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Presentation Details
| Walkable Solar Shingles Richard Perkins, David Meakin. GAF Energy, Georgetown, TX, USA |
Abstract
Abstract — Building Integrated Photovoltaics (BIPV) must successfully merge semiconductor performance with the durability required of roofing materials. Traditional rack-mounted PV modules, supported only at the frame edges, experience significant laminate deflection under wind and snow loads; consequently, manufacturers strictly prohibit walking on the laminate to prevent cell cracking and electrical failure. However, for a BIPV product to be seamlessly integrated into residential construction workflows by roofing crews, walkability is a fundamental requirement. This work evaluates the novel “Walkable by Design” architecture of the Timberline Solar™ Energy Shingle, a direct-to-deck BIPV platform engineered to meet this challenge. Unlike traditional modules, this frameless system eliminates the racking air gap, utilizing a composite laminate stack featuring a polymer-coated, impact-resistant glass front sheet texturized for traction and aesthetics, combined with an extra-thick roofing membrane backsheet. This construction ensures the module is fully supported by the roof deck, converting vertical foot traffic loads into compression rather than bending strain. We validated this design through a comprehensive dual-phase study. First, accelerated life testing subjected modules with artificially induced cracks to 600 Thermal Cycles (TC600). The results demonstrated that the unique laminate stack maintains electrical continuity, with cracked modules exhibiting less than 1% power loss deviation compared to uncracked controls. Second, a novel in-situ Outdoor Photoluminescence (OPL) drone, developed in collaboration with the University of New South Wales, was deployed to screen a fleet of installed systems. Aggregated data from nearly 100,000 cells across Timberline Solar™ generations (TLS1 and TLS2) revealed a negligible cell crack incidence rate of less than 1%, comparable to shipping baselines. These findings confirm that the platform’s materials and attachment method effectively mitigate the risk of cell-crack induced degradation, delivering a BIPV roofing solution capable of withstanding the rigors of standard roof installation workflows.
No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the author.
No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the author.