic modules includes a first photovoltaic module and a second photovoltaic module, and
- wherein the first photovoltaic module is joined with the second photovoltaic module.
11. The system of claim 1, wherein the at least one flashing includes a second flashing, and
- wherein the second flashing is located along the upper side of the array.
12. The system of claim 11, wherein the at least one flashing includes a third flashing, and
- wherein the third flashing is located along the lower side of the array.
13. The system of claim 12, wherein the array includes a second side opposite the first side of the array and extending between the upper side and the lower side of the array,
- wherein the at least one flashing includes a fourth flashing, and
- wherein the fourth flashing is located along the second side of the array.
14. A system, comprising:
- a sloped roof deck;
- a plurality of photovoltaic modules installed above the roof deck, wherein the plurality of photovoltaic modules is arranged in an array, wherein the array includes, an upper side extending along the roof deck, a lower side extending along the roof deck, a first side extending between the upper side and the lower side, and a second side opposite the first side and extending between the upper and the lower side;
- a plurality of roofing shingles installed above the roof deck, wherein the plurality of roofing shingles is proximate to at least the first side of the array, wherein the plurality of roofing shingles includes a first roofing shingle; and
- a plurality of flashing installed above the roof deck, wherein the plurality of flashing comprises at least a first flashing and a second flashing, wherein each of the plurality of flashing includes a first side and a second side, wherein the first side of the first flashing overlays at least a portion of the first side of the array, wherein the second flashing is along one of the upper side of the array, the lower side of the array, and the second side of the array.
15. The system of claim 14, wherein the first roofing shingle overlays the second side of the first flashing.
16. The system of claim 15, wherein the first flashing does not overlay the first roofing shingle, and
- wherein the first side of the array does not overlay the first flashing.
17. The system of claim 14, wherein the first flashing includes at least one channel.
18. The system of claim 17, wherein the at least one channel includes a plurality of channels.
19. The system of claim 14, wherein the second flashing is along the second side of the array,
- wherein the plurality of flashing comprises a third flashing, and wherein the third flashing is along the upper side of the array.
20. The system of claim 14, wherein the second flashing is along the second side of the array,
- wherein the plurality of flashing comprises a third flashing, and
- wherein the third flashing is along the lower side of the array.
Type: Application
Filed: May 10, 2023
Publication Date: Sep 7, 2023
Inventors: Tommy F. Rodrigues (Nutley, NJ), Sudhir Railkar (Wayne, NJ), Daniel E. Boss (Murphy, TX), David J. Gennrich (Fitchburg, WI), Cory Boudreau (Lake Elmo, MN), Daniel Roger Nett (Sun Prairie, WI), Kent J. Kallsen (Jefferson, WI)
Application Number: 18/315,384