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US 11,283,394 B2Granted
Photovoltaic module with textured superstrate providing shingle-mimicking appearance
AssigneeGAF Energy LLC
InventorsRichard Perkins, Alex Sharenko, Thierry Nguyen, Gabriela Bunea, Anna Wojtowicz
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Abstract
A system including a solar module installed on a roof deck, including a superstrate layer, an encapsulant having an upper layer and a lower layer, and a photovoltaic layer intermediate the upper layer and the lower layer of the encapsulant. An upper surface of the superstrate layer includes an indentation pattern. The indentation pattern includes a mesh of indentations indented into the upper surface of the superstrate layer and a plurality of openings defined by the mesh of indentations.
Claims7
A system, comprising:
- at least one solar module installed on a roof deck, wherein each of the at least one solar module includes:
- a superstrate layer having an upper surface and a lower surface opposite the upper surface,
- wherein the superstrate layer comprises a polymeric material,
- wherein the polymeric material comprises ethylene tetrafluoroethylene (“ETFE”), polyethylene terephthalate (“PET”), or combinations thereof;
- an encapsulant having an upper layer and a lower layer opposite the upper layer, wherein the upper layer is juxtaposed with the lower surface of the superstrate layer, wherein the upper layer includes a lower surface;
- and
- a photovoltaic layer intermediate the upper layer and the lower layer of the encapsulant, wherein the photovoltaic layer includes an upper surface,
- wherein the upper surface of the superstrate layer of a first one of the at least one solar module includes a first indentation pattern
- wherein the polymeric material of the superstrate layer includes the first indentation pattern,
- wherein the first indentation pattern includes a non-uniform mesh of indentations indented into the upper surface of the superstrate layer and a plurality of openings defined by the mesh of indentations,
- wherein a majority of the plurality of openings have a circle shape,
- wherein a majority of the plurality of openings have a surface area of 1 square millimeter to 20 square millimeters,
- wherein a depth of a measured one of the indentations of the first indentation pattern is measured from (a) the upper surface of the superstrate layer to (b) a point in the measured one of the indentations of the first indentation pattern that is closest to the lower surface of the superstrate layer, and is measured in a direction perpendicular to the upper surface of the superstrate layer,
- wherein a majority of the indentations of the first indentation pattern have a depth of 0.12 millimeter to 1.2 millimeter,
- wherein a thickness of the upper layer of the encapsulant at the measured one of the indentations of the first indentation pattern is measured from (a) the upper surface of the photovoltaic layer to (b) a point in the lower surface of the upper layer of the encapsulant at the measured one of the indentations of the first indentation pattern that is closest to the upper surface of the photovoltaic layer, and is measured in a direction perpendicular to the upper surface of the photovoltaic layer,
- wherein the thickness of the upper layer of the encapsulant is at least 100 microns, and
- wherein a transmission loss of power of light transmitted through the superstrate layer having the first indentation pattern is less than 2 percent as a compared to light transmitted through a comparison superstrate that is identical to the superstrate layer but lacks the first indentation pattern.
14 more elements
A system, comprising:
- at least one solar module installed on a roof deck, wherein each of the at least one solar module includes:
- a superstrate layer having an upper surface and a lower surface opposite the upper surface,
- wherein the superstrate layer comprises a polymeric material,
- wherein the polymeric material comprises ethylene tetrafluoroethylene (“ETFE”), polyethylene terephthalate (“PET”), or combinations thereof;
- an encapsulant having an upper layer and a lower layer opposite the upper layer, wherein the upper layer is juxtaposed with the lower surface of the superstrate layer, wherein the upper layer includes a lower surface;
- and
- a photovoltaic layer intermediate the upper layer and the lower layer of the encapsulant, wherein the photovoltaic layer includes an upper surface,
- wherein the upper surface of the superstrate layer of a first one of the at least one solar module includes a first indentation pattern,
- wherein the polymeric material of the superstrate layer includes the first indentation pattern,
- wherein the first indentation pattern includes a mesh of indentations indented into the upper surface of the superstrate layer and a plurality of openings defined by the mesh of indentations,
- wherein a majority of the plurality of openings have a surface area of 1 square millimeter to 20 square millimeters,
- wherein a depth of a measured one of the indentations of the first indentation pattern is measured from (a) the upper surface of the superstrate layer to (b) a point in the measured one of the indentations of the first indentation pattern that is closest to the lower surface of the superstrate layer, and is measured in a direction perpendicular to the upper surface of the superstrate layer,
- wherein a majority of the indentations of the first indentation pattern have a depth of 0.12 millimeter to 1.2 millimeter,
- wherein a thickness of the upper layer of the encapsulant at the measured one of the indentations of the first indentation pattern is measured from (a) the upper surface of the photovoltaic layer to (b) a point in the lower surface of the upper layer of the encapsulant at the measured one of the indentations of the first indentation pattern that is closest to the upper surface of the photovoltaic layer, and is measured in a direction perpendicular to the upper surface of the photovoltaic layer,
- wherein the thickness of the upper layer of the encapsulant is at least 100 microns, and
- wherein a transmission loss of power of light transmitted through the superstrate layer having the first indentation pattern is less than 2 percent as a compared to light transmitted through a comparison superstrate that is identical to the superstrate layer but lacks the first indentation pattern.
13 more elements
Dependencies are inferred from the claim text.