Photovoltaic modules for commercial roofing

Patent metadata

Field	Value
Publication number	US-11728759-B2
Application number	US-202217900604-A
Country	US
Kind code	B2
Filing date	Aug 31, 2022
Priority date	Sep 1, 2021
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

A system includes a roof deck having a slope of 0.25 inch to 3 inches per foot and a roofing membrane is composed of a first material, and at least one photovoltaic module installed on the roof deck. The photovoltaic module includes at least one solar cell, an encapsulant, a frontsheet, and a backsheet. The backsheet includes a head flap located at a first end of the backsheet, and a bottom flap located at a second end of the backsheet. The backsheet is composed of the first material. At least a first portion of the head flap is attached to the roofing membrane, and at least a second portion of the bottom flap is attached to the roofing membrane.

First claim

What is claimed is:

1. A system, comprising:
a roof deck,
wherein the roof deck includes a slope of 0.25 inch to 3 inches per foot,
wherein the roof deck includes a roofing membrane, and
wherein the roofing membrane is composed of a first material; and

at least one photovoltaic module installed on the roof deck, the photovoltaic module including
at least one solar cell
an encapsulant encapsulating the at least one solar cell,
wherein the encapsulant includes a first surface and a second surface opposite the first surface,

a frontsheet juxtaposed with the first surface of the encapsulant, and
a backsheet juxtaposed with the second surface of the encapsulant,
wherein the backsheet includes
a head flap located at a first end of the backsheet, and
a bottom flap located at a second end of the backsheet opposite the first end,

wherein the backsheet is composed of the first material,
wherein at least a first portion of the head flap is attached to the roofing membrane, and
wherein at least a second portion of the bottom flap is attached to the roofing membrane.

2. The system of claim 1 , wherein the first material is composed of a polymeric material.

3. The system of claim 1 , wherein the first material is composed of thermoplastic polyolefin (TPO).

4. The system of claim 1 , wherein the head flap and the bottom flap are attached to the roofing membrane by an adhesive.

5. The system of claim 1 , wherein the head flap and the bottom flap are attached to the roofing membrane by thermal bonding.

6. The system of claim 1 , wherein the head flap and the bottom flap are attached to the roofing membrane by ultrasonic welding.

7. The system of claim 1 , wherein the backsheet includes a first side flap located at a first side of the photovoltaic module and a second side flap located at a second side of the photovoltaic module opposite the first side, wherein at least a third portion of the first side flap is attached to the roofing membrane and at least a fourth portion of the second side flap is attached to the roofing membrane.

8. The system of claim 1 , wherein the backsheet includes a first surface and a second surface opposite the first surface of the backsheet, and wherein the first surface of the backsheet is juxtaposed with the second surface of the encapsulant.

9. The system of claim 1 , wherein the second surface of the second portion of the bottom flap is attached to the roofing membrane.

10. The system of claim 9 , wherein the second surface of the first portion of the head flap is attached to the roofing membrane.

11. The system of claim 9 , wherein the first surface of the first portion of the head flap is attached to the roofing membrane.

12. The system of claim 11 , wherein the head flap includes a free end, wherein the free end of the head flap is folded relative to itself and forms a rounded end.

13. The system of claim 12 , wherein the rounded end includes a first portion juxtaposed with the roofing membrane and a second portion relative to the roofing membrane, wherein the second portion of the rounded end is elevated relative to the roofing membrane.

14. The system of claim 13 , wherein the first surface of at least the first portion of the rounded end is attached to the roofing membrane.

15. The system of claim 13 , wherein the second portion of the rounded end is sloped 0.1 degrees to 15 degrees.

16. The system of claim 1 , further comprising at least one support member located intermediate a corresponding one of the at least one photovoltaic module and the roofing membrane, and wherein a portion of the at least one photovoltaic module is elevated relative to the roofing membrane.

17. The system of claim 16 , wherein
the at least one solar cell includes
a first plurality of solar cells arranged in a first array, and
a second plurality of solar cells arranged in a second array,

wherein the at least one photovoltaic module includes
a first section,
a second section, and
a region located intermediate the first section and the second section,
wherein the first array is located within the first section,
wherein the second array is located within the second section,

wherein the at least one support member is juxtaposed with the region.

18. The system of claim 17 , wherein the at least one support member includes a rod.

19. The system of claim 18 , wherein the at least one support member is composed of thermoplastic polyolefin (TPO).

20. The system of claim 17 , wherein each of the first section and the second section is elevated relative to the roofing membrane, wherein the first section is sloped 0.1 degrees to 15 degrees, and wherein the second section is sloped 0.1 degrees to 15 degrees.

Assignees

• GAF Energy LLC

Inventors

• Nguyen Thierry
• Bunea Gabriela
• Rossi Gary
• Boitnott Nicholas
• Perkins Richard
• Kavulak David

Classifications

• H10F19/804

  Materials of encapsulations · CPC title

• H10F19/80

  Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells · CPC title

• H10F19/85

  Protective back sheets · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• E04D1/22

  of specified materials {not covered by any one of groups E04D1/14 - E04D1/205}, or of combinations of materials, {where at least one is} not covered by any one of groups E04D1/14 - E04D1/205 · CPC title