Metal roofing shingles
A roofing system including a plurality of photovoltaic modules installed on a roof deck, where each of the photovoltaic modules includes at least one solar cell, and a plurality of metal roofing shingles installed on the roof deck adjacent the plurality of photovoltaic modules, where the plurality of metal roofing shingles includes at least a first metal roofing shingle and a second metal roofing shingle, where each of the metal roofing shingles includes a first layer that includes a metal material, and a second layer that includes a polymer material, where the second layer includes a nail zone with a plurality of fasteners extending therethrough, fastening the metal roofing shingle to the roof deck, where the second layer is between the roof deck and the first layer.
1 . A roofing system, comprising:
a roof deck;
a plurality of photovoltaic modules installed on the roof deck,
wherein each of the photovoltaic modules comprises at least one solar cell; and
a plurality of metal roofing shingles installed on the roof deck adjacent the plurality of photovoltaic modules,
wherein the plurality of metal roofing shingles comprises at least a first metal roofing shingle and a second metal roofing shingle,
wherein each of the metal roofing shingles comprises:
a first layer,
wherein the first layer comprises a metal material, a second layer,
wherein the second layer comprises a polymer material,
wherein the second layer includes a first end and a second end opposite the first end,
wherein the second layer includes a nail zone extending from the first end to the second end,
wherein the nail zone comprises a plurality of fasteners extending therethrough, fastening the metal roofing shingle to the roof deck,
wherein the plurality of fasteners does not penetrate the first layer,
wherein the second layer is the lowermost layer of the metal roofing shingle, and wherein the second layer is on the roof deck,
an encapsulant including a first encapsulant layer above the first layer and a second encapsulant layer below the first layer, wherein the first encapsulant layer and the second encapsulant layer encapsulate the first layer, and
a frontsheet above the first encapsulant layer,
wherein the first layer, the first encapsulant layer, the second encapsulant layer, the frontsheet, and the second layer are laminated.
2 . The roofing system of claim 1 , wherein the roof deck comprises a sloped roof deck.
3 . The roofing system of claim 1 , wherein the metal material comprises steel.
4 . The roofing system of claim 1 , wherein the polymer material comprises at least one of thermoplastic polyolefin (TPO) or ethylene tetrafluoroethylene (ETFE).
5 . The roofing system of claim 1 , wherein the second layer further comprises an intumescent material.
6 . The roofing system of claim 5 , wherein the intumescent material comprises expandable graphite.
7 . The roofing system of claim 1 , wherein the second layer directly contacts the roof deck.
8 . The roofing system of claim 1 , wherein an end of the first layer folds over an end of the second layer.
9 . The roofing system of claim 1 , wherein the second layer of the second metal roofing shingle extends beyond an end of the first layer of the second metal roofing shingle, thereby defining a sidelap, wherein the second metal roofing shingle overlays the sidelap of the first metal roofing shingle.
10 . The roofing system of claim 1 , wherein the first layer comprises a first channel and a second channel on opposite ends of the first layer, wherein the first channel of the first metal roofing shingle is positioned within the second channel of the second metal roofing shingle.
11 . The roofing system of claim 1 , wherein the plurality of fasteners comprises at least a first fastener and a second fastener, wherein the first fastener penetrates the nail zone of the first metal roofing shingle and the roof deck, thereby installing the first metal roofing shingle on the roof deck, wherein the second fastener penetrates the nail zone of the second metal roofing shingle and the roof deck, thereby installing the second metal roofing shingle on the roof deck.
12 . The roofing system of claim 11 , wherein the first fastener does not penetrate the first layer of the first metal roofing shingle.
13 . The roofing system of claim 1 , wherein the first layer of the first metal roofing shingle includes an embossed surface.
14 . The roofing system of claim 1 , wherein the frontsheet comprises a polymer material.
15 . The roofing system of claim 14 , wherein the frontsheet comprises at least one of thermoplastic polyolefin (TPO), ethylene tetrafluoroethylene (ETFE), or styrene-butadiene-styrene (SBS).
16 . A method, comprising:
obtaining a plurality of photovoltaic modules and a plurality of metal roofing shingles,
wherein the plurality of photovoltaic modules includes at least a first photovoltaic module,
wherein each of the photovoltaic modules comprises at least one solar cell,
wherein the plurality of metal roofing shingles comprises at least a first metal roofing shingle and a second metal roofing shingle,
wherein each of the metal roofing shingles comprises:
a first layer,
wherein the first layer comprises a metal material, and a second layer,
wherein the second layer comprises a polymer material,
wherein the second layer includes a first end and a second end opposite the first end,
wherein the second layer includes a nail zone extending from the first end to the second end,
wherein the nail zone is configured to receive a plurality of fasteners,
wherein the second layer is the lowermost layer of the metal roofing shingle,
an encapsulant including a first encapsulant layer above the first layer and a second encapsulant layer below the first layer, wherein the first encapsulant layer and the second encapsulant layer encapsulate the first layer, and
a frontsheet above the first encapsulant layer,
wherein the first layer, the first encapsulant layer, the second encapsulant layer, the frontsheet, and the second layer are laminated;
installing the first photovoltaic module on a roof deck; and
installing the first metal roofing shingle and the second metal roofing shingle on the roof deck with the plurality of fasteners, adjacent to the first photovoltaic module, so that:
the second layer of the first metal roofing shingle is on the roof deck and the first layer of the first metal roofing shingle, and
the second layer of the second metal roofing shingle is on the roof deck and the first layer of the second metal roofing shingle, and
wherein the plurality of fasteners does not penetrate the first layer.
17 . The method of claim 16 , wherein the installing the first metal roofing shingle and the second metal roofing shingle on the roof deck comprises:
installing the first metal roofing shingle adjacent to a side of the first photovoltaic module, in a first row on the roof deck; and
installing the second metal roofing shingle adjacent to the side of the first photovoltaic module, in a second row on the roof deck,
wherein the second row is above the first row on the roof deck.
18 . The method of claim 16 , wherein the installing the first metal roofing shingle and the second metal roofing shingle on the roof deck comprises:
installing the first metal roofing shingle adjacent to a side of the first photovoltaic module, in a first row on the roof deck; and
installing the second metal roofing shingle adjacent to the first metal roofing shingle, in the first row on the roof deck.
19 . The method of claim 16 , wherein the installing the first metal roofing shingle and the second metal roofing shingle on the roof deck comprises:
penetrating, with a first fastener, both of:
the nail zone of the second layer of the first metal roofing shingle, and
the roof deck, and
penetrating, with a second fastener, both of:
the nail zone of the second layer of the second metal roofing shingle, and the roof deck.
20 . The method of claim 16 , wherein the frontsheet comprises at least one of thermoplastic polyolefin (TPO), ethylene tetrafluoroethylene (ETFE), or styrene-butadiene-styrene (SBS).