FIELD OF THE INVENTION

The present invention relates to photovoltaic shingles and, more particularly, photovoltaic shingles for roofing systems and methods for installing same.

BACKGROUND OF THE INVENTION

Photovoltaic systems having solar panels are commonly installed on roofing of structures. What is needed is a photovoltaic shingle having features for efficient installation thereof.

SUMMARY OF THE INVENTION

In an embodiment, a method comprising the steps of obtaining a plurality of photovoltaic shingles; wherein each photovoltaic shingle of the plurality of the photovoltaic shingles includes a first end, a first layer including a head lap portion, a second layer overlaying the first layer, wherein the second layer includes at least one solar cell, laying a first photovoltaic shingle of the plurality of photovoltaic shingles directly on a deck surface of a steep slope roof; attaching the first photovoltaic shingle of the plurality of photovoltaic shingles to the deck surface of the steep slope roof; laying a second photovoltaic shingle of the plurality of photovoltaic shingles over at least a part of the head lap portion of the first photovoltaic shingle of the plurality of photovoltaic shingles; and attaching the second photovoltaic shingle to the deck surface of the steep slope roof to form a roof integrated photovoltaic system.

In an embodiment, the method further includes the step of after forming the roof integrated photovoltaic system, installing at least one wireway proximate to the first end of the first photovoltaic shingle of the plurality of photovoltaic shingles. In an embodiment, the installed at least one wireway and formed roof integrated photovoltaic system conforms to standards under ASTM E 96, Procedure B test standards. In an embodiment, the first photovoltaic shingle of the plurality of photovoltaic shingles is attached to the deck surface by a plurality of fasteners. In an embodiment, the plurality of fasteners includes a plurality of nails, rivets, screws, staples or combinations thereof. In an embodiment, the first photovoltaic shingle of the plurality of photovoltaic shingles is attached to the deck surface by an adhesive. In an embodiment, the at least one solar cell includes a plurality of solar cells.

In an embodiment, the first layer includes a polymer. In an embodiment, the polymer of the first layer includes thermoplastic polyolefin (TPO). In an embodiment, the polymer of the first layer includes a material selected from the group consisting of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyarylate (PAR), polyetherimide (PEI), polyarylsulfone (PAS), polyethersulfone (PES), polyamideimide (PAI), or polyimide; polyvinyl chloride (PVC); ethylene propylene diene monomer (EPDM) rubber; silicone rubber; fluoropolymers—ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF); tetrafluoroethylene-hexafluoropropylene copolymers (FEP), and tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymers (THV), and blends thereof. In an embodiment, none of the plurality of photovoltaic shingles is installed by a mechanical fastener. In an embodiment, the method further includes the step of installing a plurality of roofing shingles on the deck surface. In an embodiment, the plurality of roofing shingles is asphalt shingles. In an embodiment, each of the plurality of photovoltaic shingles is coplanar with the plurality of roofing shingles.

In an embodiment, the method further includes the step of laying a third photovoltaic shingle of the plurality of photovoltaic shingles over at least a part of the head lap portion of the second photovoltaic shingle of the plurality of photovoltaic shingles. In an embodiment, the deck surface includes an underlayment.

In an embodiment, a system includes a roof deck; a plurality of photovoltaic shingles installed on the roof deck, wherein each photovoltaic shingle of the plurality of photovoltaic shingles includes 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, a first layer including a head lap portion, wherein the head lap portion extends from the first end to the second end and from the first edge to a location intermediate the first edge and the second edge, a second layer overlaying the first layer, wherein the second layer includes at least one solar cell, and wherein a first photovoltaic shingle of the plurality of photovoltaic shingles overlays at least a part of the head lap portion of a second photovoltaic shingle of the plurality of photovoltaic shingles; and at least one wireway installed proximate to the first end of at least the first photovoltaic shingle.

In an embodiment, the at least one wireway is installed intermediate the first end of the first photovoltaic shingle and a second end of third photovoltaic shingle of the plurality of photovoltaic shingles. In an embodiment, the at least one wireway includes a lid, and wherein the lid is removably attached to the at least one wireway. In an embodiment, the at least one wireway includes at least one slot and the lid includes at least one rail, and wherein the at least one slot removably receives the at least one rail. In an embodiment, the lid includes a plurality of louvers. In an embodiment, the at least one wireway includes an inner surface having at least one support member extending outwardly therefrom. In an embodiment, the at least one wireway includes a plurality of wireways, and wherein one of the lids of one of the plurality of wireways overlaps another of the lids of another of the plurality of wireways. In an embodiment, each of the plurality of photovoltaic shingles incudes a side lap, and wherein the at least one wireway overlays a corresponding one of the side laps. In an embodiment, the at least one wireway includes a height in a range of 1 mm to 20 mm. In an embodiment, the at least one wireway includes a single wireway installed proximate to the first end of each of the plurality of photovoltaic shingles. In an embodiment, the at least one wireway is moisture resistant.

