Coextruded solar panel backsheet and method of manufacture

A photovoltaic solar panel backsheet comprising:

• an exterior layer having inner and outer surfaces;
• a middle layer, having inner and outer surfaces, said middle layer comprising a polyamide;
• and
• an interior layer having inner and outer surfaces, said interior layer comprising a polyolefin;
• wherein said outer surface of said middle layer is adjoined to said inner surface of said exterior layer, and said inner surface of said middle layer is adjoined to said outer surface of said interior layer.

A method for manufacturing a photovoltaic solar panel backsheet, comprising the steps of:

• drying an exterior layer material, an exterior intermediate layer material comprising a polyamide, a middle layer material comprising a polyolefin, an interior intermediate layer material comprising a polyamide, and an interior layer material;
• heating said exterior, exterior intermediate, middle, interior intermediate, and interior layer materials to a state wherein each of said materials may be extruded into individual sheets or webs;
• extruding said exterior, exterior intermediate, middle, interior intermediate, and interior layer materials into individual sheets or webs;
• forming said backsheet comprising a single, five layered sheet or web which comprises said exterior layer material sheet or web having inner and outer surfaces, said exterior intermediate layer material sheet or web having inner and outer surfaces, said middle layer material sheet or web having inner and outer surfaces, said interior intermediate layer material sheet or web having inner and outer surfaces, and said interior layer material sheet or web having inner and outer surfaces;
• wherein said outer surface of said middle layer sheet or web is adjoined to said inner surface of said intermediate exterior layer sheet or web, said inner surface of said middle layer sheet or web is adjoined to said outer surface of said intermediate interior layer sheet or web, said inner surface of said exterior layer sheet or web is adjoined to said outer surface of said intermediate exterior layer sheet or web, and said outer surface of said interior layer sheet or web is adjoined to said inner surface of said intermediate interior layer sheet or web.

A method for manufacturing a photovoltaic solar panel backsheet, comprising the steps of:

• drying an exterior layer material, a middle layer material comprising a polyamide, and an interior layer material comprising a polyolefin;
• heating said exterior, middle and interior layer materials to a state wherein each of said materials may be extruded into individual sheets or webs;
• extruding said exterior, middle and interior layer materials into individual sheets or webs;
• forming said backsheet comprising a single, three layered sheet or web which comprises said exterior layer material sheet or web having inner and outer surfaces, said middle layer material sheet or web having inner and outer surfaces;
• and said interior layer sheet or web having inner and outer surfaces;
• wherein said outer surface of said middle layer sheet or web is adjoined to said inner surface of said exterior layer sheet or web, and said inner surface of said middle layer is adjoined to said outer surface of said interior layer sheet or web.

A photovoltaic solar panel module comprising:

• a front cover having inner and outer surfaces;
• one or more photovoltaic cells substantially encapsulated in an encapsulant having a top outer surface and a bottom outer surface;
• a backsheet comprising:
• an exterior layer having inner and outer surfaces, an exterior intermediate layer having inner and outer surfaces and comprising a polyamide, a middle layer having inner and outer surfaces and comprising a polyolefin, interior intermediate layer having inner and outer surfaces and comprising a polyamide, and an interior layer having inner and outer surfaces;
• wherein said outer surface of said middle layer is adjoined to said inner surface of said intermediate exterior layer, said inner surface of said middle layer is adjoined to said outer surface of said intermediate interior layer, said inner surface of said exterior layer is adjoined to said outer surface of said intermediate exterior layer, and said outer surface of said interior layer is adjoined to said inner surface of said intermediate interior layer;
• and
• wherein said top outer surface of said encapsulant is adjoined to said inner surface of said front cover, and said bottom outer surface of said encapsulant is adjoined to said inner surface of said interior layer of said backsheet.

A photovoltaic solar panel module comprising:

• a front cover having inner and outer surfaces;
• one or more photovoltaic cells substantially encapsulated in an encapsulant having a top outer surface and a bottom outer surface;
• a backsheet comprising:
• an exterior layer having inner and outer surfaces;
• a middle layer, having inner and outer surfaces and comprising a polyamide;
• and an interior layer having inner and outer surfaces and comprising a polyolefin;
• wherein said outer surface of said middle layer may be adjoined to said inner surface of said exterior layer, and said inner surface of said middle layer may be adjoined to said outer surface of said interior layer;
• and
• wherein said top outer surface of said encapsulant is adjoined to said inner surface of said front cover, and said bottom outer surface of said encapsulant is adjoined to said inner surface of said interior layer of said backsheet.