US 11,996,797 B2
Step flaps for photovoltaic and roofing shingles
Evan Michael Wray, Cotati, CA (US); Michael David Kuiper, Newark, CA (US); Thierry Nguyen, San Francisco, CA (US); Peter Clemente, Parsippany, NJ (US); and Toby Tonascia, Arroyo Grande, CA (US)
Assigned to GAF Energy LLC, Parsippany, NJ (US)
Filed by GAF Energy LLC, Parsippany, NJ (US)
Filed on Dec. 2, 2021, as Appl. No. 17/540,773.
Claims priority of provisional application 63/120,577, filed on Dec. 2, 2020.
Prior Publication US 2022/0173694 A1, Jun. 2, 2022
Int. Cl. H02S 20/25 (2014.01); E04D 1/20 (2006.01)
CPC H02S 20/25 (2014.12) [E04D 1/20 (2013.01)] 14 Claims
OG exemplary drawing
 
1. 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.