WO2021235953A1

WO2021235953A1 - Roofing element and metal roofing tile with photovoltaic cell

Info

Publication number: WO2021235953A1
Application number: PCT/PL2020/050054
Authority: WO
Inventors: Mariusz ŁACH
Original assignee: BLACHPROFIL 2 SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIA
Current assignee: BLACHPROFIL 2 SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIA
Priority date: 2020-05-20
Filing date: 2020-07-28
Publication date: 2021-11-25
Anticipated expiration: 2022-11-20
Also published as: PL247255B1; PL433999A1

Abstract

The subject of the present invention is a roofing element, in particular a modular metal roof tile, comprises: a first layer (2) of a higher temperature-activated polymer-based adhesive material arranged on the upper surface of the at least one flat module (17); the photovoltaic element (3) disposed on the first layer (2) of the adhesive material, the photovoltaic element (3) being a passivated emitter and rear cell, fabricated in the PERC technology; a second layer (4) of the higher temperature-activated polymer-based adhesive material arranged on the photovoltaic element (3); a transparent protective layer (5) arranged on the second layer (4) of the adhesive material, wherein the first layer (2) of the adhesive material, the photovoltaic element (3), the second layer (4) of the adhesive material, and the transparent protective layer (5) are joined with each other and with the body of the roofing element (1) in the lamination process.

Description

Roofing element and metal roofing tile with photovoltaic cell

Technical field

The invention generally relates to the field of construction products used as roof coverings. More particularly, the invention relates to a roofing element, especially a modular metal roofing tile, equipped with photovoltaic cells.

Prior art

Polish patent PL226086B1 discloses a metal roofing tile made of a single sheet of metal which is shaped in the stamping process. This metal roofing tile has two side edges, an upper edge and a lower edge, and a series of modules that run parallel to the side edges and form the lower plane and the upper plane. Furthermore, it has wave-shaped ribs running parallel to the upper and lower edges, wherein the rib on the lower and upper edges have the form of a profiled bend and comprise embossings with centrally located mounting hole.

Traditional solar panels installed on existing roofing to convert solar energy into electricity are well known in the art. Such panels disturb, however, the original shape of the building and often protrude beyond its outline, which does not look attractive.

In view of the above, roofings with integrated photovoltaic cells have recently become more and more popular. Such tiles are attractive and look virtually identical to ordinary roofing in the form of traditional ceramic tiles or modular metal roof tiles.

Polish utility model specification PL69450 discloses a metal roofing tile with photovoltaic cells. This metal roofing tile comprises twelve tiles formed in a single sheet of metal, aligned in parallel planes and arranged in two rows of six. Each of the tiles has a flat recess in the upper main surface, surrounded by a rim in which the photovoltaic element is placed. Above the recess is a groove adapted to accommodate wires routed along the panel and inserted into the groove. The photovoltaic element comprises a photovoltaic cell sandwiched between two solar glass plates and joined by lamination. The width of the first solar glass plate is smaller than the width of the recess and greater than the width of the photovoltaic cell, while the width of the second solar glass plate is greater than the width of the recess, so that the second solar glass plate partially overlaps the flat rim to which it is bonded with a layer of adhesive. Between the upper and lower edges of the second solar glass plate and, respectively, the upper and lower edges of the recess, first and second gaps are formed, through which air flows to cool the photovoltaic cell. A disadvantage of this solution is the need to form additionally the recess for the photovoltaic element and the difficulties to fit it properly in the recess. Furthermore, the photovoltaic element adheres only to a narrow surface defined by the rim around the recess, which can cause it to fall off over time as a result of prolonged exposure to weather conditions. The production method of such a roofing tile is known from a Polish patent PL230854B1 which is held by the same applicant. A similar production method is disclosed also in an international patent application WO2017158429A1.

European patent EP2443668B1 discloses roof covering in the form of roofing tile made of a polymer-based plastic, e.g. by injection. This roofing tile has also a recess in the upper surface in which a photovoltaic element in the form of a foil is glued on the surface of the recess.

Another Polish utility model application W.124414 discloses a roof tile made of a glass body, the lower surface of which has a recess for a photovoltaic cell.

Yet another Polish utility model application W.127663 discloses a roof tile having a longitudinal body made of sheet metal, the length of which is a multiple of the width. A flexible photovoltaic tape made of durable material and sunlight transmitting polymer is glued on the top surface of the body. Summary of the invention

The objective of the invention is to propose a solution which, at least partially, eliminates the disadvantages of the known roof coverings with photovoltaic cells while at the same time being simple and cheap to produce.

According to a first aspect of the present invention, a roofing element is provided in the form of a metal sheet comprising a body, said body comprises: a main plane comprising an upper surface and a lower surface, said main plane is located essentially parallel to the plane of a roof; an upper edge; a lower edge; two side edges; longitudinal ribs running parallel to the side edges, wherein at least one module, the upper surface of which is flat, is formed between the longitudinal ribs; a photovoltaic element with electrical connectors, wherein a first layer of a higher temperature-activated polymer-based adhesive material is arranged on the upper surface of the at least one flat module, the photovoltaic element is disposed on the first layer of the adhesive material, the photovoltaic element being a passivated emitter and rear cell, fabricated in the PERC technology, a second layer of the higher temperature-activated polymer-based adhesive material is arranged on the photovoltaic element, a transparent protective layer is arranged on the second layer of adhesive material, wherein the first layer of the adhesive material, the photovoltaic element, the second layer of the adhesive material, and the transparent protective layer are joined with each other and with the body of the roofing element in the lamination process.

In one embodiment, the first and second layers of the adhesive material are selected from the group comprising one or more of the following polymeric materials: ethylene vinyl acetate (EVA), thermoplastic olefinic elastomer (TPO), polydimethylsiloxane (PDMS), polyvinyl fluoride (PVF).

The transparent protective layer is preferably made of tempered glass or polymeric materials.

According to a second aspect of the present invention, a metal roofing tile is provided in the form of a metal sheet comprising a body, said body further comprises: a main plane comprising un upper surface and a lower surface, said main plane is essentially located parallel to the plane of a roof, an upper edge bent upwards and outwards with respect to the main plane; a lower edge bent downwards with respect to the main plane; two side edges, one of which is bent upwards, and the other downwards with respect to the main plane; multiple longitudinal ribs running parallel to the side edges, wherein multiple modules, the upper surface of which is flat, are formed between said longitudinal ribs, wherein the longitudinal ribs together with the modules form a first row and a second row, the first row being connected to the second row by a transverse web so that the first row is located above the second row with respect to the plane of the roof; a photovoltaic element with electrical connectors, wherein a first layer of a higher temperature-activated polymer-based adhesive material is arranged on the upper surface of the flat modules, the photovoltaic element is disposed on the first layer of the adhesive material, the photovoltaic element being a passivated emitter and rear cell, fabricated in the PERC technology, a second layer of a higher temperature-activated polymer-based adhesive material is arranged on the photovoltaic element, a transparent protective layer is arranged on the second layer of the adhesive material, wherein the first layer of the adhesive material, the photovoltaic element, the second layer of the adhesive material, and the transparent protective layer are joined with each other and with the upper surface of the flat modules or the upper surface of the roofing tile body in the lamination process.

The first and second layers of the adhesive material are preferably selected from the group comprising one or more of the following polymeric materials: ethylene vinyl acetate (EVA), thermoplastic olefinic elastomer (TPO), polydimethylsiloxane (PDMS), polyvinyl fluoride (PVF).

The transparent protective layer can be made, for example, of glass, especially tempered glass, or polymeric materials.

Brief description of drawings

The invention is illustrated in the embodiment in the attached drawing, wherein:

Fig. 1 - shows a metal roofing tile without photovoltaic element in a perspective view.

Fig. 2 - shows the same metal roofing tile as in Fig. 1 in front view. Fig. 3 - shows a metal roofing tile with photovoltaic element in an exploded view.

Fig. 4 - shows a cross-section with stacked layers.

Detailed description of preferred embodiments of the invention

Figs. 1 and 2 show a preferred embodiment of a roofing element in the form of a metal roofing tile 1, which was made of a single sheet of metal, profiled in the stamping process using known methods.

According to this example, the roofing tile 1 has a sheet metal body, the body having a main plane comprising an upper surface 11 and a lower surface 12, which main plane extends essentially parallel to the plane of the roof on which the metal roofing tiles 1 are laid. Further, the body has an upper edge 13, a lower edge 14, and two side edges 15. The body is provided with a plurality of longitudinal ribs 16 running with equal spacing parallel to the side edges 15, wherein these longitudinal ribs 16 have the form of an arc-like, preferably semi-circular surface lowered downwards with respect to the main plane, i.e. towards the lower surface 12. A plurality of flat modules 17 arranged in rows are formed between the longitudinal ribs 16. Together with the flat modules 17, these longitudinal ribs 16 form a first row I and a second row II, wherein the first row I is connected to the second row II by a transverse web 18 so that the first row I is located above the second row II with respect to the plane of the roof. The lower edge 14 is bent downwards with respect to the main plane, preferably at right angles thereto. The lower edge 14 is essentially flat, except for the front surface in the area coinciding with the longitudinal ribs 16, which front surface of the lower edge 14 is placed outward and forward, parallel to the main plane, and in an arc-shaped, e.g. semicircular, cross-section. The upper edge 13, in turn, is bent upwards and outwards with respect to the main plane, i.e. the first section of the upper edge 13 extends essentially perpendicular to the main plane, preferably at right angles thereto, and the second section of the upper edge 13 extends essentially parallel to the main plane and perpendicularto the first section. Likewise, the front surface of the upper edge IB, and specifically the front surface of the first section of the upper edge 13 in the area coinciding with the longitudinal ribs 16, is placed outward and forward, i.e. inwards towards the web 18, parallel to the main plane, and its shape corresponds to the shape of the front surface at the lower edge 14. The side edges 15 are similarly profiled, i.e. one side edge 15 is bent upwards and the other side edge 15 is bent downwards with respect to the main plane. All edges 13, 14 and 15 are profiled in such a way as to overlap the respective edges of the adjacent metal roofing tiles 1 in order to form a tight connection preventing water penetration.

Fig. 3 shows the metal roofing tile 1 with individual layers in an exploded view, whereas Fig. 4 shows the arrangement of the layers in cross-section.

Each module 17 formed between the longitudinal ribs 16 comprises a photovoltaic element 3 extending essentially over the entire area of its flat surface. To this end, a first layer 2 of a higher temperature-activated polymer-based adhesive material is arranged on the upper surface of the flat module 17.

On the first layer 2 of the adhesive material there is a photovoltaic element 3, which is a passivated emitter and rear cell, fabricated in the PERC.

Further, a second layer 4 of the higher temperature-activated polymer-based adhesive material is arranged on the photovoltaic element 3, similarly to the first layer 2.

Preferably, the polymer-based adhesive material, also called encapsulant, is ethylene vinyl acetate (EVA). Another material may be a thermoplastic olefinic elastomer (TPO or POE), polydimethylsiloxane (PDMS), or polyvinyl fluoride (PVF).

On the other hand, on the second layer 4 of the adhesive material, the outermost layer is placed, which is a transparent protective layer 5 made of glass, preferably toughened glass, or other transparent material that ensures adequate sunlight transmission, at the same time being durable enough to protect metal roofing tiles

1 against weather conditions such as rain or hail.

The individual layers are joined together in the lamination process. As a result of the applied pressure and elevated temperature, the first and second adhesive layers 2, 4 become plasticized and bond all the layers together to form a modular metal roofing tile 1. The photovoltaic element 3 is tightly sealed between the first

2 and the second layer 4 of adhesive material.

Claims

1. A roofing element in the form of a metal sheet comprising a body, wherein the body comprises: a main plane comprising an upper surface (11) and a lower surface (12), said main plane is located essentially parallel to the plane of a roof when the roofing element is placed on a roof; an upper edge (IB); a lower edge (14); two side edges (15); longitudinal ribs (16) running parallel to the side edges (15), wherein at least one module (17), the upper surface of which is flat, is formed between the longitudinal ribs (16); a photovoltaic element (3) with electrical connectors (19), characterised in that a first layer (2) of a higher temperature-activated polymer-based adhesive material is arranged on the upper surface of the at least one flat module (17), the photovoltaic element (3) is disposed on the first layer (2) of the adhesive material, the photovoltaic element (3) being a passivated emitter and rear cell, fabricated in the PERC technology, a second layer (4) of the higher temperature-activated polymer-based adhesive material is arranged on the photovoltaic element (3), a transparent protective layer (5) is arranged on the second layer (4) of the adhesive material, wherein the first layer (2) of the adhesive material, the photovoltaic element (3), the second layer (4) of the adhesive material, and the transparent protective layer (5) are joined with each other and with the body of the roofing element (1) in the lamination process.

2. The roofing element according to claim 1, wherein the first and second layers (2, 4) of the adhesive material are selected from the group comprising one or more of the following polymeric materials: ethylene vinyl acetate (EVA), thermoplastic olefinic elastomer (TPO), polydimethylsiloxane (PDMS), polyvinyl fluoride (PVF).

3. The roofing element according to claim 1 or 2, wherein the transparent protective layer (5) is made of glass, especially toughened glass, or polymeric materials.

4. A metal roofing tile, in the form of a metal sheet comprising a body, wherein said body comprises: a main plane comprising an upper surface (11) and a lower surface (12), said main plane is essentially located parallel to the plane of the roof when the metal roofing tile is placed on a roof, an upper edge (13) bent upwards and outwards with respect to the main plane; a lower edge (14) bent downwards with respect to the main plane; two side edges (15), one of which is bent upwards, and the other downwards with respect to the main plane; multiple longitudinal ribs (16) running parallel to the side edges (15), wherein multiple modules (17), the upper surface of which is flat, are formed between the longitudinal ribs (16), wherein the longitudinal ribs (16) together with the modules (17) form a first row (I) and a second row (II), the first row (I) being connected to the second row (II) by a transverse web (18) so that the first row (I) is located above the second row (II) with respect to the plane of the roof; a photovoltaic element (3) with electrical connectors (19), characterised in that a first layer (2) of a higher temperature-activated polymer-based adhesive material is arranged on the upper surface of the flat modules (17), the photovoltaic element (3) is disposed on the first layer (2) of the adhesive material, the photovoltaic element (3) being a passivated emitter and rear cell, fabricated in the PERC technology, a second layer (4) of the higher temperature-activated polymer-based adhesive material is arranged on the photovoltaic element (3), a transparent protective layer (5) is arranged on the second layer (4) of the adhesive material, wherein the first layer (2) of the adhesive material, the photovoltaic element (3), the second layer (4) of the adhesive material, and the transparent protective layer (5) are joined with each other and with the upper surface of the flat modules (17) or the upper surface (11) of the roofing tile body (1) in the lamination process.

5. The metal roofing tile according to claim 4, wherein the first and second layers (2, 4) of the adhesive material are selected from the group comprising one or more of the following polymeric materials: ethylene vinyl acetate (EVA), thermoplastic olefinic elastomer (TPO), polydimethylsiloxane (PDMS), polyvinyl fluoride (PVF).

6. The metal roofing tile according to claim 4 or 5, wherein the transparent protective layer (5) is made of glass, especially tempered glass, or polymeric materials.