Back to results
US 11,996,797 B2Granted
Step flaps for photovoltaic and roofing shingles
AssigneeGAF Energy LLC
InventorsEvan Michael Wray, Michael David Kuiper, Thierry Nguyen, Peter Clemente, Toby Tonascia
Life of this patent
Estimating the term…
Abstract
A system including a plurality of photovoltaic shingles installed on a roof deck, a plurality of roofing shingles, such as asphalt shingles, installed on the roof deck, and a plurality of step flaps. One end of the roofing shingle overlays a first side of a corresponding one of the step flaps, and one end of photovoltaic shingle overlays a second side of the corresponding one of the step flaps.
Claims14
A system, comprising:
- a roof deck;
- at least first, second, third, and fourth roofing shingles installed on the roof deck,
- wherein the first roofing shingle is a first asphalt roofing shingle,
- wherein the second roofing shingle is a second asphalt roofing shingle,
- wherein the third roofing shingle is a first photovoltaic module,
- wherein the fourth roofing shingle is a second photovoltaic module, and
- wherein each of the first and second asphalt roofing shingles includes
- an upper surface,
- a lower surface opposite the upper surface,
- a first end,
- a second end opposite the first end,
- a first edge extending from the first end to the second end, and
- a second edge opposite the first edge and extending from the first end to the second end,
- wherein each of the first and second photovoltaic modules includes a first layer and a reveal portion above the first layer,
- wherein the first layer includes:
- a first end,
- a second end opposite the first end of the first layer, and
- a side lap at the second end of the first layer,
- wherein the first layer is continuous from the first end of the first layer to the second end of the first layer,
- wherein the reveal portion includes a plurality of solar cells,
- wherein the reveal portion includes a first end and a second end opposite the first end of the reveal portion,
- wherein the second end of the reveal portion is between the first end of the first layer and the second end of the first layer,
- wherein the side lap is adjacent to the second end of the reveal portion and extends from the second end of the reveal portion to the second end of the first layer;
- and
- at least one step flap having
- a first side,
- a second side opposite the first side,
- a first edge extending from the first side to the second side,
- a second edge opposite the first edge of the at least one step flap and extending from the first side to the second side, and
- an upper surface,
- wherein the upper surface of the at least one step flap extends from the first side to the second side and from the first edge of the at least one step flap to the second edge of the at least one step flap,
- wherein the upper surface of the at least one step flap is flat, wherein the second end of the first asphalt roofing shingle overlays the first side of the at least one step flap on the upper surface of the at least one step flap,
- wherein the lower surface of the first asphalt roofing shingle is juxtaposed with the upper surface of the at least one step flap,
- wherein the first end of the first photovoltaic module overlays the second side of the at least one step flap on the upper surface of the at least one step flap,
- wherein the lower surface of the first photovoltaic module is juxtaposed with the upper surface of the at least one step flap, and
- wherein the second end of the first asphalt roofing shingle is adjacent to the first end of the first photovoltaic module, and
- wherein the first end of the second asphalt roofing shingle overlays an entirety of the side lap of the second photovoltaic module at the second end of the first layer of the second photovoltaic module to form an overlap portion,
- wherein the overlap portion comprises the lower surface of the second asphalt roofing shingle overlaying an uppermost surface of the side lap of the first layer of the second photovoltaic module, and wherein the overlap portion is adjacent the reveal portion of the second photovoltaic module.
35 more elements
A method, comprising:
- obtaining at least first, second, third, and fourth roofing shingles,
- wherein the first roofing shingle is a first asphalt roofing shingle,
- wherein the second roofing shingle is a second asphalt roofing shingle,
- wherein the third roofing shingle is a first photovoltaic module,
- wherein the fourth roofing shingle is a second photovoltaic module, and
- wherein each of the first and second asphalt roofing shingles includes
- an upper surface,
- a lower surface opposite the upper surface,
- a first end,
- a second end opposite the first end,
- a first edge extending from the first end to the second end, and
- a second edge opposite the first edge and extending from the first end to the second end,
- wherein each of the first and second photovoltaic modules includes a first layer and a reveal portion above the first layer,
- wherein the first layer includes:
- a first end,
- a second end opposite the first end of the first layer, and
- a side lap at the second end of the first layer,
- wherein the first layer is continuous from the first end of the first layer to the second end of the first layer,
- wherein the reveal portion includes a plurality of solar cells,
- wherein the reveal portion includes a first end and a second end opposite the first end of the reveal portion,
- wherein the second end of the reveal portion is between the first end of the first layer and the second end of the first layer,
- wherein the side lap is adjacent to the second end of the reveal portion and extends from the second end of the reveal portion to the second end of the first layer;
- obtaining at least one step flap,
- wherein each of the at least one step flap includes
- a first side,
- a second side opposite the first side,
- a first edge extending from the first side to the second side,
- a second edge opposite the first edge of the at least one step flap and extending from the first side to the second side, and
- an upper surface,
- wherein the upper surface of the at least one step flap extends from the first side to the second side and from the first edge of the at least one step flap to the second edge of the at least one step flap,
- wherein the upper surface of the at least one step flap is flat;
- installing the at least one step flap on a roof deck;
- overlaying the first end of the first photovoltaic module over the second side of the at least one step flap,
- wherein the lower surface of the first photovoltaic module is juxtaposed with the upper surface of the at least one step flap;
- and
- overlaying the second end of the first asphalt roofing shingle over the first side of the at least one step flap,
- wherein the lower surface of the first asphalt roofing shingle is juxtaposed with the upper surface of the at least one step flap, and
- wherein the second end of the first asphalt roofing shingle is adjacent to the first end of the first photovoltaic module;
- and
- overlaying the first end of the second asphalt roofing shingle over an entirety of the side lap of the second photovoltaic module at the second end of the first layer of the second photovoltaic module to form an overlap portion,
- wherein the overlap portion comprises the lower surface of the second asphalt roofing shingle overlaying an uppermost surface of the side lap of the first layer of the second photovoltaic module,
- wherein the overlap portion is adjacent the reveal portion of the second photovoltaic module.
39 more elements
Dependencies are inferred from the claim text.