IP Library › Granted Patent US 12,414,385
Granted Patent B2
US 12,414,385 · App. 18/457,114 · Granted Sep 9, 2025

Photovoltaic modules with offset layers

Inventors: William Sirski (San Jose, CA); Emma Dohner (San Francisco, CA); Nicholas Boitnott (San Francisco, CA)
Assignee: GAF Energy LLC
H10F19/85H02S20/24
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Quick Facts
Patent No.
US 12,414,385
App. No.
18/457,114
Granted
Sep 9, 2025
Kind
B2
Abstract

A system includes a plurality of photovoltaic modules installed on a roof deck. Each of the photovoltaic modules includes solar cells, a first encapsulant encapsulating the solar cells, a frontsheet and a backsheet. The front sheet includes a glass layer. The backsheet includes a first layer and a second layer. Each of the first and second layers includes first, second, third and fourth edges. The first edge of the first layer is offset from the first edge of the second layer, the second edge of the first layer is offset from the second edge of the second layer, the third edge of the first layer is offset from the third edge of the second layer, and the fourth edge of the first layer is offset from the fourth edge of the second layer.

Claims (94)

1. A system, comprising:

a plurality of photovoltaic modules installed on a roof deck,

wherein each of the photovoltaic modules includes

at least one solar cell,

a first encapsulant encapsulating the at least one solar cell,

wherein the first encapsulant includes a first surface and a second surface opposite the first surface,

a frontsheet juxtaposed with the first surface of the first encapsulant,

wherein the frontsheet includes a glass layer, and

a backsheet juxtaposed with the second surface of the first encapsulant,

wherein the backsheet includes

a first layer,

 wherein the first layer includes a first edge, a second edge opposite the first edge, a third edge extending from the first edge to the second edge, and a fourth edge opposite the third edge and extending from the first edge to the second edge,

 wherein the first layer includes a first length extending from the first edge to the second edge, and

 a second layer adjacent and below the first layer,

 wherein the second layer includes a first edge, a second edge opposite the first edge of the second layer, a third edge extending from the first edge of the second layer to the second edge of the second layer, and a fourth edge opposite the third edge of the second layer and extending from the first edge of the second layer to the second edge of the second layer,

 wherein the second layer includes a second length extending from the first edge of the second layer to the second edge of the second layer, and wherein the first length is greater than the second length,

 wherein the second layer is the lowermost layer of the photovoltaic module,

wherein the first edge of the first layer is offset and extends outwardly from the first edge of the second layer,

wherein the second edge of the first layer is offset and extends outwardly from the second edge of the second layer,

wherein the third edge of the first layer is offset from the third edge of the second layer, and

wherein the fourth edge of the first layer is offset from the fourth edge of the second layer, and

an adhesive layer between the first layer and the second layer,

wherein the adhesive layer includes a first edge and a second edge opposite the first edge of the adhesive layer,

wherein the adhesive layer includes a third length extending from the first edge of the adhesive layer to the second edge of the adhesive layer, and

wherein the third length is equal to the second length.

2. The system of claim 1 , wherein the first layer includes a first width extending from the third edge of the first layer to the fourth edge of the first layer, wherein the second layer includes a second width extending from the third edge of the second layer to the fourth edge of the second layer, and wherein the first width is greater than the second width.

3. The system of claim 2 , wherein the second layer is composed of thermoplastic polyolefin (TPO).

4. The system of claim 2 , wherein the first layer is composed of a polymer.

5. The system of claim 4 , wherein the first layer is composed of thermoplastic polyolefin (TPO).

6. The system of claim 2 , wherein the glass layer includes:

a first edge,

a second edge opposite the first edge of the glass layer,

a third edge extending from the first edge of the glass layer to the second edge of the glass layer, and

a fourth edge opposite the third edge of the glass layer and extending from the first edge of the glass layer to the second edge of the glass layer,

wherein the first edge of the glass layer is offset from the first edge of the second layer,

wherein the second edge of the glass layer is offset from the second edge of the second layer,

wherein the third edge of the glass layer is offset from the third edge of the second layer, and

wherein the fourth edge of the glass layer is offset from the fourth edge of the second layer.

7. The system of claim 1 , wherein the first edge of the first layer is offset from the first edge of the second layer by a first distance, wherein the second edge of the first layer is offset from the second edge of the second layer by a second distance, wherein the third edge of the first layer is offset from the third edge of the second layer by a third distance, and wherein the fourth edge of the first layer is offset from the fourth edge of the second layer by a fourth distance.

8. The system of claim 7 , wherein the first distance, the second distance, the third distance and the fourth distance are equal to one another.

9. The system of claim 7 , wherein the first distance is equal to the second distance, and wherein the third distance is equal to the fourth distance.

10. The system of claim 1 , wherein the frontsheet includes a polymer layer and a second encapsulant, and wherein the polymer layer is attached to the glass layer by the second encapsulant.

11. A photovoltaic module, comprising:

at least one solar cell,

a first encapsulant encapsulating the at least one solar cell,

wherein the first encapsulant includes a first surface and a second surface opposite the first surface,

a frontsheet juxtaposed with the first surface of the first encapsulant,

wherein the frontsheet includes a glass layer, and

a backsheet juxtaposed with the second surface of the first encapsulant,

wherein the backsheet includes

a first layer,

wherein the first layer includes a first edge, a second edge opposite the first edge, a third edge extending from the first edge to the second edge, and a fourth edge opposite the third edge and extending from the first edge to the second edge,

wherein the first layer includes a first length extending from the first edge to the second edge, and a second layer attached to and below the first layer,

wherein the second layer includes a first edge, a second edge opposite the first edge of the second layer, a third edge extending from the first edge of the second layer to the second edge of the second layer, and a fourth edge opposite the third edge of the second layer and extending from the first edge of the second layer to the second edge of the second layer,

wherein the second layer includes a second length extending from the first edge of the second layer to the second edge of the second layer, and wherein the first length is greater than the second length,

wherein the second layer is the lowermost layer of the photovoltaic module,

wherein the first edge of the first layer is offset and extends outwardly from the first edge of the second layer,

wherein the second edge of the first layer is offset and extends outwardly from the second edge of the second layer,

wherein the third edge of the first layer is offset from the third edge of the second layer, and

wherein the fourth edge of the first layer is offset from the fourth edge of the second layer,

wherein the second layer forms a lower surface of the photovoltaic module, and

wherein at least one of the first layer and the second layer is composed of thermoplastic polyolefin (TPO), and

an adhesive layer between the first layer and the second layer,

wherein the adhesive layer includes a first edge and a second edge opposite the first edge of the adhesive layer,

wherein the adhesive layer includes a third length extending from the first edge of the adhesive layer to the second edge of the adhesive layer, and

wherein the third length is equal to the second length.

12. A system, comprising:

a plurality of photovoltaic modules installed on a roof deck,

wherein each of the photovoltaic modules includes

at least one solar cell,

a first encapsulant encapsulating the at least one solar cell,

wherein the first encapsulant includes a first surface and a second surface opposite the first surface,

a frontsheet juxtaposed with the first surface of the first encapsulant, and

a backsheet juxtaposed with the second surface of the first encapsulant,

wherein the backsheet includes

a first layer,

wherein the first layer includes a first edge and a second edge opposite the first edge,

wherein the first layer includes a first length extending from the first edge to the second edge, and a second layer adjacent and below the first layer,

wherein the second layer includes a first edge and a second edge opposite the first edge of the second layer,

wherein the second layer includes a second length extending from the first edge of the second layer to the second edge of the second layer, and wherein the first length is greater than the second length,

wherein the second layer is the lowermost layer of the photovoltaic module,

wherein the first edge of the first layer is offset and extends outwardly from the first edge of the second layer, and

wherein the second edge of the first layer is offset and extends outwardly from the second edge of the second layer, and

an adhesive layer between the first layer and the second layer,

wherein the adhesive layer includes a first edge and a second edge opposite the first edge of the adhesive layer,

wherein the adhesive layer includes a third length extending from the first edge of the adhesive layer to the second edge of the adhesive layer, and

wherein the third length is equal to the second length.

13. The system of claim 12 , wherein the second layer is composed of thermoplastic polyolefin (TPO).

14. The system of claim 12 , wherein the first layer is composed of a polymer.

15. The system of claim 14 , wherein the first layer is composed of thermoplastic polyolefin (TPO).

16. The system of claim 12 , wherein the frontsheet includes a glass layer.

17. The system of claim 16 , wherein the frontsheet includes a polymer layer and a second encapsulant, and wherein the polymer layer is attached to the glass layer by the second encapsulant.

18. The system of claim 16 , wherein the glass layer includes a first edge, and a second edge opposite the first edge of the glass layer, wherein the first edge of the glass layer is offset from the first edge of the second layer, and wherein the second edge of the glass layer is offset from the second edge of the second layer.

19. The system of claim 18 , wherein the glass layer includes a third edge and a fourth edge opposite the third edge of the glass layer, wherein the third edge of the glass layer is offset from the third edge of the second layer, and wherein the fourth edge of the glass layer is offset from the fourth edge of the second layer.

Continuity (2)
Provisional Application 63401976 · Aug 29, 2022
Related Publication 20240072187A1 · Feb 29, 2024
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