PHOTOVOLTAIC MODULE FOR ROOFS
A photovoltaic module generates electrical power when installed on a roof. The module is constructed as a laminated sandwich having a transparent protective upper layer adhered to a photovoltaic layer. The photovoltaic layer is adhered to a rigid layer formed from a fiber reinforced plastic. The laminated sandwich has a frame around the perimeter. The laminated panel has a layer of double stick tape on the bottom to adhere the panel to the surface of a roof.
1 . A photovoltaic module, comprising:
an upper transparent layer comprising fluorinated ethylene propylene resin;
a photovoltaic layer positioned beneath the upper transparent layer, the photovoltaic layer comprising a plurality of electrically interconnected photovoltaic cells disposed in a matrix array, and an electrical junction box disposed on the same side of the module as the matrix of cells;
a first layer of heat-activated transparent adhesive interposed between the upper transparent layer and the photovoltaic layer to adhere the photovoltaic layer to the upper transparent layer;
a rigid layer positioned beneath the photovoltaic layer;
a second layer of heat-activated transparent adhesive interposed between the photovoltaic layer and the rigid layer to adhere the photovoltaic layer to the rigid layer;
a plastic frame having an upper portion and a lower portion, the frame positioned to hold edges of the upper transparent layer, the photovoltaic layer and the rigid layer between the upper portion and the lower portion; and
an adhesion layer having a first surface attached to an exposed lower surface of the rigid layer and having a second surface for adhering the module to a roofing surface, said adhesion layer having a thickness substantially equal to a thickness of a bottom portion of said frame.
2 . The photovoltaic module of claim 1 , wherein the rigid layer comprises a fiber reinforced plastic.
3 . The photovoltaic module of claim 1 , wherein the adhesion layer comprises tape having a first adhesion side and a second adhesive side, the first adhesion side fixed to the lower surface of the rigid layer, the second adhesion side having a releasable cover, the releasable cover being removable to adhere the adhesion layer to the lower surface of the rigid layer, thereby fixing the photovoltaic panel to a roof surface.
4 . The photovoltaic module of claim 1 , wherein the heat-activated transparent adhesive comprises ethylene-vinyl-acetate.
5 . The photovoltaic module of claim 1 , wherein said adhesion layer has a bottom surface which is substantially contiguous with a bottom surface of said bottom portion of said frame.
6 . The photovoltaic module of claim 1 , wherein said frame comprises a non-conductive, flexible frame.
7 . The photovoltaic module of claim 1 , wherein said frame comprises a one-piece, non-conductive, flexible frame.
8 . The photovoltaic module of claim 1 , wherein said module is substantially 243.840 centimeters (8 feet) long by substantially 121.920 centimeters (4 feet) wide, and less than substantially 0.508 centimeter (0.2 inch) thick.
9 . The photovoltaic module of claim 1 , wherein said upper transparent layer, said photovoltaic layer, said first layer, said rigid layer, and said second layer have a strength sufficient to support the weight of a construction worker.
10 . A photovoltaic module, comprising:
an upper transparent layer;
a photovoltaic layer positioned beneath the upper transparent layer, the photovoltaic layer comprising a plurality of electrically interconnected photovoltaic cells disposed in a two-dimensional array and an electrical junction box on the same side of the module as the array of cells;
a first layer of heat-activated transparent adhesive interposed between the upper transparent layer and the photovoltaic layer to adhere the photovoltaic layer to the upper transparent layer;
a rigid layer positioned beneath the photovoltaic layer;
a second layer of heat-activated transparent adhesive interposed between the photovoltaic layer and the rigid layer to adhere the photovoltaic layer to the rigid layer;
a non-conductive, flexible plastic frame having an upper portion and a lower portion, the frame positioned to hold edges of the upper transparent layer, the photovoltaic layer and the rigid layer between the upper portion and the lower portion; and
an adhesion layer having a first surface attached to an exposed lower surface of the rigid layer and having a second surface for adhering the module to a roofing surface.
11 . The photovoltaic module of claim 10 , wherein said module is substantially 4 feet wide, 8 feet long, and less than substantially 0.508 centimeter (0.2 inch) thick.
12 . The photovoltaic module of claim 11 , wherein said upper transparent layer, said photovoltaic layer, said first layer, said rigid layer, and said second layer have a strength sufficient to support the weight of a construction worker.
13 . The photovoltaic module of claim 12 , wherein said frame comprises a single member bent around edges of said upper transparent layer, said photovoltaic layer, said first layer, said rigid layer, and said second layer.
14 . The photovoltaic module of claim 13 , wherein two free ends of said single member are butted together.
15 . The photovoltaic module of claim 10 , wherein said non-conductive, flexible frame comprises a one-piece plastic frame.
16 . The photovoltaic module of claim 15 , wherein said adhesion layer has a thickness substantially equal to a thickness of a bottom portion of said frame.
17 . The photovoltaic module of claim 10 , wherein said plurality of electrically interconnected photovoltaic cells comprises a matrix of cells, at least two cells being absent from said matrix, and wherein said junction box is disposed in a space on said photovoltaic layer where said at least two cells are absent.
18 . A photovoltaic module, comprising:
an upper transparent layer;
a photovoltaic layer positioned beneath the upper transparent layer, the photovoltaic layer comprising a plurality of electrically interconnected photovoltaic cells and an electrical output connector;
a first layer of heat-activated transparent adhesive interposed between the upper transparent layer and the photovoltaic layer to adhere the photovoltaic layer to the upper transparent layer;
a rigid layer positioned beneath the photovoltaic layer;
a second layer of heat-activated transparent adhesive interposed between the photovoltaic layer and the rigid layer to adhere the photovoltaic layer to the rigid layer;
a non-conductive, flexible frame having an upper portion and a lower portion, the frame positioned to hold edges of the upper transparent layer, the photovoltaic layer and the rigid layer between the upper portion and the lower portion; and
an adhesion layer having a first surface attached to an exposed lower surface of the rigid layer and having a second surface for adhering the module to a roofing surface, said adhesion layer being unattached to said frame.
19 . The photovoltaic module of claim 18 , wherein said adhesion layer has a thickness substantially equal to a thickness of a bottom portion of said frame.
20 . The photovoltaic module of claim 18 , wherein said adhesion layer has a bottom surface which is substantially contiguous with a bottom surface of said bottom portion of said frame.