ANGLED POLYMER SOLAR MODULES
This specification describes angled polymer solar modules, methods for producing angled polymer solar modules, and methods for installing angled polymer solar modules. In some examples, a method includes producing a flat polymer sheet including one or more photovoltaic cells. The method includes applying force to the flat polymer sheet to curve the flat polymer sheet in at least one region, forming an angled polymer sheet from the flat polymer sheet. The method includes mounting the angled polymer sheet on a roof deck such that the photovoltaic cells are angled with respect to the roof deck by virtue of the at least one region being curved.
1 . A method comprising:
producing a flat polymer sheet including one or more photovoltaic cells; and
applying force to the flat polymer sheet to curve the flat polymer sheet in at least one region, forming an angled polymer sheet from the flat polymer sheet.
2 . The method of claim 1 , comprising mounting the angled polymer sheet on a roof deck such that the photovoltaic cells are angled with respect to the roof deck by virtue of the at least one region being curved.
3 . The method of claim 1 , wherein producing the flat polymer sheet comprises forming at least one layer in the at least one region comprising a thermoplastic material, and wherein the method comprises applying heat to the at least one region before applying force to the flat polymer sheet and cooling the at least one region before removing the force to the flat polymer sheet.
4 . The method of claim 1 , comprising mounting power electronics to the angled polymer sheet and attaching cabling to the angled polymer sheet.
5 . The method of claim 1 , comprising stacking the angled polymer sheet with one or more other angled polymer sheets for transportation or storage or both.
6 . The method of claim 1 , wherein producing the flat polymer sheet comprises forming a layered structure including a transparent front sheet, a backsheet, and a layer of alternating sections of a rigid polymer and a thermoplastic material.
7 . The method of claim 1 , wherein producing the flat polymer sheet comprises forming a layer including a first section of a rigid polymer, a first section of a thermoplastic material adjacent the first section of the rigid polymer, a second section of the rigid polymer adjacent the first section of the thermoplastic material, a second section of the thermoplastic material adjacent the second section of the rigid polymer, a third section of the rigid polymer adjacent the second section of the thermoplastic material, a third section of the thermoplastic material adjacent the third section of the rigid polymer, and a fourth section of the rigid polymer adjacent the third section of the thermoplastic material.
8 . The method of claim 7 , comprising:
applying heat to the layer;
while the layer is warm from applying heat to the layer, applying force to the flat polymer sheet to bend the flat polymer sheet in the first, second, and third sections of the thermoplastic material;
cooling the layer before removing the force; and
mounting the angled polymer sheet to a roof deck by securing portions of the sheet under the first section of the rigid polymer and the fourth section of the rigid polymer to the roof deck.
9 . The method of claim 1 , wherein forming the flat polymer sheet comprises forming in-laminate diodes within the flat polymer sheet.
10 . The method of claim 1 , comprising forming a plurality of holes passing through the angled polymer sheet to allow wind to pass through the angled polymer sheet.