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Patent · US11508861B1 · B1 · US

Photovoltaic module with light-scattering encapsulant providing shingle-mimicking appearance

(11) Publication number
US11508861B1
(21) Application number
17/830,094
(22) Filing date
2022-06-01
(30) Priority date
2021-06-02
(43) Publication date
2022-11-22
(45) Date of grant
2022-11-22
(51) IPC
H01L 31/048; H01L 31/18; H02S 20/25; H02S 40/20
(52) CPC
  • H02S Generation of electric power by conversion of infrared radiation, visible light or ultraviolet light, e.g. using photovoltaic [pv] modules: 20/25, 40/20
  • H01L Semiconductor devices; electric solid state devices not otherwise provided for: 31/048, 31/18
  • H10F Inorganic semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation: 19/80, 19/804, 71/00, 77/42
  • Y02B Climate change mitigation technologies related to buildings, e.g. housing, house appliances or related end-user applications: 10/10
(73) Assignee
GAF Energy LLC
(72) Inventors
Richard Perkins; Alex Sharenko; Thierry Nguyen; Gabriela Bunea; Anna Wojtowicz
(54) Title
Photovoltaic module with light-scattering encapsulant providing shingle-mimicking appearance
(57) Abstract

A method of making a photovoltaic module includes the step of obtaining a frontsheet having a glass layer, a light scattering encapsulant layer, and a polymer layer. The light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions. The first portions of the light scattering encapsulant layer has a first light scattering value and a second portion defined by the area has a second light scattering value different from the first light scattering value. The method includes the steps of obtaining at least one solar cell, an encapsulant, and a backsheet, and laminating the frontsheet, the encapsulant, the at least one solar cell, and the backsheet.

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Claims (20)

  1. A method of making a photovoltaic module, comprising the steps of: obtaining a frontsheet, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions, a polymer layer having a first surface and a second surface opposite the first surface of the polymer layer, wherein the second surface of the polymer layer is attached to the first surface of the light scattering encapsulant layer, and wherein the plurality of first portions of the light scattering encapsulant layer has a first light scattering value as measured in accordance with an ASTM E430 standard, wherein a second portion defined by the at least one area has a second light scattering value as measured in accordance with the ASTM E430 standard, and wherein the second light scattering value is different than the first light scattering value; obtaining at least one solar cell, an encapsulant, and a backsheet wherein the encapsulant includes a first surface and a second surface opposite the first surface of the encapsulant; and laminating the frontsheet, the encapsulant, the at least one solar cell, and the backsheet, wherein the frontsheet is juxtaposed with the first surface of the encapsulant, wherein the encapsulant encapsulates the at least one solar cell, and wherein the backsheet is juxtaposed with the second surface of the encapsulant.
  2. The method of claim 1, further comprising the steps of laminating the glass layer, the light scattering encapsulant layer, and the polymer layer to form the frontsheet.
  3. The method of claim 1, wherein the first light scattering value is 0.1 HU to 12 HU.
  4. The method of claim 1, wherein the second light scattering value is 0.1 HU to 12 HU.
  5. The method of claim 1, wherein the polymer layer is attached to the light scattering encapsulant layer by an adhesive layer.
  6. The method of claim 5, wherein the adhesive layer is selected from the group consisting of thermosetting polyolefin, thermosetting polyolefin encapsulant material, ethylene-vinyl acetate (EVA), EVA encapsulants, thermoplastic olefin, thermoplastic polyolefin (TPO) and hybrids and combinations thereof.
  7. The method of claim 5, wherein the adhesive layer includes a thermosetting polyolefin encapsulant material.
  8. The method of claim 1, wherein the polymer layer includes a fluoropolymer.
  9. The method of claim 1, wherein the polymer layer includes a material selected from the group consisting of acrylics, polyesters, silicones, and polycarbonates.
  10. The method of claim 1, wherein the light scattering encapsulant layer includes a polymeric material.
  11. The method of claim 10, wherein the polymeric material includes at least one of ethylene-co-vinyl acetate, polydimethyl siloxane, a polyolefin elastomer, or a combination thereof.
  12. The method of claim 11, wherein the backsheet includes a first layer juxtaposed with the second surface of the encapsulant.
  13. The method of claim 12, wherein the first layer includes thermoplastic polyolefin (TPO).
  14. The method of claim 12, wherein the backsheet includes a second layer.
  15. The method of claim 14, wherein the second layer includes thermoplastic polyolefin (TPO).
  16. The method of claim 15, wherein the first layer is attached to the second layer by a second adhesive layer.
  17. The method of claim 16, wherein the second adhesive layer is selected from the group consisting of thermosetting polyolefin, thermosetting polyolefin encapsulant material, thermosetting polyolefin encapsulant material, ethylene-vinyl acetate (EVA), EVA encapsulants, thermoplastic olefin, thermoplastic polyolefin (TPO) and hybrids and combinations thereof.
  18. 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; an encapsulant encapsulating the at least one solar cell; and a frontsheet juxtaposed with the encapsulant, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions, a polymer layer having a first surface and a second surface opposite the first surface of the polymer layer, wherein the second surface of the polymer layer is attached to the first surface of the light scattering encapsulant layer, and wherein the plurality of first portions of the light scattering encapsulant layer has a first light scattering value as measured in accordance with an ASTM E430 standard, wherein a second portion defined by the at least one area has a second light scattering value as measured in accordance with the ASTM E430 standard, and wherein the second light scattering value is different than the first light scattering value.
  19. The system of claim 18, wherein at least one of the photovoltaic modules has a solar reflectivity index (SRI) greater than 16.
  20. The system of claim 18, wherein the difference between the first light scattering value and the second light scattering value imparts a random appearance to the system.

Description

The present invention relates to roof-integrated photovoltaic modules. More particularly, the present invention relates to roof-integrated photovoltaic modules with light-scattering encapsulants providing a non-uniform or randomized appearance, and roofing systems including such modules.

Photovoltaic modules can be placed on building roofs (e.g., residential roofs) to generate electricity. One obstacle to mass-market adoption of solar roofing is poor aesthetics. Standard rack-mounted photovoltaic (“PV”) systems have a very different appearance than traditional roofing materials (e.g., asphalt shingles, wooden shingles, slate shingles, etc.), which can draw unwanted attention. Even low-profile PV systems still receive poor aesthetic feedback from consumers.

In some embodiments, a method of making a photovoltaic module, comprising the steps of obtaining a frontsheet, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of portions extending from the first region, and at least one area located between the portions, a polymer layer having a first surface and a second surface opposite the first surface of the ...

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Record as JSON 
{
  "publication_number": "US11508861B1",
  "country": "US",
  "kind": "B1",
  "title": "Photovoltaic module with light-scattering encapsulant providing shingle-mimicking appearance",
  "abstract": "A method of making a photovoltaic module includes the step of obtaining a frontsheet having a glass layer, a light scattering encapsulant layer, and a polymer layer. The light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions. The first portions of the light scattering encapsulant layer has a first light scattering value and a second portion defined by the area has a second light scattering value different from the first light scattering value. The method includes the steps of obtaining at least one solar cell, an encapsulant, and a backsheet, and laminating the frontsheet, the encapsulant, the at least one solar cell, and the backsheet.",
  "claims": [
    "1. A method of making a photovoltaic module, comprising the steps of: obtaining a frontsheet, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions, a polymer layer having a first surface and a second surface opposite the first surface of the polymer layer, wherein the second surface of the polymer layer is attached to the first surface of the light scattering encapsulant layer, and wherein the plurality of first portions of the light scattering encapsulant layer has a first light scattering value as measured in accordance with an ASTM E430 standard, wherein a second portion defined by the at least one area has a second light scattering value as measured in accordance with the ASTM E430 standard, and wherein the second light scattering value is different than the first light scattering value; obtaining at least one solar cell, an encapsulant, and a backsheet wherein the encapsulant includes a first surface and a second surface opposite the first surface of the encapsulant; and laminating the frontsheet, the encapsulant, the at least one solar cell, and the backsheet, wherein the frontsheet is juxtaposed with the first surface of the encapsulant, wherein the encapsulant encapsulates the at least one solar cell, and wherein the backsheet is juxtaposed with the second surface of the encapsulant.",
    "2. The method of claim 1, further comprising the steps of laminating the glass layer, the light scattering encapsulant layer, and the polymer layer to form the frontsheet.",
    "3. The method of claim 1, wherein the first light scattering value is 0.1 HU to 12 HU.",
    "4. The method of claim 1, wherein the second light scattering value is 0.1 HU to 12 HU.",
    "5. The method of claim 1, wherein the polymer layer is attached to the light scattering encapsulant layer by an adhesive layer.",
    "6. The method of claim 5, wherein the adhesive layer is selected from the group consisting of thermosetting polyolefin, thermosetting polyolefin encapsulant material, ethylene-vinyl acetate (EVA), EVA encapsulants, thermoplastic olefin, thermoplastic polyolefin (TPO) and hybrids and combinations thereof.",
    "7. The method of claim 5, wherein the adhesive layer includes a thermosetting polyolefin encapsulant material.",
    "8. The method of claim 1, wherein the polymer layer includes a fluoropolymer.",
    "9. The method of claim 1, wherein the polymer layer includes a material selected from the group consisting of acrylics, polyesters, silicones, and polycarbonates.",
    "10. The method of claim 1, wherein the light scattering encapsulant layer includes a polymeric material.",
    "11. The method of claim 10, wherein the polymeric material includes at least one of ethylene-co-vinyl acetate, polydimethyl siloxane, a polyolefin elastomer, or a combination thereof.",
    "12. The method of claim 11, wherein the backsheet includes a first layer juxtaposed with the second surface of the encapsulant.",
    "13. The method of claim 12, wherein the first layer includes thermoplastic polyolefin (TPO).",
    "14. The method of claim 12, wherein the backsheet includes a second layer.",
    "15. The method of claim 14, wherein the second layer includes thermoplastic polyolefin (TPO).",
    "16. The method of claim 15, wherein the first layer is attached to the second layer by a second adhesive layer.",
    "17. The method of claim 16, wherein the second adhesive layer is selected from the group consisting of thermosetting polyolefin, thermosetting polyolefin encapsulant material, thermosetting polyolefin encapsulant material, ethylene-vinyl acetate (EVA), EVA encapsulants, thermoplastic olefin, thermoplastic polyolefin (TPO) and hybrids and combinations thereof.",
    "18. 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; an encapsulant encapsulating the at least one solar cell; and a frontsheet juxtaposed with the encapsulant, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of first portions extending from the first region, and at least one area located between the first portions, a polymer layer having a first surface and a second surface opposite the first surface of the polymer layer, wherein the second surface of the polymer layer is attached to the first surface of the light scattering encapsulant layer, and wherein the plurality of first portions of the light scattering encapsulant layer has a first light scattering value as measured in accordance with an ASTM E430 standard, wherein a second portion defined by the at least one area has a second light scattering value as measured in accordance with the ASTM E430 standard, and wherein the second light scattering value is different than the first light scattering value.",
    "19. The system of claim 18, wherein at least one of the photovoltaic modules has a solar reflectivity index (SRI) greater than 16.",
    "20. The system of claim 18, wherein the difference between the first light scattering value and the second light scattering value imparts a random appearance to the system."
  ],
  "description_excerpt": "The present invention relates to roof-integrated photovoltaic modules. More particularly, the present invention relates to roof-integrated photovoltaic modules with light-scattering encapsulants providing a non-uniform or randomized appearance, and roofing systems including such modules.\n\nPhotovoltaic modules can be placed on building roofs (e.g., residential roofs) to generate electricity. One obstacle to mass-market adoption of solar roofing is poor aesthetics. Standard rack-mounted photovoltaic (“PV”) systems have a very different appearance than traditional roofing materials (e.g., asphalt shingles, wooden shingles, slate shingles, etc.), which can draw unwanted attention. Even low-profile PV systems still receive poor aesthetic feedback from consumers.\n\nIn some embodiments, a method of making a photovoltaic module, comprising the steps of obtaining a frontsheet, wherein the frontsheet includes a glass layer having a first surface, a light scattering encapsulant layer having a first surface and a second surface opposite the first surface of the light scattering encapsulant layer, wherein the second surface of the light scattering encapsulant layer is attached to the first surface of the glass layer, wherein the light scattering encapsulant layer includes a first region, a plurality of portions extending from the first region, and at least one area located between the portions, a polymer layer having a first surface and a second surface opposite the first surface of the ...",
  "cpc": [
    "H02S 20/25",
    "H01L 31/048",
    "H01L 31/18",
    "H02S 40/20",
    "H10F 19/80",
    "H10F 19/804",
    "H10F 71/00",
    "H10F 77/42",
    "Y02B 10/10"
  ],
  "ipc": [
    "H01L 31/048",
    "H01L 31/18",
    "H02S 20/25",
    "H02S 40/20"
  ],
  "assignees": [
    "GAF Energy LLC"
  ],
  "inventors": [
    "Richard Perkins",
    "Alex Sharenko",
    "Thierry Nguyen",
    "Gabriela Bunea",
    "Anna Wojtowicz"
  ],
  "filing_date": "2022-06-01",
  "publication_date": "2022-11-22",
  "grant_date": "2022-11-22",
  "priority_date": "2021-06-02",
  "application_number": "US-202217830094-A",
  "family_id": "84104938",
  "cited_by_count": 48,
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Record 939 of 8,000 in Patents full text (MLC-0201). Request the full dataset.